LUBRICATION TECHNOLOGY FOR ADVANCED ENGINES: AN ASSESSMENT OF INDUSTRIAL NEEDS

prepared by STEPHEN M. HSU AND MARSHALL PETERSON

THE SURFACE PROPERTIES GROUP NATIONAL INSTITUTE OF STANDARDS AND TECHNOLOGY

for THE U.S. DEPARTMENT OF ENERGY

OFFICE OF TRANSPORTATION TECHNOLOGIES OFFICE OF TRANSPORTATION MATERIALS

MECHANICAL ENGINEERS

Street • New York, N.Y. 10017

TABLE OF CONTENTS

EXECUTIVE SUMMARY vii

1.0 INTRODUCTION 1

2.0 BACKGROUND 1

2.1 EMISSION CONTROL 2

2.2 FUEL EFFICIENCY 5

2.3 ALTERNATIVE FUELS 6

2.4 LIGHTWEIGHT AND NEW MATERIALS 7

2.5 ADVANCED ENGINE DEVELOPMENT 9

3.0 INDUSTRIAL WORKSHOP 13

3.1 WORKSHOP FORMAT AND ORGANIZATION 13

4.0 AUTOMOTIVE ENGINES AND THEIR COMPONENTS 23

4.1 TECHNICAL PRESENTATIONS 23

4.1.1 Dr. Shirley Schwartz, GM 23

4.1.2 Dr. Larry Ting, Ford Motor Co 24

4.1.3 Dr. Frank Savel, TRW 27

4.1.4 Dr. Herbert Cheng, Northwestern University 28

4.1.5 Dr. Phil Mott, Borg Warner . 28

4.1.6 Dr. Vaughn Hackworth, GM Harrison Radiator Division 33

4.2 PANEL DISCUSSIONS AND REPORTS 36

4.2.1 Group 1. Transmission and Gears, Dr. Phil Mott, Borg Warner, Chairman 36

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4.2.2 Group 2. Future Automotive Lubrication Needs,

Dr. Vaughn Hackworth, GM, Chairman . , 37

5.0 HEAVY DUTY DIESEL ENGINES 40

5.1 TECHNICAL PRESENTATIONS 40

5.1.1 Dr. Frank Kelley, Caterpillar 40

5.1.2 Dr. Tom Gallant, Cummins Engine Co 42

5.1.3 Dr. Mike Haselkorn, Caterpillar 44

5.1.4 Dr. Malcolm Naylor, Cummins 44

5.1.5 Dr. Roy Kamo, Adiabatics 45

5.1.6 Dr. Rifat Keribar, Ricardo NA 50

5.1.7 Dr. Nabu Hakim, Detroit Diesel 52

5.1.8 Dr. Bob Burrahm, SwRI 52

5.2 PANEL REPORTS 54

5.2.1 Group 3. Materials for Diesel Engines, Dr. Malcolm Naylor, Cummins Engine Co., Chairman 54

5.2.2 Group 4. Heavy Duty Diesel-Million Mile Engine,

Dr. Frank Kelley, Caterpillar Inc., Chairman 55

6.0 LUBRICANT/ADDITIVE INDUSTRIES 57

6.1 PANEL REPORT 58

6.1.1 Group 5. Lubricant and Lubricant Additives,

Dr. Stephen Roby, Lubrizol, Chairman 58

7.0 OTHER RELATED PROGRAMS AND INDUSTRIES 60

7.1. TECHNICAL PRESENTATIONS AND SUBMITTED INFORMATION . 60

7.1.1 Dr. Bill Nieman, Allied-Signal Corp 60

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7.1.2 Dr. Robert Bill, U.S. Army Vehicle Propulsion Directorate 61

7.1.3 Heavy Duty Transport Program, Mr. John Fairbanks,

DOE 62

7.1.4 DOE OTM Tribology Program, Dr. Joseph Perez, DOE 63

7.1.5 Engineered Surfaces and Interfaces, Dr. George Fenske, Argonne 64

7.1.6 The Role of Government in Fostering Industrial Cooperative Research, Dr. J. J. Eberhardt, Office of Transportation Materials, DOE 69

8.0 TECHNICAL SURVEY AND QUESTIONNAIRE RESULTS 71

8.1 TECHNICAL SURVEY 72

8.2 QUESTIONNAIRE RESULTS 75

9.0 CONCLUSIONS 79

10.0 REFERENCES 83

11.0 APPENDIX 87

Participants List 87

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