Praise for the previous edition:
“Contains something for everyone involved in lubricant technology” - Chemistry & Industry
This completely revised third edition incorporates the latest data available and reflects the knowledge of one of the largest companies active in the business. The authors take into account the interdisciplinary character of the field, considering aspects of engineering, materials science, chemistry, health and safety. The result is a volume providing chemists and engineers with a clear interdisciplinary introduction and guide to all major lubricant applications, focusing not only on the various products but also on specific application engineering criteria.
- A classic reference work, completely revised and updated (approximately 35% new material) focusing on sustainability and the latest developments, technologies and processes of this multi billion dollar business
- Provides chemists and engineers with a clear interdisciplinary introduction and guide to all major lubricant applications, looking not only at the various products but also at specific application engineering criteria
- All chapters are updated in terms of environmental and operational safety. New guidelines, such as REACH, recycling alternatives and biodegradable base oils are introduced
- Discusses the integration of micro- and nano-tribology and lubrication systems
- Reflects the knowledge of Fuchs Petrolub SE, one of the largest companies active in the lubrication business
wileyonlinelibrary.com/ref/lubricants
Table of Contents
List of Contributors XXXVII
A Word of Thanks XXXIX
Preface to the 3rd Edition XLI
Abbreviations XLIII
Volume 1
1 Lubricants and Their Market 1
Theo Mang and Apu Gosalia
1.1 Introduction 1
1.2 Lubricants Demand 2
1.3 Lubricants Competitor Landscape 5
1.4 Lubricant Systems 7
References 9
2 Lubricants in the Tribological System 11
Theo Mang and Christian Busch
2.1 Lubricants as Part of Tribological Research 11
2.2 The Tribological System 12
2.3 Friction 12
2.4 Wear 21
References 29
3 Rheology of Lubricants 31
Theo Mang
3.1 Viscosity 31
3.2 Influence of Temperature on Viscosity (V–T Behaviour) 33
3.3 Viscosity–Pressure Dependency 34
3.4 The Effect of Shear Rate on Viscosity 37
3.5 Special Rheological Effects 38
3.6 Viscosity Grades 39
3.7 Viscosity Measurements 42
Nael Zaki
3.8 Viscosity Measurements at High Pressure 47
References 49
4 Base Oils 51
Theo Mang and Georg Lingg
4.1 Base Oils: A Historical Review and Outlook 51
4.2 Chemical Characterization of Mineral Base Oils 52
4.3 Refining 55
4.4 Base Oil Manufacturing by Hydrogenation and Hydrocracking 62
4.5 Boiling and Evaporation Behaviour of Base Oils 73
4.6 Base Oil Categories and Evaluation of Various Petroleum Base Oils 78
References 81
5 Synthetic Base Oils 83
Wilfried Dresel
5.1 Synthetic Hydrocarbons 84
5.2 Halogenated Hydrocarbons 91
5.3 Synthetic Esters 92
5.4 Polyalkylene Glycols 98
5.5 Other Polyethers 100
5.6 Other Synthetic Base Oils 105
5.7 Comparison of Synthetic Base Oils 109
5.8 Mixtures of Synthetic Lubricants 109
References 110
6 Additives 117
Jürgen Braun
6.1 Antioxidants 118
6.2 Viscosity Modifiers 124
6.3 Pour Point Depressants (PPD) 129
6.4 Detergents and Dispersants 130
6.5 Antifoam Agents 136
6.6 Demulsifiers and Emulsifiers 137
6.7 Dyes 138
6.8 Antiwear (AW) and Extreme Pressure (EP) Additives 138
6.9 Friction Modifiers (FM) 144
6.10 Corrosion Inhibitors 145
References 151
7 Lubricants in the Environment 153
Rolf Luther
7.1 Definition of ‘Environment-Compatible Lubricants’ 153
7.2 Current Situation 156
7.3 Tests to Evaluate Biotic Potential 162
7.4 Environmental Legislation 1: Registration, Evaluation and Authorization of Chemicals (REACh) 169
7.5 Globally Harmonized System of Classification and Labelling (GHS) 175
7.6 Environmental Legislation 2: Classification and Labelling of Chemicals 177
7.7 Environmental Legislation 3: Regular use 180
7.8 Environmental Legislation 4: Emissions 184
7.9 Standardization of Environment-Compatible Hydraulic Fluids 188
7.10 Environmental Seal 194
7.11 Base Fluids 214
7.12 Additives 216
7.13 Products (Examples) 218
7.14 Safety Aspects of Handling Lubricants (Working Materials) 220
7.15 Skin Problems Caused by Lubricants 225
Further Reading 232
8 Disposal of Used Lubricating Oils 237
Theo Mang
8.1 Possible Uses of Waste Oil 237
8.2 Legislative Influences on Waste Oil Collection and Reconditioning 239
8.3 Re-Refining 240
References 246
9 Lubricants for Internal Combustion Engines 249
Manfred Harperscheid
9.1 Four-Stroke Engine Oils 249
9.2 Two-Stroke Oils 278
9.3 Tractor Oils 283
9.4 Gas Engine Oils 285
9.5 Marine Diesel Engine Oils 287
References 290
10 Gear Lubrication Oils 293
Thorsten Bartels
10.1 Requirements of Gear Lubrication Oils 294
10.2 Gear Lubrication Oils for Motor Vehicles 297
10.3 Gear Lubricants for Industrial Gears 316
Wolfgang Bock
References 343
11 Hydraulic Oils 345
Wolfgang Bock
11.1 Introduction 345
11.2 Hydraulic Principle: Pascal’s Law 346
11.3 Hydraulic Systems, Circuits and Components 347
11.4 Hydraulic Fluids 353
11.5 Hydraulic System Filters 395
11.6 Machine Tool Lubrication 400
11.7 Summary 416
References 416
Further Reading 419
Books 419
Standards 419
12 Compressor Oils 421
Wolfgang Bock and Christian Puhl
12.1 Air Compressor Oils 421
12.2 Refrigeration Oils 436
References 450
13 Turbine Oils 453
Wolfgang Bock
13.1 Introduction 453
13.2 Demands on Turbine Oils – Characteristics 454
13.3 Formulation of Turbine Oils 454
13.4 Physical and Chemical Data of Turbine Oils 455
13.5 Turbine Lubricants: Description According to DIN 51515, Parts 1 and 2 473
13.6 Turbine Lubricants: Specifications 474
13.7 Turbine Oil Circuits 479
13.8 Flushing Turbine Oil Circuits 480
13.9 Monitoring and Maintenance of Turbine Oils – General 481
13.10 Turbine Oils: Evaluation of Used Oil Values – Parameters and Warning Values/Limits According to VGB Recommendation 481
13.11 Turbine Oils: Evaluation of Used Oil Values – Causes and Measures 482
13.12 Lifetime of (Steam) Turbine Oils 485
13.13 Gas Turbine Oils: Application and Requirements 486
13.14 Fire-Resistant, Water-Free Fluids for Power Station Applications 487
13.15 Lubricants for Water Turbines and Hydroelectric Plants 488
References 489
Volume 2
14 Metalworking Fluids 491
Theo Mang, Carmen Freiler, and Dietrich Hörner
14.1 Action Mechanism and Cutting Fluid Selection 492
14.2 Friction and Wear Assessment Method for the Use of Cutting Fluids 501
14.3 Water-Miscible Cutting Fluids 505
14.4 Neat Cutting Fluids 545
14.5 Machining with Geometrically Defined Cutting Edges 554
14.6 Machining with Geometric Non-Defined Cutting Edges 564
14.7 Specific Material Requirements for Machining Operations 572
14.8 Metalworking Fluid Circulation System 581
14.9 Coolant Costs 613
14.10 New Trends in Coolant Technology 619
References 631
15 Forming Lubricants 639
Theo Mang
15.1 Sheet Metal Working Lubricants 639
Theo Mang, Achim Losch, and Franz Kubicki
15.2 Lubricants for Wire, Tube and Profile Drawing 693
Theo Mang
15.3 Lubricants for Rolling 728
Theo Mang
15.4 Solid Metal Forming Lubricants: Solid Forming, Forging and Extrusion 747
Theo Mang, Wolfgang Buss
References 773
16 Lubricating Greases 781
Wilfried Dresel and Rolf-Peter Heckler
16.1 Introduction 781
16.2 Thickeners 784
16.3 Base Oils 797
16.4 Grease Structure 799
16.5 Additives 800
16.6 Manufacture of Greases 803
16.7 Grease Rheology 807
16.8 Grease Performance 808
16.9 Applications of Greases 812
16.10 Grease Market 824
16.11 Ecology and the Environment 825
16.12 Grease Tribology 827
References 827
17 Solid Lubrication 843
Christian Busch
17.1 Classification of Solid Lubricants 845
17.2 Characteristics 852
17.3 Products Containing Solid Lubricants 860
17.4 Industrial Uses of Products Containing Solid Lubricants 871
Further Reading 877
Journals 877
Standards, Reprints 879
Books 879
18 Laboratory Methods for Testing Lubricants 881
Roman Müller
18.1 Introduction 881
18.2 Density 881
18.3 Viscosity 882
18.4 Refractive Index 883
18.5 Structural Analyses 883
18.6 Flash Point 884
18.7 Surface Phenomena 884
18.8 Cloud Point, Pour Point 885
18.9 Aniline Point 885
18.10 Water Content 886
18.11 Ash Content 886
18.12 Acidity, Alkalinity 886
18.13 Ageing Tests 887
18.14 Hydrolytic Stability 888
18.15 Corrosion Tests 888
18.16 Oil Compatibility of Seals and Insulating Materials 889
18.17 Evaporation Loss 889
18.18 Analysis and Testing of Lubricating Greases 890
18.19 Elemental Analyses by Spectroscopic Methods 894
18.20 List of Equivalent Standardized Methods for Testing Lubricants 896
References 901
19 Mechanical–Dynamic Test Methods and Tribology 903
Thorsten Bartels
19.1 Tribological System Categories within Mechanical–Dynamic Tests 906
19.2 Simple Tribological Mechanical–Dynamic Test Machines and Test Methods 907
19.3 Mechanical–Dynamic Tests for Gearbox and Transmission Application 920
19.4 Mechanical–Dynamic Tests for Internal Combustion Engines 968
19.5 Hydraulic Pump and Circuit Design 1009
19.6 Interpretation and Precision of Tribological Mechanical–Dynamic Testing 1041
Acknowledgements 1041
References 1041
20 Lubrication Systems 1053
Theo Mang
20.1 Introduction 1053
20.2 The Taxonomy of Centralized Lubrication Systems DIN 24271 Part 1 and DIN ISO 5170 1054
20.4 Circulating Lubrication Systems 1061
20.5 Special Applications 1065
Reference 1088
21 Removal of Lubricants: Industrial Cleaners 1089
Achim Losch
21.1 Introduction to Industrial Cleaning 1089
21.2 Substrates (Workpieces) 1090
21.3 Contamination: Soil 1091
21.4 Mechanisms of Aqueous Cleaning 1093
21.5 Detection and Control of Cleaning Result 1095
21.6 Cleaning Methods and Equipment 1098
21.7 Aqueous Cleaners 1108
21.8 Solvent Cleaners 1115
21.9 Maintenance of Cleaner Systems 1119
References 1122
Index 1125
