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Specific frictional properties are essential to provide correct and pleasurable shifting in a manual transmission. Synchroniser rings are being manufactured from an increasingly wider range of materials, and so it is important to understand synchroniser-additive interactions in order to develop tailored lubricants that provide the desired frictional performance. This paper describes a study of the interaction of various friction modifier additives with a range of synchroniser materials in order to better understand the potential to develop lubricants that provide optimal frictional performance across a wide range of manual transmission-synchroniser systems. This presentation will outline the results of testing fluids with a range of synchroniser materials and will be followed by a future paper that will describe details of the fluids and analysis of their interactions with the different synchroniser surfaces.

Our basic understanding of the chemical and physical nature of soot, its interaction with lubricant components and its role in promoting wear and oil thickening in heavy duty diesel engines continues to grow. Our current study in the GM 6.5L engine focuses on examining the effects of variations in base stock type (Group I vs. Group II), viscosity index improver or viscosity modifier (VM) chemistry (OCP vs. dispersant OCP), zinc dithiophosphate (ZDP) type and dispersant type (low MW vs. high MW) on roller follower wear, viscosity growth and other measured responses. In this study, more robust fluids were tested producing very low wear results and minimal viscosity increase of the lubricant. Fluids containing dispersant OCP (DOCP) and high MW dispersant produced a lower degree of wear, whereas varying the ZDP type (1° vs. 2°) showed no effect on wear. The use of Group II base stocks was associated with significantly lower viscosity increases.

A major drive to develop methanol-fueled vehicles began with the 1973 oil embargo. Early work with dedicated methanol-fueled vehicles demonstrated that lubricant choice influenced engine durability. The qualities desired were not defined by the gasoline engine oil classification system in place at the time. As a result oils were developed which optimized those properties deemed desirable for methanol fuel. The advent of fuel sensors made it possible to design a vehicle which can operate on gasoline or gasoline with varying levels of methanol without intervention by the operator. This created a need for a lubricant that can handle a diversity of methanol/gasoline mixtures as well as conventional gasoline. The paper reviews some of the lubricants that have been used in prototype methanol-capable vehicles and the improvement of these formulations to meet the latest gasoline engine performance criteria while maintaining satisfactory methanol performance.

Water-emulsified diesel fuel technology has been proven to reduce nitrogen oxides (NOx) and particulate matter (PM) simultaneously at relatively low cost compared to other pollution-reducing strategies. While the mechanisms which result in these reductions have been postulated, the development of new analytical tools to measure in-cylinder soot formation using optically accessible engines can lead to a deeper understanding of combustion and the chemical and physical mechanisms when water is present during combustion. In this study, an optically accessible single cylinder engine was used to study how water brought into the combustion chamber via an emulsified fuel changes the combustion process and thereby reduces emissions. In-cylinder measurements of relative soot concentrations were used to determine the effect of water-emulsified fuel on soot formation.

A discriminating dynamometer-based test was developed for evaluating cold start and warmup engine performance based on in-cylinder pressure measurements. The dynamometer test offers advantages in time required, flexibility and reduced variability over the vehicle procedure on which it was based. A parametric study on fuel driveability index (DI), ethanol content and intake valve deposit (IVD) rating demonstrated that each of these parameters had a statistically significant impact on engine cold start performance. Simple numerical offsets to fitted models based on oxygen content of the fuel did not account for the difference in engine performance of hydrocarbon-only versus ethanol-containing fuels. The effect of IVD on engine performance did not appear to depend on the DI of the fuel. The benefits of cleaner valves are seen even in fuels of very low DI.

The lubricant is a key component in the successful operation of a manual transmission, but it is important that the interactive effects with the friction material are understood. This paper examines the effect of several key additive components on the friction and wear performance of a single sinter composition in a carefully controlled laboratory test. In addition, the test method allows one to develop information about the shift behavior of the fluid-synchronizer material combination which provides useful information about shift quality. From the original experimental design program a predictive model was developed and an optimized formulation was tested as a validation of the results.

Extended drain of axle and transmission lubricants has gained wide acceptance in both passenger car and commercial vehicle applications. Understanding how the lubricant changes during extended drain operations is crucial in determining appropriate lubricants and drain intervals for these applications. A suitable aging screen test with an established relationship to field performance is essential. Over the years numerous methods have been studied (DKA, GFC, ISOT, ASTM L-60) with varying degrees of success1,2,3. Current methods tend to be overly severe in comparison to field experience, hence the need for further work in this area. As a result of recent work, a lubricant aging test method has been developed which shows good correlation with field experience, giving us an effective tool in the development of long drain oils.

Requirements to reduce emissions and improve vehicle fuel economy continue to increase, spurred on by agreements such as the Kyoto Protocol. Lubricants can play a role in improving fuel economy, as evidenced by the rise in the number of engine oil specifications worldwide that require fuel economy improvements. A novel friction modifier technology has been developed to further improve vehicle fuel economy. The development of this novel friction modifier technology which contains only N,O,C,H was previously published along with the initial demonstration of performance in motorized Toyota engines. In order to validate this performance in fired engine tests, oil was evaluated in a Toyota Corolla Fielder with a 1500 cc gasoline engine. Testing was conducted in the Japanese 10-15 and JC08 modes, as well as the European EC mode, and the US FTP mode.

Specific frictional properties are essential to provide correct and pleasurable shifting in a manual transmission. Synchroniser rings are being manufactured from an increasingly wider range of materials, and it is important to understand synchroniser-additive interactions in order to develop tailored lubricants that provide the desired frictional performance. This paper describes a study of the interaction of various friction modifier additives with a range of synchroniser materials in order to better understand the potential to develop lubricants that provide optimal frictional performance across a wide range of manual transmission-synchroniser systems.

The international Lubricant Standardization and Approval Committee (ILSAC) GF-2 specification requires Passenger Car Motor Oils to provide enhanced fuel economy in a modern low friction engine (ASTM Sequence VIA). In previous SAE publications the authors have studied the boundary lubrication regime and documented the impact of friction modifiers and antiwear additives on Sequence VIA fuel economy. This paper shifts the focus to the hydrodynamic lubrication regime and details fundamental studies of viscosity modifiers and base oils on fuel economy as measured by this low friction engine. The viscosity modifiers were found to have surprisingly little impact on this test, while moving to base oils of higher viscosity index improved fuel economy as might be theoretically expected. A study of formulating SAE 5W-30 motor oils with base oils of increasing viscosity index showed the optimum fuel economy was able to be obtained with a high viscosity index base stock.

Piston ring land deposit formation is a key performance criterion in the ASTM Sequence IIIE engine test. Because engine testing of lubricant formulation variables is expensive, a ring land deposit bench test was developed replicating the Sequence IIIE bulk oxidation and deposit formation mechanisms. Following an initial bulk oxidation of the candidate oils, deposits similar in chemical composition and morphology to Sequence IIIE ring land deposits are produced in a modified panel coker apparatus. Good correlation with the ASTM Sequence IIIE engine test has been established. Lubricant additive and base oil effects on oxidation control and deposit formation have been investigated. Their influences on lubricant formulation strategy are discussed.

The technology has been developed which will allow manufacturers to produce cars capable of running on methanol/gasoline blends with a methanol content up to 85% (i.e., M85). These cars will operate on varying methanol/gasoline ratios without any adjustments from the driver. The dual-fuel capability is attractive since vehicle use will not be handicapped by a restricted fuel distribution system. In addition, it provides the option of running on an environmentally “cleaner” fuel where it is available. The advent of fuel-flexible vehicles encourages the development of lubricants which will satisfy the demands of both fuels. The unique properties of methanol, however, increase the challenges of meeting the lubricant performance needs. Field and engine dynamometer testing have been aimed at understanding the response of key lubricant variables with M85. Short-trip, cold-weather conditions have been of particular concern.

The effects of gasoline composition, as represented in typical regular and premium unleaded gasolines and fuel additives, on Combustion Chamber Deposits (CCD) were investigated in BMW and Ford tests. In addition, the influences of engine lubricant oil and ethanol oxygenate on CCD were examined in Ford 2.3L engine dynamometer tests. Also, additive effects of packages based on mineral oil fluidizers versus synthetic fluidizers were studied in several different engines for CCD. Finally, a new method for evaluating the effect of fluidizers on valve sticking is introduced.

The proposed International Lubricant Standardization and Approval Committee (ILSAC) GF-2 specification requires Passenger Car Motor Oils to provide enhanced fuel economy in a modern low friction engine (Sequence VIA). This paper details fundamental studies of lubricant effects on fuel economy as measured by this low friction engine. Several conventional friction modifiers were tested with surprising results. One ester friction modifier, Ester B, which provides excellent fuel economy improvement in the Sequence VI, was found to be detrimental to the Sequence VIA. A second ester friction modifier, Ester A, performed as expected. Additionally, two molybdenum compounds, which are reported to provide excellent fuel economy in the Sequence VI, showed no fuel economy benefit in the Sequence VIA.

Statistically designed experiments were developed to investigate the nature of soot, to understand its role in oil viscosity growth, and to study the interactions involved with additives that inhibit viscosity growth. The matrix was designed to examine effects of engine type, mode of operation, and the oil formulations. Mack EM6-285 and GM 6.2L engines operating under both high speed and high torque conditions were used in this study. An API CE\SG quality lubricant was used as the baseline. The detergent sulfonate substrate was varied from standard to three-fold levels; the dispersant TBN contribution ranged from 1.1 to over 3.0. The surface and bulk exhaust soot properties were determined. Colloidal suspension stability and rheology were measured to evaluate the design factor effects on the formation of soot and subsequent effects on oil thickening. The Mack EM6-285 engine produced less soot, less oil viscosity growth, and less oxidation than the GM 6.2L engine.

Two prominent trends are facing diesel engine builders and their customers, environmental regulations and cost containment. Increasingly stringent exhaust emissions regulations have necessitated major changes in diesel engine design. Combustion temperatures and fuel injection pressures continue to rise. This and other factors, such as lower oil consumption for exhaust particulate reduction, place greater demands on crankcase lubricating oils. Another prominent environmentally related cost factor facing fleet operators is that of waste oil management. The inventory and disposal of used lubricants must now be handled in accordance with regulated guidelines and their associated costs. To compensate, new lubricant categories have been designed in both North America and Europe, such that 1994 and later emission controlled engines will perform as reliably as their earlier counterparts.

The functions of engine oil are reviewed. The chemistry of engine oil additives and synthetics is described in terms for the non-chemist. The latest SAE engine oil viscosity classifications and API service designations are detailed. Developments underway to upgrade engine oil quality are discussed.

The authors provide evidence indicating that oils meeting only the minimum requirements of API GL-5 do not always provide adequate gear protection, especially in severe duty applications. Increases in commercial vehicle power and loading have accentuated the need for oils of greater load carrying ability. A modified version of the standard L-37 test may help identify oils that possess superior durability and thermal characteristics. Future gear lubricants should provide improved fuel economy, increased manual transmission life; and frictional characteristics that allow noise free performance in limited slip differentials.

In order to assess the field needs of engine oils to be used in methanol-fueled vehicles, six oils were run in a fleet test over a ten-month period under short-trip service conditions. The results from the field test were compared with results with the six oils in the laboratory engine tests which have been used to predict field performance with methanol fuel. A lack of correlation between the field test and the laboratory engine tests suggests that the laboratory tests need revisions to better serve field needs.

This paper provides an overview of gear lubrication related to automotive equipment. A brief background in various aspects of lubrication, including lubrication theory, lubricant evaluation, performance designations, and formulation technology, is presented. This information is designed to assist those involved in the selection of automotive gear lubricants.