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The world is firmly focused on reducing energy consumption and on increasingly stringent regulations on CO2 emissions. Examples of regulatory changes include the new United States Environmental Protection Agency's (U.S. EPA) fuel economy test procedures which were required beginning with the 2008 model year for vehicles sold in the US market. These test procedures include testing at higher speeds, more aggressive acceleration and deceleration, and hot-weather and cold-temperature testing. These revised procedures are intended to provide an estimate that more accurately reflects what consumers will experience under real world driving conditions. The U.S.

Prior work by various OEMs has identified the ability of phosphorus-containing compounds to interfere with the efficiency of modern emissions control systems utilized by gasoline-powered vehicles. Considering the growing societal concerns about ecological effects of exhaust emissions, greenhouse gas emissions and related global climatic changes, it becomes desirable to examine the effect of reduced phosphorous (P) deposits in various vehicle makes, models and types of service, over the lifetime of a vehicle's operation. This paper assesses advantages and disadvantages of various methods to examine the path of P transfer throughout exhaust catalytic systems. Test types discussed include examples of bench testing focusing on catalyst compatibility, dyno mileage accumulation and field trial examinations.

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.

Phosphorus is known to reduce effectiveness of the three-way catalysts (TWC) commonly used by automotive OEMs. This phenomenon is referred to as catalyst deactivation. The process occurs as zinc dialkyldithiophosphate (ZDDP) decomposes in an engine creating many phosphorus species, which eventually interact with the active sites of exhaust catalysts. This phosphorous comes from both oil consumption and volatilization. Novel low-volatility ZDDP is designed in such a way that the amounts of volatile phosphorus species are significantly reduced while their antiwear and antioxidant performances are maintained. A recent field trial conducted in New York City taxi cabs provided two sets of “aged” catalysts that had been exposed to GF-4-type formulations. The trial compared fluids formulated with conventional and low-volatility ZDDPs. Results of field test examination were reported in an earlier paper (1).

Newly developed, low volatility zinc dialkyldithiophosphate (ZDDP) technology significantly reduces the amounts of volatile phosphorus (P) species while retaining their antiwear protective behavior and antioxidant performances. In the past researchers gathered a variety of engine data supporting the hypothesis that P volatility can have a significant impact on catalytic converter efficiency, but corresponding field performance results were limited. A recent field trial was conducted with New York City taxi cabs that provided extended sets of engine and drain performance parameters data. This trial compared side-by-side performance of oils formulated with conventional and low volatility ZDDPs. Following completion of the test, the extensive engine inspections and used oil analysis revealed excellent antiwear control and oxidation inhibition with both types of ZDDP technologies.

One of the key functions of lubricating oil additives in diesel engines is to control oil thickening caused by soot accumulation. Over the last several years, it has become apparent that the composition of the base oil used within the lubricant plays an extremely important role in the oil thickening phenomenon. In particular, oil thickening observed in the Mack T-8 test is significantly affected by the aromatic content of the base oil. We have found that the Mack T-8 thickening phenomenon is associated with high electrical activity, i.e., engine drain oils which exhibit high levels of viscosity increase show significantly higher conductivities. These findings suggest that electrical interactions are involved in soot-induced oil thickening.

Wet clutch friction devices are the primary means by which torque is transmitted through many of today's modern vehicle drivelines. These devices are used in automatic transmissions, torque vectoring devices, active on-demand vehicle stability systems and torque biasing differentials. As discussed in a previous SAE paper ( 2006-01-3271 - Next Generation Torque Control Fluid Technology, Part II: Split-Mu Screen Test Development) a testing tool was developed to correlate to full-vehicle split-mu testing for limited slip differential applications using a low speed SAE #2 friction test rig. The SAE #2 Split-Mu Simulation is a full clutch pack component level friction test. The purpose of this test is to allow optimization of the friction material-lubricant hardware system in order to deliver consistent friction performance over the life of the vehicle.

Wet clutch friction devices are the primary means by which torque is transmitted in many of today's modern vehicle drivelines. These devices are used in automatic transmissions, torque vectoring devices, active on-demand vehicle stability systems, and torque biasing differentials. As discussed in a previous SAE paper ( 2006-01-3270 - Next Generation Torque Control Fluid Technology, Part I: Break-Away Friction Slip Screen Test Development), a testing tool was developed to simulate a limited slip differential break-away event using a Full Scale-Low Velocity Friction Apparatus (FS-LVFA). The purpose of this test was to investigate the fundamental interactions between lubricants and friction materials. The original break-away friction screen test, which used actual vehicle clutch plates and a single friction surface, proved a useful tool in screening new friction modifier technology.

The popularity of SUVs and light trucks in North America, combined with the return to rear-wheel-drive cars globally, is significantly increasing the installation of torque control devices that improve vehicle stability and drivability. As with other driveline hardware, it is important to optimize the friction material-lubricant-hardware system to ensure that a torque control device provides consistent performance over the life of the vehicle. While there are many publications on friction tests relevant to automatic transmission fluids, the literature relating to torque control testing is not as well developed. In this paper, we will describe a split-mu vehicle test and the development of a split-mu screening test. The screening test uses the SAE#2 friction test rig and shows how results from this test align with those from actual vehicle testing.

With government mandates, original equipment manufacturers are increasingly focusing on fuel economy and finding efficiency gains throughout the vehicle. Lubricant companies have been asked to design fluids that aid in this effort. Demonstrating real gains becomes complex given the intricacies of these systems and methods range from bench top screen tests to component test stands to full vehicle testing. This paper addresses the variation that was encountered when testing automatic transmission fluid efficiency within a full vehicle test. While it is well known that variability in testing conditions such as engine load or vehicle speed will lead to variability in results, the magnitude of their impact on average throughout the test cycle suggests that repeat testing may not be sufficient to guard against improper conclusions.

The growing need for improved fuel economy is a global challenge due to continuously tightening environmental regulations targeting lower CO2 emission levels via reduced fuel consumption in vehicles. In order to reach these fuel efficiency targets, it necessitates improvements in vehicle transmission hardware components by applying advanced technologies in design, materials and surface treatments etc., as well as matching lubricant formulations with appropriate additive chemistry. Axle lubricants have a considerable impact on fuel economy. More importantly, they can be tailored to deliver maximum operational efficiency over specific or wide ranges of operating conditions. The proper lubricant technology with well-balanced chemistries can simultaneously realize both fuel economy and hardware protection, which are perceived to have a trade-off relationship.

The popularity of SUVs and light trucks in North America, combined with the return to rear-wheel-drive cars globally, is significantly increasing the installation rates of torque control devices that improve vehicle stability and drivability. As with other driveline hardware, it is important to optimize the friction material-lubricant-hardware system in order to ensure that a torque control device provides consistent performance over the life of the vehicle. While there are many publications on friction tests relevant to automatic transmission fluids, the literature relating to torque control testing is not as well developed. In this paper we will describe the development of a break-away friction screening test using a Full-Scale Low-Velocity Friction Apparatus (FS-LVFA). Additionally, we will illustrate how this screening test can be used to investigate the fundamental friction material-lubricant interactions that occur in continuously engaged limited slip differentials.

Polyol ester-based diesel engine lubricants which achieve maximum theoretical high-temperature performance have been developed in our laboratories during the past three years. New lubricant basestocks and additives are currently being developed to perform under more severe thermal conditions, anticipated in low heat rejection diesel engines at the turn of the century. In this paper, the status of our current laboratory development and evaluation of new diesel engine lubricants, with high-temperature applicability beyond polyol esters, is summarized. Our final work in the polyol ester class of lubricants, through single-cylinder engine tests, is also presented.

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.

In response to industry demands for a method to qualify fuels for their intake valve deposit (IVD) forming tendencies, the Coordinating Research Council (CRC) has developed an engine dynamometer test procedure. In Phase I, the 2.3L Ford engine was chosen as the focus test engine in comparison testing with two other high volume U.S. manufactured engines.1* A two-mode dynamometer test was developed in Phases II-A & II-B and shown to discriminate among the test fuels at a 95% confidence level.2 In Phase III, both an interlaboratory study (ILS) of the two-mode dynamometer test and a vehicle fleet study were performed. The ILS was conducted to determine the repeatability and reproducibility of the test procedure and also to fulfill requirements for consideration of the test as an American Society for Testing and Materials (ASTM) standard.

Fundamental knowledge investigations of soot-lubricant interactions continue. In earlier work [1-2], we examined the impact of formulation variables, engine type and mode of engine operation on the formation and nature of diesel soot and its interactions with the crankcase lubricant. Three types of North American heavy duty diesel engines were utilized: Mack EM6-285, GM 6.2L and GM 6.5L. Experiments identified additive compositions capable of providing good viscosity and wear control. Furthermore, we identified soot agglomeration, rather than amount of soot, as the phenomenon responsible for roller follower wear at low dispersant levels. Oil thickening results from the level of soot contamination, in combination with the “state” of the soot. The latter is noticeably affected by the lubricant dispersant level. Part 4 of our studies examines the impact of oil composition on a fluid's ability to handle soot in the Mack T-8 Test.

Forthcoming on-highway 2005/2007 European and North American emission regulations will require modern diesel engines to be equipped with Diesel Particulate Filters (DPF) capable of trapping up to 99% of the exhaust particulate matter. Since diesel particulates (soot) accumulate in the filter over time, the overall system needs to be regenerated by attaining the ignition temperature of soot, which in the presence of oxygen is >600 °C. Catalyzed DPFs regenerate at temperatures as low as ∼300 °C. One of the major issues facing OEMs, aftertreatment system manufacturers, and lubricant formulators is the potential effects of the lubricant-derived ash deposits and their impact on a pressure increase across filters, as well as overall filter performance and its service characteristics.

Global emission legislations for diesel engines are becoming increasingly stringent. While the exhaust gas composition requirements for prior iterations of emission legislation could be met with improvements in the engine's combustion process, the next issue of European, North American and Japanese emission limits greater than 2005 will require more rigorous measures, mainly employment of exhaust gas aftertreatment systems. As a result, many American diesel OEMs are considering NOx adsorbers as a means to achieve 2007+ emission standards. Since the efficacy of a NOx adsorber over its lifetime is significantly affected by sulfur (“sulfur poisoning”), forthcoming reductions in diesel fuel sulfur (down to 15 ppm), have raised industry concerns regarding compatibility and possible poisoning effects of sulfur from the lubricant.

Four 1998 Mitsubishi Carismas, two equipped with direct injection and two with port fuel injection engines, were tested in 20,100 km intervals to determine the effect of mileage accumulation cycle, engine type, fuel and lubricant on vehicle deposits and emissions, acceleration and driveability performance. The program showed that engine fuel system deposits, including specifically those on intake valves, combustion chambers and injectors are formed in higher amounts in the GDI engine than the PFI engine. The fuel additive used reduced injector deposits and combustion chamber deposits in the GDI, but had no significant effect on intake valve deposits, which are affected by crankcase oil formulation. In GDI vehicles, deposited engines were found to have increased hydrocarbon and carbon monoxide emissions and poorer fuel economy and acceleration, but lower particulate emissions.

Four 1998 Mitsubishi Carismas, two equipped with direct injection (GDI) and two with port fuel injection engines (PFI) were tested in a designed experiment to determine the effect of mileage accumulation cycle, engine type, fuel and lubricant type on engine wear and engine oil performance parameters. Fuel types were represented by an unadditised base fuel meeting EEC year 2000 specifications and the same base fuel plus synthetic deposit control additive packages. Crankcase oils were represented by two types (1) a 5W-30 API SJ/ILSAC GF-2 type engine oil and (2) a 10W-40 API SH/CF ACEA A3/ B3-96 engine oil. The program showed that specific selection of oil additive chemistry may reduce formation of intake valve deposits in GDI cars.. In general, G-DI engines produced more soot and more pentane insolubles and were found to be more prone to what appears to be soot induced wear than PFI engines.