Grease and Applications
Outline
• Greases Overview
• Types of Greases
• Production of Grease
• Grease Trends - Market & Development
• Important Attributes of Greases
• Selection Criteria for Greases
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Grease - the evolution?
DATE GREASE DEVELOPED HIGH TEMPERATURE
LIMIT
1400B.C. EGYPTIAN OLIVE OIL/LIME GREASE 60oC
‘PRE-18TH ANIMAL FAT 50oC
CENTURY’
18TH COLD PROCESS LIME GREASE 60oC
CENTURY
1900-1930 Ca, Al, Na GREASES 65-110 oC
1930-1940 Ca, Li COMPLEX GREASE 130-150oC
1950 & Al, Li COMPLEX 140-150 oC
BEYOND
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The 1st grease?
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Grease - Basic Components
Oil Syntheti Simple Soap (Na, Ca, Li, Al, Ba,
cMineral etc.)
Soa Mix
p Soap
Clay,
Complex
Thickene Silica, etc.
Soap
r
Non- Polyme
Soap r
Carbon
Black
Additive
s Anti-oxidation,
Anti-Corrosion, Anti-wear,
EP,
Tackiness, Fillers, Anti-bleed
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Grease vs Oil
Consistency shear- Viscosity Generally
rate dependent Shear-Rate Independent
No Elaborate Seals, Mechanism needed for
Pumps, Reservoirs Sealing, Pumping &
Needed Storage
GREASE OIL
In Place Regardless
of Orientation of Can be ‘Flung away’ by
Mechanism Rotation/other operation
Corrosion Protection Might not be in Place
After Long Machine after Long Machine
Inactivity Inactivity
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Grease vs Oil
For Parts Where More Frequent
Replenishment of Replenishment expected
Lubricants is Difficult
Sealing Effect to No Protection
Prevent Entry of against
Contaminants Contaminants
GREASE
GREASE OIL
OIL
Suitable for Parts Suitable for Accurately
without Accurate Fitting Fitted Parts
No/Low Circulation - Function as Coolant
Poor Cooling Effect Through Circulation
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Grease Important Attributes
• Consistency
–NLGI (National Lubricating Grease Institute, USA) System Based
on ‘Working Penetration Resistance’
–Shear-rate Dependent
• Drop Point (ASTM D566, D2265, IP132)
–Temperature at Plastic to Fluid Transition
• Texture & Structure - Grease Components, Additives Dependent
• Mechanical Stability (ASTM D217, D1831, IP 50)
–Permanent Drop of Consistency under a Prolonged Stress Force
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Grease Important Attributes
• Heat Stability
–To Avoid Hardening or Softening
• Oxidation Stability
–Oxidation as a result of Prolonged Air Exposure & High
Temperature
–Might lead to corrosion, seizure, leakage
• Wear Resistance & Load Carrying Capacity
–Related to Toughness of Grease Film in Condition of
Loading
–EP Agents Needed for Heavily, Shock-loaded Bearing
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Grease Important Attributes
• Corrosion/Water Resistance
- Related to Water Absorbence, Water Corrosion & Wash-out
Properties
• Bleeding
- Leads to Leakage in Extreme Cases
• Channeling
- ‘Clearing’ of Un-used Grease by Machine Part Movements
• Pumpability & Slumpability
- Affect The Flowing & Feeding of Grease within the Machining
Parts
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NLGI Cone Penetration Test for
Grease Consistency
IP50/ASTM D-217
Penetration
Depth
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Grease - NLGI Consistency Grade
Penetration Depth (cm) NLGI Grade Applications
4.44 - 4.75 000 Semi-fluid
4.00 - 4.30 00 gear grease
3.55 - 3.85 0 Centralised
3.10 - 3.40 1 grease
2.65 - 2.95 2 Bearing
2.20 - 2.50 3 grease
1.75 - 2.05 4
1.30 - 1.60 5 Rarely used
0.85 - 1.15 6
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Grease with Simple Soap Thickeners
Type Texture Water Mechanical Service
Resistance Stability Life
Al Smooth/ V.Good Poor Short
Ductile
Ca Smooth, Good Good Medium-Long
Butter-Like
Li Smooth, Good V.Good Medium-Long
Butter-like
Na Fibrous Poor Average Medium-Long
Clay Smooth Average Average Long-
Medium
Silica Smooth Poor Good Medium-
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Grease with Complex Soaps
Type Non-Fatty Salt Features
Ca Complex Acetate High Drop Pt, Good
Water Resistance, Thermal Stability &
EP Properties. Poor pumpability &
Mechanical Stability
Al Complex Hydroxy-Stearate Good Pumpability, EP Benzoate,
Phthalate Properties. Flame retarding.
Li Complex Stearate, Borate Wide Temperature, Salicylicate
Range, Multi-Purpose Dodecandioate
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Grease Selection Criteria I
• Gear Applications
– Control Factors:-
• Shear Stability, Adhesion, Leakage
• Resistance, Flow Characteristics
• NLGI Grade 000-00
• Anti-Friction Bearing, Water Pumps
– Roller/Ball Bearings
• D<50mm - NLGI Grade 2
• D>50mm - NLGI Grade 3
– Vertical/Inclined Shafts - NLGI Grade 2-3
– Low Starting Torque - NLGI Grade 1-2
– Good Sealing - NLGI Grade 3
– Good Transportability - NLGI Grade 1-2
– Low Running Noise - NLGI Grade 2-3
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Grease Selection Criteria II
Special Operation Conditions
• Low Temperature (<-30°C) Start-up
- Low Viscosity Mineral/Synthetic Oil Required
• Condensate
- Emulsifiable Grease (Na, Li) Required
• Excessive Vibration
- Cause Grease Churning & Bleeding
- High Viscosity Grease Required (Li EP G2 or 3)
• Vacuum
- Specially Low Evaporation Required for <10-5mbar
• Inclined/Vertical Shafts
- Good Adhesion Required
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Grease Sales by Thickener Types
Na Al
Others
3% 6%
6% Polyurea
Ca
10% 6%
Li
69%
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Global Grease Market Shares
Estimated Total Tonnage: 1,200,000mt
W.Europe S.America
13% 11%
Africa &
N.America M.East
16% 7%
C&E
Europe
Asia-Pacific 32%
22%
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Global Industrial Grease
Market Distribution
Rail Road Mining
19% 10%
Auto Mfg
8%
Steel
17%
Gen Mfg
18%
Others
28%
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Main Brands Marketed by Castrol
• Castrol WB Grease
• Castrol CLS Grease
• Castrol AP, 2,3 Grease
• Castrol BB EPL 0,1,2
• Castrol LMM grease
• Castrol LCG 2
• Castrol HITEMP 295
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Thank you for your
Attention !!
