Failure Analysis of Industrial Gear Oil Additive Packages
In the modern industrial production system, the efficient and stable operation of mechanical equipment is a crucial factor for ensuring production continuity and product quality. As a core component for power transmission in mechanical equipment, industrial gears are subjected to high loads, high rotational speeds, and complex alternating stress. The industrial gear oil additive package, as a key part of the industrial gear lubrication system, can not only effectively reduce the friction and wear between gears but also possess multiple functions such as extreme pressure resistance, anti-wear, oxidation resistance, and anti-corrosion. It plays a vital role in extending the service life of gears and improving the reliability of equipment. However, in actual industrial applications, affected by various factors, the performance of industrial gear oil additive packages may decline or even fail. This, in turn, leads to increased gear wear, frequent equipment failures, and in severe cases, production safety accidents, resulting in huge economic losses. Therefore, conducting in-depth failure analysis of industrial gear oil additive packages, accurately identifying the causes of failure, and promptly taking effective preventive measures are of great practical significance for ensuring the normal operation of industrial gears and enhancing the overall performance of mechanical equipment.
I. Common Causes of Failure
Shear Degradation
During the operation of industrial gears, the gear oil additive package is subjected to extremely high shear stress in the tooth surface contact area. When the gears operate at high speeds or bear heavy loads, the polymer additives in the gear oil additive package, such as viscosity index improvers, will have their molecular chains broken. These polymers originally use their long-chain structures to curl at low temperatures to reduce the impact on the fluidity of the oil and stretch at high temperatures to increase the oil viscosity, thus improving the viscosity-temperature performance of the gear oil. Once the molecular chains are broken, their relative molecular mass decreases, and they cannot effectively maintain the viscosity and viscosity-temperature performance of the gear oil. As a result, the viscosity of the gear oil drops too quickly at high temperatures, the thickness of the lubricating film decreases, and it cannot provide sufficient lubrication protection for the gears, ultimately leading to increased gear wear. In addition, shear degradation will also reduce the anti-wear and extreme pressure resistance of the gear oil, further accelerating the failure process of the gears.
Oxidation Deterioration
During the use of industrial gear oil additive packages, they will inevitably come into contact with oxygen in the air. Under the influence of factors such as high temperature, metal catalysts (such as iron, copper, and other metal elements on the gear surface), and mechanical agitation, the base oil and additives in the gear oil will undergo oxidation reactions. The oxidation reaction first oxidizes the saturated hydrocarbons in the base oil into peroxides, which further decompose to produce oxidation products such as aldehydes, ketones, and acids. These oxidation products will not only cause the color of the gear oil to darken and the acid value to increase but also reduce the oxidation resistance and corrosion resistance of the gear oil. At the same time, macromolecular substances such as gums and asphaltenes generated by the oxidation reaction will form a film and sludge on the gear surface, blocking the oil passages of the lubrication system, affecting the normal circulation and lubrication effect of the gear oil, and accelerating the failure of the gear oil additive package. In addition, the high-temperature environment will significantly accelerate the rate of the oxidation reaction, making the gear oil more prone to oxidation deterioration under high-temperature working conditions.
Contamination
The industrial production environment is usually complex, and industrial gear oil additive packages are vulnerable to the intrusion of external contaminants. Solid particle contaminants, such as metal debris, dust, and sand grains, may come from gear wear, equipment processing residues, or environmental dust. Once these solid particles enter the gear oil, they will act as abrasive particles between the gear teeth, exacerbating gear wear. At the same time, solid particles may also scratch the gear surface,broken the integrity of the lubricating film, and reduce the lubrication performance of the gear oil. In addition, moisture is also a common contaminant. The intrusion of moisture will cause the additives in the gear oil to undergo hydrolysis reactions,broken the molecular structure of the additives, and reduce the performance of the additives. For example, additives such as anti-wear agents and rust inhibitors will lose their activity under the action of moisture and cannot perform their proper functions. At the same time, moisture will also promote the rusting of gears, further affecting the normal operation of gears. In addition, the mixed use of different types of gear oils will also lead to contamination problems. Due to the possible differences in the base oil and additive formulations of different gear oils, chemical reactions may occur after mixing, resulting in phenomena such as precipitation and stratification,broken the stability of the gear oil, and accelerating the failure of the gear oil additive package.
Additive Consumption
The various additives in the industrial gear oil additive package will be gradually consumed during the process of exerting their functions. For example, the anti-wear agent will undergo a chemical reaction with the gear surface during the process of forming a protective film on the gear surface and be gradually consumed; the antioxidant will also participate in the oxidation reaction and be consumed while inhibiting the oxidation reaction of the gear oil. As the additives are continuously consumed, if they are not replenished in a timely manner, the various performances of the gear oil additive package will gradually decline. When the additive content drops to a certain extent, the gear oil will not be able to meet the lubrication requirements of the gears, resulting in failure. In addition, some special working conditions, such as high load, high temperature, and high rotational speed, will accelerate the consumption rate of additives, causing the failure time of the gear oil additive package to be advanced.
II. Detection Technologies for Failure Analysis
Infrared Spectroscopy Analysis
Infrared spectroscopy analysis is an analytical technology based on the infrared light absorption characteristics of substance molecules and has a wide range of applications in the failure analysis of industrial gear oil additive packages. Each compound has its unique infrared absorption spectrum. By conducting infrared spectroscopy analysis on the gear oil sample, the composition and content changes of various compounds in the gear oil can be detected. In the failure analysis of gear oil additive packages, infrared spectroscopy can be used to detect the oxidation degree of the gear oil. For example, by observing the intensity change of the carbonyl (C=O) absorption peak in the infrared spectrum, the generation of oxidation products in the gear oil can be judged. As the oxidation degree of the gear oil deepens, the intensity of the carbonyl absorption peak will gradually increase. In addition, infrared spectroscopy can also be used to detect the content changes of additives in the gear oil. By analyzing the intensity of the absorption peaks of the characteristic functional groups of the additives, it can be determined whether the additives are consumed or degraded. For example, for gear oils containing sulfur-containing anti-wear agents, the content change of the anti-wear agent can be judged by detecting the intensity of the absorption peak of the sulfur-containing functional group. Infrared spectroscopy analysis has the advantages of fast analysis speed, small sample consumption, and non-destruction of the sample, and can quickly and accurately obtain the chemical composition information of the gear oil additive package, providing an important basis for failure analysis.
Chromatographic Analysis
Chromatographic analysis includes gas chromatography (GC) and liquid chromatography (LC), which are effective techniques for separating and analyzing complex mixtures. Gas chromatography is mainly suitable for analyzing volatile compounds. In the failure analysis of industrial gear oil additive packages, it can be used to separate and detect the base oil components and volatile additives in the gear oil. Through gas chromatography analysis, the composition and content changes of different hydrocarbons in the base oil can be understood, and it can be judged whether the base oil has undergone oxidation, cracking, and other reactions. For example, when the base oil is oxidized, some low-boiling-point oxidation products will appear as new peaks in the gas chromatogram. By analyzing these peaks, the types and contents of the oxidation products can be determined. Liquid chromatography is suitable for analyzing compounds that are not volatile or have poor thermal stability, such as polymer additives and macromolecular substances in oxidation products. Liquid chromatography can separate and detect the content changes of additives such as viscosity index improvers and antioxidants in the gear oil, as well as macromolecular substances such as gums and asphaltenes generated during the oxidation process. Through chromatographic analysis, the changes in the various components of the gear oil additive package can be accurately understood, providing detailed data support for in-depth analysis of the causes of failure.
Viscosity Detection
Viscosity is one of the important performance indicators of industrial gear oil and directly affects the lubrication performance of the gear oil. By measuring the kinematic viscosity or dynamic viscosity of the gear oil, the performance state of the gear oil additive package can be judged. When the gear oil additive package undergoes shear degradation or oxidation deterioration, its viscosity will change significantly. When the gear oil undergoes shear degradation, the molecular chains of the polymer additives break, resulting in a decrease in the viscosity of the gear oil; while when the gear oil undergoes oxidation deterioration, the generated oxidation products will increase the viscosity of the gear oil. By regularly detecting the viscosity of the gear oil and comparing it with the viscosity of the new oil, the performance changes of the gear oil can be detected in a timely manner. In addition, the viscosity of the gear oil at different temperatures can also be measured to draw a viscosity-temperature curve and analyze the changes in the viscosity-temperature performance of the gear oil. The viscosity detection method is simple and fast and is a commonly used means for daily monitoring and preliminary failure judgment of gear oil additive packages in industrial sites.
Acid Value Detection
The acid value is an important indicator for measuring the content of acidic substances in industrial gear oil and can reflect the oxidation degree of the gear oil and the consumption of additives. During the oxidation process of the gear oil, a large number of acidic substances, such as carboxylic acids and keto acids, will be generated, resulting in an increase in the acid value of the gear oil. At the same time, some additives will also decompose or react during use, generating acidic substances and affecting the acid value of the gear oil. By regularly detecting the acid value of the gear oil, the oxidation process of the gear oil and the consumption of additives can be understood. When the acid value of the gear oil exceeds the specified limit, it indicates that the gear oil has undergone serious oxidation deterioration, and the gear oil needs to be replaced in a timely manner to avoid damage to the gears. The acid value detection method is simple and easy to implement, and is usually measured by potentiometric titration or indicator titration, and is one of the important detection items in the failure analysis of industrial gear oil additive packages.
Ferrography Analysis
Ferrography analysis is a technology that uses a high-gradient strong magnetic field to separate the wear particles in the gear oil and observe and analyze them. Through ferrography analysis, the wear state and wear mechanism of the gears can be understood, and the lubrication performance of the gear oil additive package can be judged. In ferrography analysis, first, the gear oil sample containing wear particles is passed through a special glass substrate. Under the action of a high-gradient strong magnetic field, the wear particles will be orderly deposited on the glass substrate according to their size and shape to form a ferrogram. Then, an optical microscope or an electron microscope is used to observe the ferrogram and analyze the morphology, size, composition, and other information of the wear particles. Different wear mechanisms will produce wear particles of different morphologies. For example, the particles generated by normal wear are generally flaky, while the particles generated by fatigue wear are generally spherical or blocky. Through the analysis of the wear particles, it can be judged whether the gears have abnormal wear and whether the gear oil additive package can effectively protect the gears. In addition, ferrography analysis can also detect whether there are external contaminants, such as dust and sand grains, in the gear oil, providing important clues for failure analysis.
III. Preventive Strategies for Failure
Reasonable Selection of Gear Oil Additive Packages
Selecting a suitable industrial gear oil additive package according to the working conditions of industrial gears, such as load size, rotational speed, and working temperature range, is the primary measure for preventing failure. For industrial gears with high loads and low speeds, a gear oil additive package with high extreme pressure performance and anti-wear performance should be selected to ensure that an effective lubricating film can be formed under harsh working conditions to protect the gear surface. For example, gear oil additive packages containing sulfur-phosphorus type extreme pressure anti-wear agents are suitable for heavy-duty industrial gears. For gears operating under high-temperature working conditions, a gear oil additive package with good oxidation resistance and high-temperature stability should be selected to prevent the gear oil from undergoing oxidation deterioration at high temperatures. At the same time, it is necessary to ensure that the selected gear oil additive package has good compatibility with the sealing materials and metal components of the equipment to avoid chemical reactions that may affect the performance of the gear oil and the normal operation of the equipment. In addition, gear oil additive package products that are reliable in quality and meet the requirements should be selected according to the recommendations of the equipment manufacturer and industry standards.
Strengthening Equipment Operation Management
Optimizing the operation parameters of the equipment and avoiding the operation of gears under harsh working conditions such as overloading and overspeed is helpful for extending the service life of industrial gear oil additive packages. Formulating reasonable equipment operation procedures, strictly controlling the working load and rotational speed of the gears, avoiding frequent starting, stopping, and variable load operation, and reducing the shear stress and impact load on the gear oil additive package. Regularly maintain the equipment, check the meshing condition of the gears, the operation state of the bearings, etc., and promptly adjust and repair the faults of the equipment to ensure the normal operation of the equipment. In addition, it is necessary to keep the working environment of the equipment clean, reduce the intrusion of contaminants such as dust and moisture, and create a good working condition for the gear oil additive package.
Regular Monitoring and Maintenance
Establishing a complete monitoring system for gear oil additive packages, regularly sampling and detecting the gear oil, and promptly mastering the performance changes of the gear oil. According to the detection results, formulate a reasonable oil change cycle. Generally speaking, the gear oil can be comprehensively judged whether it needs to be replaced by detecting the viscosity, acid value, moisture content, additive content, and other indicators of the gear oil. When the performance indicators of the gear oil exceed the specified limits, the new oil should be replaced in a timely manner to ensure the normal lubrication of the gears. In addition, during the operation of the equipment, it is necessary to pay attention to observing the operation state of the gears, such as whether there are abnormal noises, vibrations, and other phenomena. Once an abnormality is found, the equipment should be stopped for inspection in a timely manner, the cause should be analyzed, and corresponding measures should be taken for treatment.
Prevention of Contamination
Taking effective measures to prevent the intrusion of external contaminants into the gear oil additive package system. During the design and installation of the equipment, the sealing measures should be strengthened to ensure that the sealing of components such as the gearbox and the lubrication system is good and prevent the entry of contaminants such as dust and moisture. During the storage and transportation of the gear oil, special containers and equipment should be used to avoid mixing with other oil products and prevent contamination. At the same time, the filtration system of the gear oil should be regularly inspected and maintained to ensure the normal operation of the filter and promptly remove the solid particle contaminants in the gear oil. In addition, when adding new oil, it is necessary to ensure the cleanliness of the new oil and avoid introducing contaminants into the gear oil system.
Additive Supplementation and Formulation
For some working conditions where the additives are consumed relatively quickly, the gear oil additive package can be supplemented with additives regularly according to the actual situation. By detecting the additive content in the gear oil, determine the types and quantities of additives that need to be supplemented, and then add them to the gear oil according to the specified ratio. During the additive supplementation process, attention should be paid to the compatibility of the additives to avoid adverse reactions between different types of additives. In addition, the gear oil additive package can also be formulated according to the actual use situation of the gear oil to optimize the additive formulation to meet the lubrication requirements of the gears under specific working conditions. For example, under high-temperature and high-load working conditions, the content of antioxidants and extreme pressure anti-wear agents can be appropriately increased to improve the performance of the gear oil.
Conclusion
The failure analysis of industrial gear oil additive packages is an important means for ensuring the normal operation of industrial gears and enhancing the reliability of mechanical equipment. Through in-depth analysis of common causes of failure, such as shear degradation, oxidation deterioration, contamination, and additive consumption, and combining advanced detection technologies such as infrared spectroscopy analysis, chromatographic analysis, viscosity detection, acid value detection, and ferrography analysis, the causes and types of failure of gear oil additive packages can be accurately identified. On this basis, taking effective preventive strategies such as reasonable selection of gear oil additive packages, strengthening equipment operation management, regular monitoring and maintenance, prevention of contamination, and additive supplementation and formulation can significantly reduce the failure risk of industrial gear oil additive packages, extend the service life of the gear oil, reduce equipment failures and maintenance costs, and improve the efficiency and safety of industrial production. Therefore, the failure analysis of industrial gear oil additive packages has important application value and practical significance in industrial production practice and should attract the high attention of industrial enterprises and relevant technical personnel. With the continuous development and progress of industrial technology, the research on the failure analysis of industrial gear oil additive packages will also be continuously deepened, providing more powerful technical support for the lubrication and protection of industrial gears.
The Price of Additive Packages
The price of Additive Packages varies depending on factors such as brand, specification, composition, and sales channels. If you are interested in Additive Packages, please feel free to contact us.
Supplier of Additive Packages
UNPChemicals is a professional supplier of high-quality and effective Additive Packages. We offer several remarkable products, namely Industrial Gear Oil Additives UNP IG402A,High extreme pressure (EP) type industrial gear oil additive packages UNP IG402B,Low-Odor Type Industrial Gear Oil Additive Package UNP IG402C,etc.
Industrial Gear Oil Additives UNP IG402Aare a specialized class of compounds designed to enhance the performance of gear oils in various industrial applications.These additives are carefully formulated to provide a combination of properties that improve the efficiency,longevity,and reliability of gear systems.
High extreme pressure (EP) type industrial gear oil additive packages, like UNP IG402B, are specialized blends of chemical compounds designed to enhance the performance of base oils used in industrial gear lubricants. These packages are formulated to provide exceptional protection under conditions where gears experience heavy loads, high pressures, and potential metal-to-metal contact.
The Low-Odor Type Industrial Gear Oil Additive Package UNP IG402C is a specialized blend of chemical additives designed to enhance the performance of industrial gear oils while minimizing the strong odors typically associated with traditional gear oil additives, particularly those containing sulfur-based extreme pressure (EP) agents. This additive package is mixed with base oils (mineral or synthetic) to create gear lubricants that protect industrial gearboxes under demanding conditions, such as high loads and temperatures, while being more user-friendly in terms of smell—ideal for environments where odor control is a priority.
Professional Lubricant Additive Manufacturer
UNPChemicals,aka Luoyang Pacific United Petrochemical Co., Ltd., focuses on the application and development of special lubricating grease additives such as MODTC, MODTP, molybdenum amide, thiadiazole metal deactivators, and phosphate esters. With nearly 30 products in seven series, including extreme pressure anti-wear additives and special grease additives, it is a global manufacturer of special lubricating grease additives and a national high-tech enterprise with great influence and leading role in the industry. If you are looking for Lubricant Additive or technical information, feel free to contact UNPChemicals.