Fuels and Lubricants Research Division

Transcription

2014
22
The Fuels and Lubricants Research Division of Southwest Research
®
Institute includes extensive engines, fuels and lubricants research,
development and evaluation activities.
Fuels and
Lubricants
Research
Division
Technical
Services
The result is unequaled capabilities for automotive product research,
development, testing and evaluation. A client-driven and technologyoriented staff of more than 400 provides a broad range of services
for research, development, qualification, demonstration, certification,
or evaluation of automotive components and petroleum products
used in cars, trucks, buses, locomotives, tractors, motorcycles and
outboard engines, or any other internal combustion engine
application.
Our services include bench, laboratory or field demonstrations and
include worldwide specifications. We provide all relevant and
applicable ASTM, OEM and other recognized procedures. An even
greater variety and range of services is provided for specific
applications and special needs. This publication contains a partial list
of the services available, organized by department. We welcome
your inquiries and will provide price quotes on request at no
obligation. Key personnel are listed at the beginning of each section.
Steven D. Marty, P.E., Vice President
Southwest Research Institute
6220 Culebra Road
P.O. Drawer 28510
San Antonio, Texas USA 78228-0510
(210) 522-5929
[email protected]
www.flrd.swri.org
www.swri.org
The Fuels and Lubricants Research Division is:
• Certified to ISO 9001:2008, “Quality Management Systems Requirements”
• Accredited to ISO/IEC 17025:2005, “General Requirements for the
Competence of Testing and Calibration Laboratories”
• Certified to ISO 14001:2004, “Environmental Management
Systems”
The Division also has achieved Ford Tier 1 status for providing
engineering services and has received the Ford Q1 Quality Award.
In conjunction with these Divisional quality system accomplishments:
• The Petroleum Products Research Department is a Nuclear
Procurement Issues Committee (NUPIC)-Approved Laboratory.
• The Fuels and Lubricants Research Department has maintained its
status as an American Chemistry Council (ACC)-Approved
Laboratory.
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Table of Contents
ENGINE LUBRICANTS RESEARCH DEPARTMENT ................................................... 1
ENGINE LUBRICANTS RESEARCH DEPARTMENT ................................................... 2
Gasoline Engine Lubricant Certification Testing ................................................................... 2
Calibrated Sequence IIIF Lubricant Test .................................................................................................. 2
Calibrated Sequence IIIFHD Lubricant Test ............................................................................................. 2
Calibrated Sequence IIIG Lubricant Test .................................................................................................. 2
Calibrated Sequence IIIGA Lubricant Test ............................................................................................... 2
Calibrated Sequence IIIGB Lubricant Test ............................................................................................... 2
Calibrated Sequence IVA Lubricant Test .................................................................................................. 2
Calibrated Sequence VG Lubricant Test .................................................................................................. 2
Calibrated Sequence VIB Lubricant Test .................................................................................................. 2
Calibrated Sequence VID Lubricant Test.................................................................................................. 2
Calibrated Sequence VIII Lubricant Test .................................................................................................. 2
Calibrated Ball Rust Test .......................................................................................................................... 2
Diesel Engine Lubricant Certification Testing ....................................................................... 2
Caterpillar 1K Lubricant Test..................................................................................................................... 2
Caterpillar 1M-PC Lubricant Test .............................................................................................................. 3
Caterpillar 1N Lubricant Test .................................................................................................................... 3
Caterpillar 1P Lubricant Test..................................................................................................................... 3
Caterpillar 1R Lubricant Test .................................................................................................................... 3
Caterpillar C13 Lubricant Test .................................................................................................................. 3
Mack T8/T8A/T8E Lubricant Test ............................................................................................................. 3
Mack T10A Lubricant Test ........................................................................................................................ 3
Mack T11 Lubricant Test........................................................................................................................... 3
Mack T12 Lubricant Test........................................................................................................................... 3
Roller Follower Wear Test (RFWT) ........................................................................................................... 3
Engine Oil Aeration Test (EOAT) .............................................................................................................. 3
Cummins ISB Lubricant Test .................................................................................................................... 3
Cummins ISM Lubricant Test .................................................................................................................... 4
Specialized Diesel Engine Testing.......................................................................................... 4
Railroad and Marine .................................................................................................................................. 4
Fuel Additives ............................................................................................................................................ 4
Fuel Consumption ..................................................................................................................................... 4
Alternative Fuels ....................................................................................................................................... 4
Fuel System Wear..................................................................................................................................... 4
Durability ................................................................................................................................................... 4
Injector Deposit/Coking ............................................................................................................................. 4
Engine Hardware ...................................................................................................................................... 4
Oil Consumption ........................................................................................................................................ 4
New Engine vs. Available Lubricants ........................................................................................................ 4
Valve Guttering ......................................................................................................................................... 4
Destructive Evaluations ............................................................................................................................. 4
Oil Consumption Apparatus ...................................................................................................................... 4
Parts Analysis ........................................................................................................................................... 4
Ratings ...................................................................................................................................................... 5
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Turbocharger Durability/Lubrication .......................................................................................................... 5
Tribology and Advanced Lubricant Evaluations ................................................................... 5
Plint TE-77 Reciprocating Test Rig ........................................................................................................... 5
High-Pressure, -Temperature and -Frequency Reciprocating Rig ........................................................... 5
Falex Block-on-Ring Test Rig ................................................................................................................... 5
PCS Instruments Mini Traction Machine (MTM2) ..................................................................................... 5
JASO Diesel Engine Lubricant Testing .................................................................................. 5
Mitsubishi 4D34T4 Valve Train Wear JASO M354:1999 .......................................................................... 5
ASTM-TC Procedures for Two-Stroke, Air-Cooled Engines.................................................. 5
D4857-12 TC Seq. I (Y350M2 Detergency) .............................................................................................. 5
D4863-13 TC Seq. II (CE50S Lubricity) .................................................................................................... 5
D4858-13 TC Seq. III (CE50S Pre-Ignition) .............................................................................................. 5
NMMA TC-W3® Procedures for Two-Cycle Outboard Engines ............................................. 6
CE50S Lubricity ........................................................................................................................................ 6
NMMA TC-W3 AF-27 Lubricity.................................................................................................................. 6
OMC 40 HP General Performance ........................................................................................................... 6
OMC 70 HP Detergency ........................................................................................................................... 6
Mercury 15 HP Detergency ....................................................................................................................... 6
Pre-Ignition ................................................................................................................................................ 6
NMMA FC-W ® and FC-W Catalyst Compatible® Procedures for Four-Cycle Outboard
Engines ..................................................................................................................................... 6
NMMA FC-W 115 HP General Performance Engine Test ........................................................................ 6
JASO FB, FC, FD, EGB, EGC & EGD Procedures for Two-Stroke Lubricant Engine Testing
.................................................................................................................................................. 6
M 342-92 Smoke ....................................................................................................................................... 6
M 343-92 Exhaust System Blocking ......................................................................................................... 6
M 341-92 Detergency................................................................................................................................ 6
M 340-92 Lubricity..................................................................................................................................... 6
M 341-02 Three-Hour Detergency ............................................................................................................ 6
Field Test Engine – Complete New Powerhead Inspection ...................................................................... 6
Field Test Engine – Block and Piston Inspection ...................................................................................... 6
Component, Product and Additive Testing ............................................................................ 7
Engine Rating and Measurements ............................................................................................................ 7
Aircraft Product Testing............................................................................................................................. 7
Additive Testing ......................................................................................................................................... 7
Sequence Test Development .................................................................................................................... 7
Gaskets and Seals .................................................................................................................................... 7
Two-Stroke Cycle Tests ............................................................................................................................ 7
Test Equipment, Fabrication and Training Export Services...................................................................... 7
Natural Gas Lubricant Evaluations ........................................................................................................... 7
FUELS AND DRIVELINE LUBRICANTS RESEARCH DEPARTMENT......................... 8
FUELS AND DRIVELINE LUBRICANTS RESEARCH DEPARTMENT......................... 9
Transmission Fluid Testing..................................................................................................... 9
General Motors Automatic Transmission Fluids Testing...................................................... 9
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®
®
DEXRON -VI Chemical and Bench Tests (DEXRON -VI Items A-M, and O-U) ...................................... 9
®
DEXRON -VI Oxidation Test .................................................................................................................... 9
®
DEXRON -VI Cycling Test........................................................................................................................ 9
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DEXRON -VI Plate Clutch Friction Test ................................................................................................... 9
®
DEXRON -VI Wear Test ........................................................................................................................... 9
®
DEXRON -VI Aeration Test ...................................................................................................................... 9
®
DEXRON -VI Low Speed Clutch Friction and Torque Capacity Test ....................................................... 9
Ford Automatic Transmission Fluid Testing.......................................................................... 9
®
®
MERCON V Chemical and Bench Tests (MERCON V items 3.1 thru 3.7, 3.9 and 3.10) ..................... 9
®
MERCON V Wear Tests ........................................................................................................................ 10
®
MERCON V Aluminum Beaker Oxidation Test (ABOT) ........................................................................ 10
®
MERCON V Clutch Friction Durability Test ........................................................................................... 10
®
MERCON V Anti-Shudder Durability ..................................................................................................... 10
Ford Over-Running Clutch (AX4N OWC) Wear Test Procedure ............................................................ 10
Allison Severe Duty, Extended Drain Interval Automatic Transmission Fluid Testing ......10
Allison TES-295 Chemical and Bench Tests .......................................................................................... 10
Allison TES-295 Oxidation Test .............................................................................................................. 10
Allison TES-295 Wear Tests ................................................................................................................... 10
Allison TES-295 Frictional Properties Tests ........................................................................................... 10
Allison On-Highway Automatic Transmission Fluid Testing ...............................................10
Allison TES-389 Chemical and Bench Tests .......................................................................................... 10
Allison TES-389 Wear Test ..................................................................................................................... 10
Allison TES-389 Oxidation Resistance Test ........................................................................................... 10
Allison TES-389 Friction Tests ................................................................................................................ 11
Allison Heavy-Duty Automatic Transmission Fluid Testing ................................................11
Allison TES-439 Chemical and Bench Test ............................................................................................ 11
Allison TES-439 Oxidation Test .............................................................................................................. 11
Allison TES-439 Graphite High-Energy Friction Test ............................................................................. 11
JASO SAE #2 Testing .............................................................................................................11
JASO T903:2011 and M348:2002 Clutch Friction Test .......................................................................... 11
Caterpillar Transmission and Drivetrain Fluid Testing ........................................................11
TO-4 Physical Properties ........................................................................................................................ 11
TO-4 Elastomer Compatibility ................................................................................................................. 11
TO-4 Oxidation Stability .......................................................................................................................... 11
TO-4 Gear Wear Test (ASTM D4998) .................................................................................................... 11
TO-4 Pump Wear Test ............................................................................................................................ 11
TO-4 Friction Properties .......................................................................................................................... 11
Hydraulic Fluid Testing ..........................................................................................................12
DIN 51389-2 Vane Pump Wear Test ...................................................................................................... 12
Conestoga Pump Test (ASTM D7043) ................................................................................................... 12
Eaton 35VQ25A Pump Test .................................................................................................................... 12
Denison T6H20C Hybrid Pump - Phase I ............................................................................................... 12
Manual Transmission and Rear Axle Gear Lubricant Performance Testing .......................12
L-20 High-Torque Test ............................................................................................................................ 12
L-33-1 Moisture Corrosion Test (ASTM D7038) ..................................................................................... 12
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L-37 High-Torque Test (ASTM D6121) ................................................................................................... 12
L-42 High-Speed Shock Axle Test (ASTM D7452) ................................................................................. 12
L-60-1 Thermal and Oxidative Stability Test (ASTM D5704) .................................................................. 12
FZG Gear Wear Test (ASTM D4998) ..................................................................................................... 13
FZG Load Stage Test (ASTM D5182) .................................................................................................... 13
Axle Efficiency Test ................................................................................................................................. 13
FZG Pitting Test with Type C Gear ......................................................................................................... 13
FZG Step Load (A10/16.6R/90:120) ....................................................................................................... 13
Manual Transmission High-Temperature Cyclic Durability Test (ASTM D5579) .................................... 13
SSP 180 Synchronizer ............................................................................................................................ 13
Mack GO-J/J+ and Eaton PS-163 Test Procedures ............................................................................... 13
Manual Transmission and Dry Clutch Transmission (dDCT) Fluid Testing ........................14
General Motors Dry Dual Clutch Transmissions Fluids Testing .........................................14
®
DEXRON -dDCT Chemical and Bench Tests ........................................................................................ 14
®
DEXRON -dDCT Wear Test ................................................................................................................... 14
®
DEXRON -dDCT Scuffing Protection Test ............................................................................................. 14
®
DEXRON -dDCT Synchronizer Function Test ....................................................................................... 14
Tractor Testing ........................................................................................................................14
Tractor Field Tests .................................................................................................................................. 14
Tractor Fluids Specification Testing......................................................................................14
Tractor Hydraulic Fluid Testing ............................................................................................................... 14
JDQ-84 Dynamic Corrosion Sauer-Danfoss Pump Test ........................................................................ 14
JDQ-94 Powershift Transmission Clutch Friction Test ........................................................................... 14
JDQ-102 Shear Stability.......................................................................................................................... 14
JDQ-95 Spiral Bevel/Final Drive Wear Test............................................................................................ 15
JDQ-96B Torque Variation and Brake Friction Retention Test ............................................................... 15
John Deere Hydraulic Pump Shear Stability ........................................................................................... 15
JDQ-95A Spiral Bevel Gear Wear .......................................................................................................... 15
John Deere High Energy Clutch ............................................................................................................. 15
John Deere TZT Oxidation ...................................................................................................................... 15
Automotive Fleet Testing .......................................................................................................15
Axle and Axle Lubricant Evaluations, Heavy-Duty .................................................................................. 15
Axle and Axle Lubricant Evaluations, Light-Duty .................................................................................... 15
Truck Axle Lubricant Fuel Economy ....................................................................................................... 15
Crankcase Engine Lubricant Fuel Economy ........................................................................................... 15
Truck Fuel Economy Improvements ....................................................................................................... 16
Durability and Reliability Evaluation of Engine/Vehicle Compatibility ..................................................... 16
Road Simulators/Mileage Accumulation Dynamometers ........................................................................ 16
Vehicle Test Tracks................................................................................................................................. 16
Off-Highway Evaluations ......................................................................................................................... 16
John Deere Engine Coolant Cavitation Test ........................................................................................... 16
Specialized Fuel Testing ........................................................................................................16
Vehicle Evaluations for Fuel Injector Plugging........................................................................................ 16
Intake System and Combustion Chamber Deposits ............................................................................... 16
Intake Valve-Sticking Evaluations ........................................................................................................... 16
Vehicle Driveability and Performance Testing ........................................................................................ 16
v
Vehicle Octane Requirement and ORI Evaluations ................................................................................ 17
Alternative Fuels Testing (Methanol, Ethanol, Natural Gas and others) ................................................ 17
Octane Requirement Increase (ORI) ...................................................................................................... 17
Gasoline Direct Injection GDI) Fuel Injector Deposits ............................................................................ 17
Sequential Central Port Injection Fouling Test........................................................................................ 17
PETROLEUM PRODUCTS RESEARCH DEPARTMENT ............................................ 18
PETROLEUM PRODUCTS RESEARCH DEPARTMENT ............................................ 19
Fuel, Lubricant and Fluid Inspection ....................................................................................................... 19
Metals Analyses ...................................................................................................................................... 19
Fuel Conformance/Fuel Surveys/Field Studies....................................................................................... 19
Trace Organic Analysis ........................................................................................................................... 19
Laboratory Engine Technology ............................................................................................................... 19
SwRI-developed Instruments .................................................................................................................. 19
Petroleum Products Research ................................................................................................................ 20
Used Lubricant Field Studies .................................................................................................................. 20
Procedural Development......................................................................................................................... 20
Trend Analysis ........................................................................................................................................ 20
Lubricants and Fluid Evaluations ............................................................................................................ 20
Engine Lubricants ................................................................................................................................... 20
Gear Lubricants ....................................................................................................................................... 20
Transmission Fluids ................................................................................................................................ 20
Industrial Lubricants ................................................................................................................................ 20
Engine Coolants ...................................................................................................................................... 20
FUELS AND LUBRICANTS TECHNOLOGY DEPARTMENT ..................................... 21
FUELS AND LUBRICANTS TECHNOLOGY DEPARTMENT ..................................... 22
Automotive Filtration Performance Testing ............................................................................................. 22
Fluids Filtration and Handling Research ................................................................................................. 22
Fuels, Lubricants, and Fluids Applications .............................................................................................. 22
Fuel Systems and Contamination Research........................................................................................... 23
Filtration and Fine Particle Technology................................................................................................... 23
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Engine Lubricants Research Department
Mike Lochte, Director ................................................................................ (210) 522-5430
William A. Buscher III, Manager, Gasoline Lubricant Evaluations ............................... (210) 522-6802
Jim McCord, Manager, Diesel Engine Lubricants ........................................................ (210) 522-3439
Dr. Peter Lee, Principal Engineer, Tribology................................................................ (210) 522-5545
Dr. Sylvain Kouame, Research Engineer, Advanced Lubricant Evaluations ............... (210) 522-5271
1
Calibrated Sequence IIIGB Lubricant Test
This 100-hour test evaluates phosphorus
retention of a lubricant after operation at high
temperature test conditions. Test conditions are
identical to the Sequence IIIG test.
Engine Lubricants
Research Department
Mike Lochte, Director
(210) 522-5430
Calibrated Sequence IVA Lubricant Test
This 100-hour engine dynamometer lubricant
test is designed to evaluate low temperature
camshaft lobe wear. It evaluates the VE wear
aspect that has been eliminated from the VG
test.
William A. Buscher III, Manager
Gasoline Lubricant Evaluations
(210) 522-6802
Jim McCord, Manager
Diesel Engine Lubricants
(210) 522-3439
Calibrated Sequence VG Lubricant Test
test is designed to evaluate a lubricant’s
performance in combating low temperature
sludge and varnish formation.
Dr. Peter Lee, Principal Engineer
Tribology
(210) 522-5545
Dr. Sylvain Kouame, Research Engineer
Advanced Lubricant Evaluations
(210) 522-5271
Calibrated Sequence VIB Lubricant Test
test measures the effects of lubricants on fuel
economy of gasoline engine passenger cars and
light-duty trucks.
Gasoline Engine Lubricant
Certification Testing
Calibrated Sequence VID Lubricant Test
test measures the effects of lubricants on fuel
economy of gasoline engine passenger cars and
light-duty trucks equipped with a “low-friction”
engine.
Calibrated Sequence IIIF Lubricant Test
This 80-hour engine dynamometer lubricant test
evaluates a lubricant’s ability to prevent
camshaft lobe wear, valve lifter wear, and hightemperature oxidation. In addition, varnish and
piston deposits are evaluated.
Calibrated Sequence VIII Lubricant Test
This 40-hour test measures lubricant shear
stability and evaluates a lubricant’s ability to
inhibit bearing corrosion.
Calibrated Sequence IIIFHD Lubricant Test
This 60-hour test measures high temperature
oxidation performance of a lubricant. Test
conditions are identical to the Sequence IIIF test
with the exception of test length.
Calibrated Ball Rust Test
This 18-hour bench test is designed to simulate
the Sequence IID test. This test evaluates a
lubricant’s ability to prevent rust formation on
critical engine components.
Calibrated Sequence IIIG Lubricant Test
This 100-hour test evaluates a lubricant’s ability
to prevent camshaft lobe wear, valve lifter wear
and high temperature oxidation. In addition,
varnish and piston deposits are evaluated.
Operational conditions are similar to the
Sequence IIIF but at a more severe level.
Diesel Engine Lubricant Certification
Testing
Caterpillar 1K Lubricant Test
This test evaluates the piston deposits, liner
wear, and oil consumption associated with test
lubricants using 0.4 percent sulfur fuel. Run on a
Caterpillar 1Y540 single-cylinder direct injection
engine, the procedure is steady state at 2,100
rpm and 8,000 BTU per minute fuel rate for 252
Calibrated Sequence IIIGA Lubricant Test
This 100-hour test evaluates the cold
temperature viscosity of a lubricant after
operation at high temperature test conditions.
Test conditions are identical to the Sequence
IIIG test.
2
hours. This test is required by CI-4, CH-4 and
MIL-L-2104F.
250 hours for the T8, 150 hours for the T8A, and
300 hours for the T8E.
Caterpillar 1M-PC Lubricant Test
This 120-hour lubricant test is conducted on a
1Y73 indirect injection single-cylinder engine at
1,800 rpm and 42 hp. The test evaluates piston
deposits, ring sticking, ring and cylinder liner
wear, and piston, ring, and liner scuffing.
Mack T10A Lubricant Test
This 75-hour test evaluates the ability of an
engine lubricant to control its low temperature
viscometrics. A prototype E-Tech engine is
used. This test is required for the CI-4 category.
Mack T11 Lubricant Test
This 252-hour test uses a Mack prototype ETech engine operating at 1,800 rpm with noncondensing cooled EGR and production 2002
heads, injectors and pistons, to evaluate a
lubricant’s ability to limit viscosity increase with
high soot loading. This test is part of Mack
engine lubricant specifications EON+ 03, CI-4+
and CJ-4.
Caterpillar 1N Lubricant Test
calibrated 1Y540 engine, exactly like the 1K test
except 0.05 percent sulfur fuel is used. This test
is required for the CJ-4 category.
Caterpillar 1P Lubricant Test
This test evaluates piston deposits, ring sticking,
ring and cylinder liner wear, and piston, ring and
liner scuffing, as well as lubricant consumption.
The test is required for the CH-4 API category.
calibrated 1Y3700 single-cylinder overhead
cam, electronically-controlled, direct injection
engine using 0.05 percent sulfur fuel and a twopiece piston with a steel crown and aluminum
skirt.
Mack T12 Lubricant Test
This 300-hour test uses much the same
hardware as the T10 test, but now has a
variable geometry turbocharger and production
EGR cooling heat exchangers. To simulate 2007
engine operation, EGR rates are increased
significantly from the T10 levels. Test objectives
are the same; to minimize cylinder liner, ring and
bearing wear. This test is required for the CJ-4
category.
Caterpillar 1R Lubricant Test
The purpose of this 504-hour test is to evaluate
the performance of crankcase lubricants with
respect to piston deposits, ring sticking, ring and
cylinder wear, piston, ring and liner scuffing, as
well as lubricant consumption. This test is
required for the CI-4 category and uses a
calibrated 1Y3700 engine with 0.05 percent
sulfur fuel.
Roller Follower Wear Test (RFWT)
This high-soot engine test is used to evaluate
how well test lubricants limit axle wear in the
roller cam lifter. For the test, a 6.5-liter, eightcylinder, naturally aspirated, indirect-injection
diesel engine is operated at 1,000 rpm with a
high load for 50 hours. The test is required for
CH-4, CI-4, and CJ-4 qualifications.
Caterpillar C13 Lubricant Test
This 500-hour test uses a Caterpillar C13 engine
with all steel pistons operated at 1,800 rpm and
1,200 grams per minute fuel rate to evaluate the
performance of crankcase lubricants with regard
to piston deposits and lubricant consumption.
The test is required for the CJ-4 category.
Engine Oil Aeration Test (EOAT)
This 20-hour test, using an International truck,
7.3-liter engine running at 3,000 rpm and wideopen throttle, evaluates an engine lubricant’s
resistance to aeration. This test is required for
CH-4, CI-4, and CJ-4 qualifications.
Mack T8/T8A/T8E Lubricant Test
Test lubricants are evaluated for their ability to
minimize viscosity increase and oil filter plugging
associated with soot loading. The test, required
for API classifications CH-4, CI-4, and Mack
EOL/M specifications, uses a 1991 in-line, sixcylinder, Mack E7-350, turbocharged, charge
air-cooled, direct-injection diesel engine at 1,800
rpm. The engine is operated at rated load for
Cummins ISB Lubricant Test
This 350-hour test uses a Cummins ISB engine
and is used to evaluate a crankcase lubricant’s
ability to reduce camshaft lobe and sliding cam
follower wear. After an initial 100 hours of steady
state operation at 1,600 rpm to accumulate 3.25
percent soot in the oil, the engine is operated for
250 hours on a 28-second cycle simulating front-
3
end loader operation. This test is required for
CJ-4 qualifications.
Fuel System Wear
New techniques are used to rapidly access the
wear of fuel-lubricated fuel system components,
especially pumps.
Cummins ISM Lubricant Test
This 200-hour test uses a Cummins ISM engine
and is intended as a replacement test for the
M11 EGR, using newer hardware. The engine
has variable geometry turbo-charging,
production EGR coolers and EGR valve. It
evaluates a lubricant’s effectiveness at reducing
soot related overhead wear, sludge and filter
plugging. This test is required for CJ-4, as well
as being an alternative to the M-11 EGR for the
CI-4 category.
Durability
Durability evaluations are conducted around the
clock under steady-state or cyclic conditions.
Injector Deposit/Coking
Evaluation and product experiments are
developed to meet specific requirements using a
range of engines and coking/deposit
mechanisms.
Specialized Diesel Engine Testing
Engine Hardware
Evaluations of engine hardware (pistons, rings,
cylinder liners, bearings, injectors, etc.) can be
tailored to meet specific requirements. Tests can
include special durability procedures and
evaluation of how metallurgy, surface finish, etc.
affect part performance.
SwRI uses many single- and multi-cylinder
engines to improve the understanding of fuel,
lubricant and special hardware behavior.
Standard, experimental and modified test
procedures are employed. The Institute offers an
array of services and will prepare proposals and
facilities for experimental work. Examples of
developmental activities include:
Oil Consumption
SwRI has designed specific programs to
correlate oil consumption to cylinder liner finish,
piston ring design, piston design, turbocharger
effects or other engine parameters in any diesel
engine.
Railroad and Marine
SwRI helps develop and conduct screening tests
and procedures that correlate with large-scale
tests to save time and money.
New Engine vs. Available Lubricants
The Institute develops and conducts procedures
to evaluate the compatibility of available
lubricants to newly designed engines.
Fuel Additives
Using a variety of test engines, SwRI evaluates
how fuel additives affect combustion deposits,
fuel consumption, power loss and gain, lubricant
additive reactions, etc. Fuel additive clean-up
and keep-clean tests are performed on the GM
6.5-liter engines.
Valve Guttering
Evaluations related to this aspect of lubricant
performance are available on a selection of twocycle engines. SwRI is experienced in the
experimental procedures that enhance valve
guttering.
Fuel Consumption
Special testing techniques are used to evaluate
how lubricants or fuel property changes affect
engine fuel consumption.
Destructive Evaluations
Tests to find the “weakest link” are performed
under maximum power or over-fuel conditions.
Alternative Fuels
Evaluations include optional fuels in a diesel
engine and extended fuel evaluations. For
example, appropriate engine and power
analyses are conducted for diesel fuels mixed
with alcohols or with esters of cottonseed or
sunflower oil.
Oil Consumption Apparatus
SwRI fabricates and evaluates various oil
consumption measurement devices for diesel
engines.
Parts Analysis
Specialized equipment is used to evaluate and
screen parts to understand how they can affect
4
lubricant testing and to determine parts durability
and predicted service life. SwRI offers
metallurgical analysis, including electron
microscopic analysis.
be manufactured from specific materials of
interest and surface finished or textured as
desired. Post-test wear scar analysis and
component surface film analysis provide indepth understanding of wear mechanisms.
Ratings
Institute staff members rate pistons, rings, liners
and other engine parts to industry standards.
Specialized ratings, including rating procedure
development, are available to meet specific or
unique applications.
PCS Instruments Mini Traction Machine
(MTM2)
A PCS Instruments Mini Traction Machine is yet
another method used to investigate the frictional
response and wear properties of materials and
lubricants. This machine utilizes a disk and
ball/barrel that can be rotated at different
speeds, giving slide roll rations from 0 to 100
percent. The SwRI rig has been modified to
allow extended temperature and load ranges.
There is also a pin-on-disk attachment, disc
reciprocating mode and real-time wear
measurement capability.
Turbocharger Durability/Lubrication
Turbocharger durability or engine lubricant
suitability tests are performed for turbocharged
engines.
Tribology and Advanced Lubricant
Evaluations
Plint TE-77 Reciprocating Test Rig
Standard ASTM D5706, D5707, D6079 and
ISO/DIN 12156-2 procedures as well as customdesigned test services are performed using a
Plint TE-77 test rig to investigate the frictional
response and wear properties of materials and
lubricants. Test components can be
manufactured from specific materials of interest
and surface finished or textured as desired.
Post-test wear scar analysis and component
surface film analysis provide in-depth
understanding of wear.
JASO Diesel Engine Lubricant
Testing
High-Pressure, -Temperature and -Frequency
Reciprocating Rig
A modified High-Frequency Reciprocating Rig
that also provides high pressure and high
temperature is used to measure the lubricity, or
ability of a fluid to affect friction and wear,
between surfaces in relative motion under load.
The system uses an electromagnetic vibrator to
oscillate a moving steel ball specimen over a
small amplitude while pressing it against a
stationary steel disk. This rig is capable of
operating up to 300°C and high pressure,
enabling testing of highly volatile fuels. ASTM
D6079 and D7688 tests can also be performed.
D4857-12 TC Seq. I (Y350M2 Detergency)
This 20-hour test primarily evaluates a
lubricant’s ability to inhibit piston ring sticking
and piston deposit formation. The fuel to
lubricant ratio is 50:1. The reference lubricant is
run in one cylinder, and the candidate lubricant
is run in the other.
Mitsubishi 4D34T4 Valve Train Wear
JASO M354:1999
This 160-hour test evaluates wear resistance on
valve operating systems for automotive diesel
engine lubricants using the Mitsubishi 4D34T4
engine.
ASTM-TC Procedures for Two-Stroke,
Air-Cooled Engines
D4863-13 TC Seq. II (CE50S Lubricity)
This test evaluates a lubricant’s ability to prevent
scuffing. The fuel to lubricant ratio is 150:1.
D4858-13 TC Seq. III (CE50S Pre-Ignition)
to prevent damage from deposit-induced preignition. The fuel to lubricant ratio is 20:1.
Falex Block-on-Ring Test Rig
Several ASTM standard tests including D2509,
D2714, D2782, D2981, D3704 and G77 as well
as customized investigations are conducted
using the Falex Block-on-Ring device to quantify
frictional response and wear properties of
materials and lubricants. Test components can
5
NMMA TC-W3®
Procedures for Two-Cycle
Outboard Engines
JASO FB, FC, FD, EGB, EGC & EGD
Procedures for Two-Stroke Lubricant
Engine Testing
CE50S Lubricity
This test evaluates how effectively a lubricant
prevents scuffing. The fuel to lubricant ratio is
150:1.
M 342-92 Smoke
This eight-hour test evaluates the visible smoke
level emitted from an engine exhaust system
operating at 10:1 fuel to lubricant ratio.
Candidate performance is evaluated against a
known quality reference lubricant.
NMMA TC-W3 AF-27 Lubricity
This test enhances the ability to evaluate the
lubricity of lubricating oils in two-stroke cycle
gasoline engines using a refinement of the
JASO M340-92 and TC-W3 CE-50S lubricity
tests.
M 343-92 Exhaust System Blocking
This test, which is run until the exhaust system
deposit formation causes a specified decrease
in intake vacuum, is run at a fuel to lubricant
ratio of 5:1. Typical reference test length is 8 to
12 hours. Candidate performance is evaluated
against a known quality reference lubricant.
OMC 40 HP General Performance
This 98-hour test evaluates how well lubricants
inhibit piston deposits, ring sticking and general
engine deposits. The fuel to lubricant ratio is
100:1.
M 341-92 Detergency
This test evaluates a lubricant for piston deposit
formation and ring sticking resistance. The fuel
to lubricant ratio is 100:1. Candidate
performance is evaluated against a known
quality reference lubricant.
OMC 70 HP Detergency
This 100-hour test evaluates piston ring sticking
and piston deposits associated with a special
ring sticking fuel. The fuel to lubricant ratio is
50:1.
M 340-92 Lubricity
This eight-hour test measures engine lubricant
performance with minimal cooling. Candidate
performance is evaluated against a known
quality reference lubricant. The fuel to lubricant
ratio is 50:1.
Mercury 15 HP Detergency
This 100-hour test evaluates how well lubricants
inhibit scuffing, ring sticking and wrist pin needle
bearing gum. The fuel to lubricant ratio is 100:1.
M 341-02 Three-Hour Detergency
This test is based on the one-hour JASO
detergency test. The engine is operated at a
higher temperature for the increased duration of
three hours. The results are more severe than
those collected during the one-hour test. The
fuel to lubricant ratio is 50:1.
Pre-Ignition
to prevent damage from combustion chamber
deposit-induced pre-ignition. The fuel to
lubricant ratio is 20:1.
NMMA FC-W ® and FC-W Catalyst
Compatible® Procedures for FourCycle Outboard Engines
Field Test Engine – Complete New
Powerhead Inspection
Post-test service is available and can include
teardown, rating, photos and/or measurement if
required.
NMMA FC-W 115 HP General Performance
Engine Test
This procedure evaluates the general
performance of a four-stroke cycle water-cooled
marine engine lubricant when subjected to fuel
dilution levels above 7 percent during the course
of operation.
Field Test Engine – Block and Piston
Inspection
Post-test service is available and can include
teardown, rating, photos and/or measurement if
required.
6
Two-Stroke Cycle Tests
Engine and component durability, power
determination, fuel and lubricant investigation,
and other specialized tests are conducted on
engine dynamometer test stands.
Component, Product and Additive
Testing
Engine Rating and Measurements
SwRI offers a wide and varying range of engine
parts rating, blueprinting and/or measurements
to meet customer requirements. Engines can be
removed from vehicles at the test sponsor’s site,
where work is performed, and then replaced in
the vehicle, or the engine can be crated and
shipped to SwRI. The engines can be
disassembled and the required parts rated,
measured and weighed. Engines can then be
reassembled and reinstalled in the vehicle or
shipped to the sponsor. Any combination of
parts rating/measurements and the frequency of
these inspections can be arranged.
Test Equipment, Fabrication and Training
Export Services
SwRI’s charter encourages the worldwide
exchange of technology. One of the many
services provided by the Institute is the design
and fabrication of custom test equipment and
engine dynamometer apparatus used to
evaluate fuels and lubricants. This equipment is
tailored for the end user’s laboratory facilities
and uses state-of-the-art computer controls and
electronic data acquisition. An important feature
of this service is the training of the end user’s
personnel in ASTM test procedures, test engine
rebuild, test equipment operations and
evaluation of test results. Through technology
transfer, SwRI helps domestic and foreign
clients meet the ever-increasing demands on
petroleum and related products. With complex,
fired-engine, microprocessor-controlled
evaluation equipment, the Institute assists
clients in new lubricant formulation. Such
technology transfer requires appropriate training
in the safe and proper operation of all
equipment, bench tests, instruments, bench
apparatus, and ancillary laboratory equipment.
Aircraft Product Testing
Services include lubricant testing according to
Federal Test Method 3407 “Navy Hot” and
materials certification according to FAA 150hour flight simulation test.
Additive Testing
The performance of fuel and lubricant additives
is evaluated for improvements and/or
detrimental effects. Additives with a base
reference fluid can be tested per military
guidelines or other Institute/client-developed
techniques.
Natural Gas Lubricant Evaluations
SwRI has utilized various engine platforms for
the evaluation and study of crankcase lubricants
utilizing natural gas. The evaluations include
chemical analysis to measure the lubricant
degradation throughout the duration of the
engine test, as well as a measurement of the
piston deposit formations, engine lubricant
consumption and engine component durability.
Sequence Test Development
When current sequence tests are inappropriate,
SwRI can develop proprietary or industry-shared
lubricant test techniques.
Gaskets and Seals
Using engine dynamometer test stands, SwRI
assesses the durability of engine sealing
components. These materials are analyzed for
size change, deformation, leakage, corrosion,
etc.
7
Fuels and Driveline Lubricants
Research Department
Mike Lochte, Director .................................................................................. (210) 522-5430
Brent Shoffner, Manager, Fuels Performance Evaluations ..........................................(210) 522-6986
Larry Eckhard, Manager, Fleet and Field Evaluations .................................................(210) 522-2980
Matt Jackson, Manager, Specialty and Driveline Fluid Evaluations .............................(210) 522-6981
8
protection. The test is run for 42,000 cycles in a
V-8 engine-driven General Motors 4L60E
automatic transmission.
Fuels and Driveline
Lubricants Research
Department
®
DEXRON -VI Plate Clutch Friction Test
Using the SAE No. 2 Friction Test Machine, this
test determines the friction characteristics and
durability of an automatic transmission fluid with
plate clutch operation. Fluids must provide
satisfactory performance for 200 hours (36,000
cycles) of continuous operation.
Mike Lochte, Director
(210) 522-5430
Brent Shoffner, Manager
Fuels Performance Evaluations
(210) 522-6986
®
DEXRON -VI Wear Test
This test determines the anti-wear properties of
automatic transmission fluids using an electric
motor-driven model 104C hydraulic pump. Antiwear performance is determined by measuring
the weight loss of the pump’s vanes and cam
ring after 100 hours of continuous operation.
Larry Eckhard, Manager
Fleet and Field Evaluations
(210) 522-2980
Matt Jackson, Manager
Specialty and Driveline Fluid Evaluations
(210) 522-6981
®
DEXRON -VI Aeration Test
The DEXRON -VI Aeration Test Rig utilizes a
VTi pump, operated under load, to determine the
air entrainment and density properties of
automatic transmission fluid as a function of
temperature.
®
Transmission Fluid Testing
General Motors Automatic
Transmission Fluids Testing
SwRI conducts the following procedures
associated with the General Motors automatic
transmission service fill fluid specification,
®
DEXRON -VI.
®
DEXRON -VI Low Speed Clutch Friction and
Torque Capacity Test
The DEXRON -VI Low Speed Clutch and
Torque Capacity Test Rig utilizes a 30 hp
variable speed electric drive that provides input
power to a Greening SAE No. 2 Universal Wet
Friction Material Test Machine through a speedreducing gearbox. The purpose of the test is to
determine the torque capacity and shudder
tendency of automatic transmission fluid on
torque converter carbon fiber friction material at
low rotational speeds.
®
®
DEXRON -VI Chemical and Bench Tests
®
(DEXRON -VI Items A-M, and O-U)
These procedures include tests to evaluate
automatic transmission fluids for color,
elemental content, fluid profile, miscibility,
density, high- and low-temperature viscosity,
flash and fire points, copper strip corrosion, antifoaming properties, corrosion and rust
protection, film thickness, and effects on seals.
Ford Automatic Transmission Fluid
Testing
®
DEXRON -VI Oxidation Test
This test is run with an electric motor-driven
General Motors Powertrain 4L60-E automatic
transmission. The 450-hour test is used to
determine the oxidation resistance, thermal
stability, and corrosion protection characteristics
of a fluid.
SwRI conducts the following Ford Motor
Company automatic transmission service fill fluid
®
MERCON V specification procedures:
®
MERCON V Chemical and Bench Tests
®
(MERCON V items 3.1 thru 3.7, 3.9 and 3.10)
These procedures evaluate automatic
transmission fluids for miscibility, high- and lowtemperature viscosity, color, flash point, copper
strip corrosion, corrosion and rust protection,
cleanliness level, anti-foaming properties and
elastomer compatibility.
®
DEXRON -VI Cycling Test
This procedure determines the performance of
an automatic transmission fluid with respect to
frictional stability, viscosity stability, lubricating
properties, oxidation resistance, and corrosion
9
®
Allison TES-295 Chemical and Bench Tests
These tests evaluate fluids for elemental
content, infrared spectrum, viscosity, flash point,
fire point, foam resistance, copper strip
corrosion, corrosion and rust protection, and
elastomer compatibility.
®
Allison TES-295 Oxidation Test
This test is conducted using an electric motordriven GM 4L60-E transmission. The 600-hour
test is used to determine the oxidation
resistance, thermal stability and corrosion
protection characteristics of a fluid.
MERCON V Wear Tests
The anti-wear properties of an automatic
transmission fluid are determined by the Vickers
Vane Pump Wear Test, FZG Wear Test, FourBall Wear Test, Falex EP Test, and Timken
Wear Test.
MERCON V Aluminum Beaker Oxidation
Test (ABOT)
This bench test determines the oxidation stability
of automatic transmission fluids in the presence
of materials used in automatic transmissions.
The 300-hour test is conducted in an aluminum
beaker heated by an aluminum block test fixture.
Allison TES-295 Wear Tests
These tests asses the antiwear performance of
a fluid utilizing the ASTM D5182 gear scuffing
wear test and a modified version of the ASTM
D7043 vane pump wear test.
®
MERCON V Clutch Friction Durability Test
This test determines the static and dynamic
torque capacity of an automatic transmission
fluid when new and after 30,000 cycles of
continuous operation. The test uses the SAE
No. 2 Friction Test Machine.
Allison TES-295 Frictional Properties Tests
Utilizing the SAE No. 2 Friction Test Machine,
these tests assess the friction and durability
characteristics of a fluid utilizing two friction
materials. The graphitic material is evaluated for
5,500 continuous test cycles. The paper
material is evaluated for 30,000 continuous
cycles.
®
MERCON V Anti-Shudder Durability
®
The MERCON SP Anti-Shudder Durability
(ASD) Test Rig utilizes a Greening SAE No. 2
Universal Wet Friction Test Machine test head,
operated to determine the frictional
characteristics of a fluid through high-speed
clutch engagements, low-speed aging and
torque sweeps, as well as static breakaway
measurements. A copper coupon is immersed in
the test fluid, which is pumped into the test head
along with instrument air.
Allison On-Highway Automatic
SwRI evaluates automatic transmissions for onhighway use according to the Allison
Transmission TES-389 specification.
Ford Over-Running Clutch (AX4N OWC)
Wear Test Procedure
The goal of this test is to determine the ability of
a fluid to protect the inner race of the
overrunning clutch in a free-wheeling situation.
The test result will be “no trenching” (inner race
intact) or “trenching” (rollers have worn a visible
grove in the inner race).
Allison TES-389 Chemical and Bench Tests
These tests evaluate fluids for color, elemental
content, flash point, cleanliness, miscibility,
water content, viscosity, shear stability, copper
strip corrosion, corrosion and rust protection,
foam resistance and elastomer compatibility.
Allison Severe Duty, Extended Drain
Interval Automatic Transmission
Fluid Testing
Allison TES-389 Wear Test
a fluid using an electric motor-driven model
104C hydraulic pump. Antiwear performance is
determined by measuring the weight loss of the
pump’s vanes and cam ring after 100 hours of
continuous operation.
SwRI evaluates automatic transmissions for
severe duty and extended drain interval use
according to the Allison Transmission TES-295
specification.
Allison TES-389 Oxidation Resistance Test
This 300-hour test determines the oxidation
10
protection characteristics of a fluid through a
modified aluminum beaker oxidation test
procedure.
5,000 cycles for M348:2002. Clutches are
engaged once each cycle and absorb 24,500
joules of total energy. Fluid temperature is
maintained at 100°C. The steel and composition
plates are evaluated. Both test procedures are
considered “modified,” as they are conducted
using a sump size of 750 ml.
Allison TES-389 Friction Tests
These tests utilize the SAE No. 2 Friction Test
Machine to assess the friction characteristics
and durability of a fluid. Fluids are evaluated
using two different friction materials, each for
150 hours.
Caterpillar Transmission and
Drivetrain Fluid Testing
Allison Heavy-Duty Automatic
SwRI conducts the following Caterpillar, Inc.,
powershift transmission and drivetrain fluid test
procedures:
SwRI evaluates heavy-duty diesel engine
lubricants and higher viscosity automatic
transmission fluids according to the Allison
Transmission TES-439 Off-Highway
Transmission Fluid Specification.
TO-4 Physical Properties
These tests evaluate fluids for homogeneity,
fluid compatibility, foaming characteristics,
humidity, corrosion, copper corrosion, lowtemperature storage, flash and fire points, pour
point and water content.
Allison TES-439 Chemical and Bench Test
These tests evaluate fluids for elemental
content, total acid number, flash point, high- and
low-temperature viscosity, antifoaming
properties, copper strip corrosion, corrosion and
rust protection, glycol response and elastomeric
compatibility.
TO-4 Elastomer Compatibility
These tests evaluate compatibility with
fluoroelastomer compounds, seals, O-rings and
other elastomeric materials.
TO-4 Oxidation Stability
resistance, thermal stability, and corrosion
protection characteristics of fluids. This test,
conducted with an electric motor-driven 4L60-E
automatic transmission, is similar to the test
®
specified by DEXRON -II(E).
Allison TES-439 Oxidation Test
protection characteristics of fluids. This test is
conducted as a modified aluminum beaker
oxidation test.
TO-4 Gear Wear Test (ASTM D4998)
Using the FZG rig, the gear-wear protection
provided by lubricants is evaluated according to
ASTM D4998.
Allison TES-439 Graphite High-Energy
Friction Test
Using the SAE No. 2 Friction Test Machine, the
friction characteristics and durability of fluids are
determined on heavy-duty graphite clutch plates.
Fluids must provide satisfactory performance for
5,500 cycles of continuous operation.
TO-4 Pump Wear Test
This test evaluates the anti-wear characteristics
of hydraulic fluids by measuring cam ring and
vane weight loss for a 35VQ25A pump. The
pump operates for 50 hours at an outlet
pressure of 3,000 psi and an inlet fluid
temperature of 203°F. This test is the same as
the Vickers (Eaton) 35VQ25A wear test. The
first three or four of five tests must pass.
JASO SAE #2 Testing
JASO T903:2011 and M348:2002 Clutch
Friction Test
These tests determine a fluid’s friction
characteristics and durability. The procedures
simulate satisfactory performance in a normally
functioning transmission under service
conditions. Performance of these tests requires
the SAE No. 2 Friction Test Machine. Test
duration is 1,000 cycles for T903:2011 and
TO-4 Friction Properties
Using six different materials and seven total
tests, the frictional characteristics of lubricating
fluids are evaluated using the Link Engineering
Model M1158 Test Machine.
11
L-20 High-Torque Test
This test determines the load-carrying, wear,
and extreme pressure characteristics of gear
lubricants under low-speed, high-torque
operating conditions. A test axle is operated for
30 hours at 32,311 lb.-in. of ring gear torque
while the axle lubricant is cycled between 93°C
(200°F) and 121°C (250°F). No longer part of
U.S. requirements, this procedure has been
replaced by L-37, although L-20 is used for
some international clients and for screening and
research in the United States.
Hydraulic Fluid Testing
DIN 51389-2 Vane Pump Wear Test
The purpose of this test is to determine the antiwear properties of hydraulic fluids. The fluid is
run through an electric-driven vane pump for
250 hours at an inlet temperature selected to
2
maintain a kinematic viscosity of 13 mm /sec.
The pump components are weighed before and
after the test. Weight loss determines the fluid
performance.
Conestoga Pump Test (ASTM D7043)
The purpose of this test is to determine the antiwear properties of hydraulic fluids. The fluid is
run through an electric-driven Model 104C
hydraulic pump for 100 hours. The pump’s
vanes and cam ring are weighed before and
after the test. Weight loss determines the fluid
performance.
L-33-1 Moisture Corrosion Test (ASTM
D7038)
To determine the corrosion prevention
properties of gear lubricants, an axle is filled with
40 ounces of test lubricant and one ounce of
distilled water and operated for four hours at
2,500 rpm and 180°F. After being soaked for
162 hours at 51°C (125°F), the axle is
disassembled and rated for rust. This test is
referred to in FTMS No. 791, MIL-PRF-2105E,
SAE J2360, API GL-5 and Federal Test Method
5326.1.
Eaton 35VQ25A Pump Test
This test evaluates the anti-wear characteristics
of hydraulic fluids by measuring cam ring and
vane weight loss for a 35VQ25A pump. The
pump operates for 50 hours at an outlet
pressure of 3,000 psi and an inlet fluid
temperature of 203°F. This test is the same as
the Vickers 35VQ25A wear test. The first three
or four of five tests must pass.
L-37 High-Torque Test (ASTM D6121)
To determine the load-carrying, wear, and
extreme pressure characteristics of gear
lubricants, a test axle is operated under highspeed, low-torque and low-speed, high-torque
conditions. A test axle is first operated for 100
minutes at 440 axle rpm, 147.2°C (297°F)
lubricant temperature, and 9,460 lb.-in. of ring
gear torque and then operated for 24 hours at
80 axle rpm, 135°C (275°F) lubricant
temperature and a higher ring gear torque. This
method is referred to in FTMS No. 791, MILPRF-2105E, SAE J2360, API GL-5 and Federal
Test Method 6507.1.
Denison T6H20C Hybrid Pump - Phase I
Denison T6H20C Hybrid Pump - Phase II
These tests sponsored by Denison evaluate the
effect of hydraulic fluid on flow, pressure loss
and wear using a hybrid T6H style piston and
vane pump run near rated conditions. The tests
are made up of a break-in phase, a dry fluid
testing phase (no water added), and a wet fluid
(water added) testing phase. The dry and wet
phases are a little over 300 hours long each and
are priced separately. These are cyclic tests with
the outlet pressures for both pumps changing
every two seconds. The same test pump is used
for both wet and dry phases.
L-42 High-Speed Shock Axle Test
(ASTM D7452)
This high-speed shock test determines a
lubricant’s ability to prevent coast-side pinion
and ring gear scoring. The axle torque and coast
down rates are measured and recorded. This
method is referred to in FTMS No. 791, MILPRF-2105E, SAE J2360, API GL-5 and Federal
Test Method 6507.1.
Manual Transmission and Rear Axle
Gear Lubricant Performance Testing
Required bench and performance tests are
conducted to qualify automotive gear lubricants
under various specifications. Numerous other
test procedures for the lubricant and additive
industries may be conducted, as well as custom
programs tailored to clients’ individual needs.
L-60-1 Thermal and Oxidative Stability Test
(ASTM D5704)
This method determines lubricant deterioration
under severe thermal and oxidative conditions.
12
A set of spur gears is rotated at 1,750 rpm for 50
hours. The lubricant is maintained at 163°C
(325°F) with controlled airflow in the presence of
a copper catalyst. The physical and chemical
properties of the lubricant and deposits on the
test gears are evaluated at the end of the test.
This method is referred to in FTMS No. 791,
MIL-PRF-2105E, SAE J2360, API GL-5, Federal
Test Method 2504 and API MT-1 (ASTM D
5760).
The test normally runs 300 hours and is usually
carried out in triplicate to cover outliers.
FZG Step Load (A10/16.6R/90:120)
This test procedure is for industrial or
automotive gear lubricants that exceed the loadcarrying capacity of the standard FZG load
stage test (A/8.3/90). The smaller 10 mm wide
gears are run in the reverse direction at 2910
rpm through a dozen 7.5-minute stages with
incremental increases in load until failure or until
the test sequence is complete. The test can run
at either 90°C or 120°C (194°F or 248°F). Ten
millimeters of tooth scuffing indicates test failure.
A pass in load stage nine at 90°C (194°F)
indicates GL-5 or better performance.
FZG Gear Wear Test (ASTM D4998)
To evaluate the anti-wear properties of
lubricants, particularly hydraulic fluids for
tractors, test gears on the FZG rig are operated
at 100 rpm for 20 hours at 121°C (250°F) and
load stage 10. The gears are weighed before
and after the test and the weight loss associated
with wear indicates lubricant anti-wear
performance.
Manual Transmission High-Temperature
Cyclic Durability Test (ASTM D5579)
The high-low range synchronizer of a Mack
T2180 transmission is cycled with lubricant
temperatures at 121°C (250°F). The shift time is
monitored continuously during the test. As the
lubricant degrades, the shift time increases. The
test continues until two “missed shifts” are
reached. This test is part of Mack Trucks, Inc.,
Gear Oil Specifications GO-H and GO-H/S,
Eaton PS-164 rev. 7, as well as the industry
specification API MT-1 (ASTM D5760) and MILPRF-2105E (ASTM D5760).
FZG Load Stage Test (ASTM D5182)
Various speeds, temperatures, etc. are available
to evaluate the load-carrying capacity of
lubricants. The variable speed FZG test rig runs
through a dozen 15-minute stages with
incremental increases in load until failure or until
the test sequence is complete. Twenty
millimeters of tooth scuffing indicate test failure.
This test method is referenced in API MT-1
(ASTM D 5760) and other OEM specifications.
SSP 180 Synchronizer
The purpose of this test is to evaluate the
frictional performance of a lubricant in a
synchronizer assembly. The test is conducted in
an SSP-180 test machine. The synchronizer is
loaded by a flywheel that is accelerated and
decelerated between rest and top speed. Test
conditions are dependent upon the type of
synchronizer tested.
Axle Efficiency Test
SwRI has a stand designed and constructed at
SwRI to accept various types of rear-wheel drive
axle assemblies. This stand is equipped with a
Prism data acquisition system and is computer
controlled. It has the capability of running the
torque sweep method, simulating the Federal
Test Procedure (FTP) light-duty truck highway
fuel economy test cycle using a dynamic
procedure and the heavy-duty SAE J1321, also
using a dynamic procedure. In addition, the
stand has the capability of programming test
procedures/profiles specifically designed by
customers.
Mack GO-J/J+ and Eaton PS-163 Test
Procedures
Mack and Eaton call for modified versions of
some of the axle tests listed above. SwRI can
perform the modified tests for these procedures
and act as an intermediary for OEM contact
when requested.
FZG Pitting Test with Type C Gear
This test procedure is used to discriminate
different lubricants based upon their ability to
prevent pitting, a fatigue failure due to rolling
contact. The test consists of a break-in phase
and a durability phase. Depending on lubricant
viscosity, the durability phase loading will vary.
13
Manual Transmission and Dry Clutch
Transmission (dDCT) Fluid Testing
Tractor Testing
Tractor Field Tests
Tractors across the country operate with test
fluids monitored by SwRI personnel. Lubricantrelated testing has been conducted on John
Deere, New Holland and CASE tractors.
General Motors Dry Dual Clutch
Transmissions Fluids Testing
SwRI conducts the following procedures
®
associated with the General Motors DEXRON Dry Dual Clutch Transmission (dDCT) Gear Box
and Manual Transmission Fluid Specification.
Tractor Fluids Specification Testing
New Holland specifications for tractor hydraulic
fluids require satisfactory performance in gear
wear protection, independent power take off
(IPTO) and powershift clutch capacity, and
brake chatter protection.
®
DEXRON -dDCT Chemical and Bench Tests
These procedures include tests to evaluate dry
dual clutch and manual transmission fluids for
appearance, elemental content, water content,
fluid profile, miscibility, density, storage and
compatibility characteristics, high- and lowtemperature viscosity, pour point, flash point,
total acid and base number, copper corrosion,
oxidation stability, shear stability, volatility, antifoaming properties, film thickness, and effects
on seals.
Tractor Hydraulic Fluid Testing
John Deere J20 specifications for tractor
hydraulic fluid require satisfactory performance
of test lubricants in tests that simulate severe
duty of farm tractor and industrial equipment
components.
JDQ-84 Dynamic Corrosion Sauer-Danfoss
Pump Test
This test screens fluids that cause corrosion of
copper-containing metals in high-pressure
pumps. A Sauer-Danfoss 90 Series axial piston
pump is operated for 25 hours at 3,000 psi.
Water is then added to the test fluid. The output
pressure of the pump is increased to 5,500 psi
and maintained at that pressure for another 200
hours.
®
DEXRON -dDCT Wear Test
dry dual clutch and manual transmission fluids
using electric motor driven model 104C
hydraulic pump. Anti-wear performance is
determined by measuring the weight loss of the
pump’s vanes and cam ring after 100 hours of
continuous operation.
®
DEXRON -dDCT Scuffing Protection Test
The FZG Step Load (A10/16.6R/90) test
procedure is used for fluids that exceed the
extreme pressure characteristics of the standard
FZG load stage test. The smaller 10 mm wide
gears are run in the reverse direction through 12
7.5 minute stages with incremental increases in
load until failure or until the test sequence is
complete. The test is run at 90°C.
JDQ-94 Powershift Transmission Clutch
Friction Test
This test assesses the effects of tractor
hydraulic fluids on wet clutch capacity, dynamic
friction coefficient, and clutch disc wear. A 200
hp John Deere engine drives a modified John
Deere 4850 15-speed, powershift transmission,
loaded by an eddy current dynamometer. A
typical test cycle consists of eight seconds of
slipping the clutch at high dynamometer load
and engine power.
®
DEXRON -dDCT Synchronizer Function Test
The purpose of this test is to evaluate the
frictional performance of a dry dual clutch or
manual transmission fluid in a synchronizer
assembly. The test is conducted in the SSP-180
test machine. The test lubricant temperature is
controlled while the synchronizer is shifted. The
synchronizer is loaded by a flywheel that is
accelerated and decelerated between rest and
top speed. The test conditions are dependent
upon the type of synchronizer tested.
JDQ-102 Shear Stability
This test determines the shear stable viscosity of
a tractor hydraulic fluid. Using a diesel injection
pump and 6 fuel injectors for a John Deere 6466
engine, the fluid is circulated under high
pressure through the fine orifices of the
injectors. This test is also used to prepare a
fluid for the JDQ-95 spiral bevel/final drive wear
test.
14
JDQ-95 Spiral Bevel/Final Drive Wear Test
This 50-hour test evaluates how effectively
tractor hydraulic fluids protect the spiral bevel
gears from scoring and the final drive planetary
reduction gears from surface distress and wear.
A John Deere engine and powershift
transmission drive an industrial axle housing the
test gears. A pair of high torque dynamometers
provide load.
protection characteristics of fluids. The test is
conducted with an electric motor-driven
hydrostatic transmission from a John Deere
zero-turn mower.
Automotive Fleet Testing
To assist new product development, SwRI
applies a variety of fleet and laboratory
procedures that can be adapted to a variety of
research requirements. Services include gear
and gear lubricant evaluations, fleet evaluation
of experimental engines and components and
examination of fuel deposit tendencies in
vehicles.
JDQ-96B Torque Variation and Brake Friction
Retention Test
A John Deere 1400 series industrial axle
equipped with annular wet disk brakes is used
for the test axle. The brake chatter test consists
of 30,000 brake engagements. After 1,000,
10,000, 20,000 and 30,000 brake engagements,
a series of brake chatter tests are performed at
different wheel speeds, brake pressures and
temperatures.
Axle and Axle Lubricant Evaluations, HeavyDuty
The Institute conducts in-service evaluations of
heavy-duty axles; frequently for MIL-PRF-2105E
and/or standard SAE J2360 gear lubricant
qualification programs. Three or four trucks are
operated for 200,000 miles on test lubricants.
Performance of a lubricant is judged from the
appearance of gears, bearings and carrier.
Periodic lubricant samples are analyzed for wear
metals, additives and contaminants.
John Deere Hydraulic Pump Shear Stability
This 48-hour test uses a Sauer-Danfoss 90
series axial piston pump to circulate fluid across
a hydraulic relief valve to determine the shear
stable viscosity of a tractor hydraulic fluid. This
test is also used to prepare a fluid for the JDQ95 spiral bevel/final drive wear test.
Axle and Axle Lubricant Evaluations,
Light-Duty
SwRI conducts 100,000-mile in-service
evaluations of gear lubricants in light-duty
vehicles such as pickups and cargo vans. These
evaluations are frequently related to MIL-PRF2105E and/or standard SAE J2360 qualification
programs.
JDQ-95A Spiral Bevel Gear Wear
This 50-hour test evaluates how effectively a
tractor hydraulic fluid protects the spiral bevel
gear set from distress. An electric motor drives
the front axle center section from a John Deere
8000 series tractor with independent link
suspension, and a pair of high torque dry brake
dynamometers provides the load.
Truck Axle Lubricant Fuel Economy
The fuel economy benefits of axle lubricants in
light- and heavy-duty trucks are evaluated using
SAE procedures. Heavy-duty trucks outfitted
with precision fuel consumption measurement
equipment are operated on road routes with
precise control of speed, time and distance.
Light-duty trucks operate similarly but on a
chassis dynamometer following a prescribed
cycle.
John Deere High Energy Clutch
This test assesses the effects of tractor
hydraulic fluids on the degradation of dynamic
friction coefficient and clutch disk wear. The test
uses a modified driveline from a John Deere
7000 series tractor with a “PowrReverser”
transmission. A typical test cycle consists of
fixing the driveline output and slipping the clutch
for several seconds before releasing the output
to spin freely and cool the transmission. This
cycle is repeated 2,000 times using the forward
clutches and 2,000 times using the reverse
clutches.
Crankcase Engine Lubricant Fuel Economy
The fuel economy benefits associated with
engine lubricants in heavy-duty vehicles are
evaluated by SAE procedures that involve
operation on road routes with precision fuel
consumption measuring equipment and precise
control of speed, time and distance.
John Deere TZT Oxidation
15
Truck Fuel Economy Improvements
The fuel economy benefits associated with
various fuel additives, wheels, tires,
aerodynamic devices, etc., in heavy-duty trucks
are evaluated by SAE and TMC procedures.
Trucks operate on road routes with precision
fuel consumption measuring equipment and
precise control of speed, time and distance.
Specialized Fuel Testing
Vehicle Evaluations for Fuel Injector
Plugging
Vehicles equipped with multi-port fuel injection
systems encounter injector-plugging problems
associated with gasolines with inadequate
amounts of detergents. In severe cases, this
problem can render a vehicle inoperative. This
test reproduces fuel injector plugging under
controlled conditions to assess the effect of fuel
additives as they relate to injector “clean-up” and
“keep-clean.” The keep-clean test is conducted
according to ASTM D 5598 protocol. During the
test, injector flows and spray patterns are
evaluated. Fuel injector spray patterns can be
photo-documented to provide a visual record of
test results.
Durability and Reliability Evaluation of
Engine/Vehicle Compatibility
Durability and reliability of medium- and heavyduty diesel- and alternative-fueled engines are
evaluated in Class 7 and 8 trucks and buses on
city and highway routes. Engine performance,
reliability and maintainability are determined by
this 100,000-mile test.
Road Simulators/Mileage Accumulation
Dynamometers
Rapid vehicle mileage accumulation programs
are performed on 24 road simulators capable of
speeds up to 100 miles per hour on vehicles up
to 7,000 pounds at steady-state conditions or
programmed transient driving cycles. The road
simulators support two- and four-wheel drive
vehicles with up to 400 horsepower.
Temperature and humidity controlled engine
inlet air can be provided on four of the 24 units.
Intake System and Combustion Chamber
Deposits
The Institute evaluates fuels and fuel additives
for intake system cleanliness. The BMW 10,000Mile (ASTM D5500 protocol) and Ford 2.3 Liter
Intake Valve Deposit Tests (ASTM D6201
protocol) qualify fuels and fuel additives for the
Environmental Protection Agency, the California
Air Resources Board and Top Tier gasoline
specifications. Specialized fuel evaluation
programs focus on current vehicles, both foreign
and domestic. The relationship between engine
design, fuel properties and additive performance
is investigated. Evaluation techniques include
deposit analysis, combustion chamber deposit
thickness measurements and deposit weight
measurements.
Vehicle Test Tracks
SwRI performs vehicle testing on a variety of
test tracks including a one-mile track located on
the SwRI grounds. High-speed vehicle testing is
performed on an eight-mile track including fuel
economy measurement, driveability, endurance
and component evaluations.
Intake Valve-Sticking Evaluations
Vehicle test programs are conducted to assess
the effect of fuels and fuel additives on intake
valve sticking. The ability of fuels to prevent
intake valve stem deposits from causing the
intake valves to stick at cold temperatures -20°C
(-4°F) can be evaluated.
Off-Highway Evaluations
The Institute provides multiple courses with
varying configurations on its grounds for offhighway evaluations of vehicles such as
agricultural machinery, recreational and
sport/utility vehicles, and industrial equipment.
Vehicle operation parameters can be monitored
on a real-time basis.
Vehicle Driveability and Performance Testing
SwRI conducts CRC-type vehicle driveability
and performance tests to evaluate vehicle
operation as it relates to test fuels, additives and
vehicle components. Onsite track facilities, as
well as the trained personnel and specialized
equipment necessary for these tests, are
available. Cold chambers allow vehicle soak
temperatures as low as -20°C (-4°F).
John Deere Engine Coolant Cavitation Test
A 250-hour test on a Deere 6101H engine is
used to evaluate a coolant’s ability to suppress
cavitation and corrosion damage to power
cylinder liners.
16
Vehicle Octane Requirement and ORI
Evaluations
Fleet programs for octane requirement and
octane requirement increase (ORI) assess
engine-operating parameters as related to fuel
octane number and combustion requirements.
The CRC-E-15 Road Test method is used for
these evaluations, and the prescribed reference
fuels are in inventory.
Alternative Fuels Testing (Methanol, Ethanol,
Natural Gas and others)
For spark-ignition and compression-ignition
engines, the tests evaluate how test fuels affect
engine durability or lubricant suitability.
Octane Requirement Increase (ORI)
While determining how well various
gasolines/additives prevent combustion
chamber deposits, this test also measures the
resulting octane requirement increase.
Gasoline Direct Injection GDI) Fuel Injector
Deposits
A variety of specialized test methods are
available to characterize fuel deposits in GDI
injectors. These include both vehicle and engine
dynamometer-based procedures and may
include injector flow measurements, high speed
video for visualization of spray patterns and
changes in exhaust particulate matter (PM)
emissions.
Sequential Central Port Injection Fouling
Test
The effects of fuel additives related to fuel
injector poppet nozzle sticking are assessed
during an eight-day test procedure using a
General Motors vehicle equipped with the
Sequential Central Port Injection (SCPI) system.
The SCPI fuel system is susceptible to fuelderived deposits that can cause poppet sticking,
which can render the injector inoperable.
17
Petroleum Products Research Department
Gerry Estrada, Director ................................................................................ (210) 522-3006
Robert Legg, Manager, Fuels Analysis Laboratory...................................................... (210) 522-2701
Michelle Ratchford, Manager, Fuels Surveys/Fuels Conformance.............................. (210) 522-2986
Ken Jacks, Manager, Lubricant Analysis Laboratory ................................................... (210) 522-2989
18
wear metals in used lubricants, transmission
fluids and turbine lubricants; additive metals in
new lubricants, including transmission fluids,
gear lubricants, turbine fluids, coolants and
greases; metals in gasoline, diesel fuel
lubricants and jet fuel, including phosphorus;
military certification for additives in engine
lubricants; metals in captured exhaust
particulate samples and engine deposits; metals
in crude oils; and sulfur, carbon, hydrogen and
nitrogen in gasoline, diesel fuel, crude oil, etc.
Petroleum Products
Research Department
Gerry Estrada, Director
(210) 522-3006
Robert Legg, Manager
Fuels Analysis Laboratory
(210) 522-2071
Michelle Ratchford, Manager
Fuel Surveys/Fuels Conformance
(210) 522-2986
Fuel Conformance/Fuel Surveys/Field
Studies
The Institute performs national fuel and lubricant
quality assurance surveys to: determine the
variation in physical and chemical properties of
gasoline and diesel fuels at terminals, refineries
and retail outlets of major petroleum marketers
throughout the United States; and surveys to
procure and analyze the quality of engine
lubricants and transmission fluids as blended,
branded and marketed. Field sampling services
include sample acquisition at automotive
dealerships.
Ken Jacks, Manager
Lubricant Analysis Laboratory
(210) 522-2989
The Petroleum Products Research Department
provides analytical and physical testing required
by clients and other SwRI departments to
evaluate and qualify all fuels, lubricants and
functional fluids. Specification tests are
performed on gasolines, diesel fuels, synthetic
or exotic fuels, crankcase lubricants, automatic
transmission fluids, coolants and greases,
among others. In addition to standard tests such
as ASTM, UOP, SAE and others, a number of
independent programs support clients’ efforts to
characterize or evaluate a broad range of
petroleum and automotive products. Programs
specifically designed by clients to satisfy their
needs or requirements are provided in a timely,
professional manner. In addition, SwRI offers
innovative approaches or tailored research
programs to solve unique or unusual problems.
The department welcomes confidential inquiries
and discussions with clients who want to
address specific problems, to evaluate products
or to improve product performance. Among the
many services provided by the department are
the following:
Trace Organic Analysis
PPRD performs analysis for polycyclic aromatic
hydrocarbons, (PAH), nitro-PAH and other
organic species in fuels, lubricants or emission
samples.
Laboratory Engine Technology
SwRI uses various evaluations and studies
utilizing special engine and bench protocols to
evaluate carburetor, fuel injector and intakevalve deposit-forming tendencies of gasolines;
to determine Research Octane Number (RON),
Motor Octane Number (MON) and Cetane
Number (CN); and to train research specialists
in research, motor and cetane engine use,
covering fundamental fuel testing concepts and
detailed engine component coverage with
reference to function, service requirements and
overhauls.
Fuel, Lubricant and Fluid Inspection
ASTM procedures determine the chemical and
physical properties of gasoline, aviation,
biodiesel and middle distillate fuels; engine
crankcase lubricants, hydraulic fluids, automatic
transmission fluids, gear lubricants, greases and
coolants.
SwRI-developed Instruments
The Institute has developed specialized test
procedures and instruments for fuel and
lubricant research, such as an Intake Valve
Deposit Apparatus (IVDA) to predict the depositforming characteristics of a gasoline or gasoline
and detergent additive blend, if it were evaluated
in a full-scale engine; a CRC Port Fuel Injector
(PFI) Test Apparatus to evaluate the fouling
Metals Analyses
ICP, energy- and wave-length dispersive X-ray,
and other techniques are used to determine
19
tendencies of gasolines and the effectiveness of
additives; a Gear Oil Scuff Test (GOST)
Apparatus, which accurately predicts the loadcarrying characteristics of a test lubricant as
measured by either the Ryder of FZG load stage
gear tests; and an Induction System Deposit
(ISD) apparatus to measure intake valve
deposits associated with gasolines.
Transmission Fluids
Oxidation, rust, copper corrosion, shear stability,
seal degradation, coefficient of friction, foam,
miscibility and compatibility, and lowtemperature viscosities.
Industrial Lubricants
Thermal stability, rust, extreme pressure, wear,
foam, miscibility and compatibility, and
evaporation losses.
Petroleum Products Research
A variety of performance and research services
are available to help develop automotive
chemicals, such as hydraulic fluids, synthetic
lubricants and fluids, coolants and cleaners,
greases and grease additives, fuel additives,
lubricant additives, gear lubricant additives and
low-friction lubricants.
Engine Coolants
Antifreeze glassware corrosion, aluminum
corrosion, antifreeze effect on automotive
finishes, boiling point of antifreeze, foaming
tendency of antifreeze, freezing point of
antifreeze, pH of antifreeze, reserve alkalinity of
antifreeze, water content of antifreeze, simulated
service test, cavitation test, ash content and
specific gravity.
Used Lubricant Field Studies
A full complement of ASTM procedures is
available to evaluate lubricant and coolant
performance for in-service engines and vehicles,
and maintenance programs to prevent
catastrophic engine failure.
Procedural Development
New or novel analytical procedures or in-service
performance simulations can be arranged using
analytical methods, bench testing, and lubricity,
friction and wear testing.
Trend Analysis
SwRI evaluates fleet and motor pool lubricants
to assure timely lubricant changes and to
determine the performance of new formulations,
as well as evaluation of industrial lubricants for
changes in condition for maintenance purposes.
Lubricants and Fluid Evaluations
Laboratory ASTM, FTM, UOP and other tests for
lubricants and functional fluids include:
Engine Lubricants
Oxidation, varnish formation, dispersancy,
detergency, thermal stability, rust, corrosion,
shear stability, foam, seal degradation, and
miscibility and compatibility.
Gear Lubricants
Oxidation, thermal stability, rust, copper
corrosion, seal degradation, extreme pressure
and wear, coefficient of friction, foam and
miscibility and compatibility.
20
Fuels and Lubricants Technology Department
Gary Bessee, Director...................................................................................(210) 522-6941
Scott Hutzler, Manager, Fluids Filtration and Handling Research ............................... (210) 522-6978
Ed Frame, Manager, Fuels, Lubricants and Fluids Applications ................................. (210) 522-2515
Larry Hollingsworth, Group Leader, Fuel Systems and Contamination Research ...... (210) 522-5711
Martin Treuhaft, Manager, Filtration and Fine Particle Technology ............................. (210) 522-2626
21
removal characteristics and single-pass particle
retention; and associated test sequences for
media migration, collapse test and hydrostatic
burst.
Fuels and Lubricants
Technology Department
Gary Bessee, Director
(210) 522-6941
Fluids Filtration and Handling Research
The Fluids Filtration and Handling Research
Section perform a wide variety of research in the
Fuels and Lubricants Technology Department.
The technical strengths of the group include
sensor development, liquid filtration,
contamination control and identification, fuel and
water logistics, and test method development.
Scott Hutzler, Manager
Fluids Filtration and Handling Research
(210) 522-6978
Ed Frame, Manager
Fuels, Lubricants and Fluids Applications
(210) 522-2515
Technical strengths and contracts include:
Larry Hollingsworth, Group Leader
Fuel Systems and Contamination Research
(210) 522-5711
• Material Compatibility
• Aviation filtration qualification
• Fluid filtration and cleanliness
• Fuel logistics
• Advanced methods of fuel property
measurement
• Sensors and instrumentation development
• Chromatography
• Coolant testing
• Analysis of LPG
• Particle counting
• Fuels filtration
• Lubrication filtration
• Soot contamination
• Debris analysis
• Test method development
• Field service
• Aviation fuel fit-for-purpose testing
Martin Treuhaft, Manager
Filtration and Fine Particle Technology
(210) 522-2626
The Fuels and Lubricants Technology
Department provides a range of non-routine
testing and evaluation services focused on the
performance of transportation-related fluids.
Projects typically examine the characteristics
and performance of the fuels, engine, power
transmission and gear lubricants, and hydraulic
fluids used in land-based vehicles. A major
facility within the department is devoted to gas
turbine engine fuels and combustion. Programs
conducted for both commercial and government
clients include product development support,
problem investigation services and field troubleshooting.
Fuels, Lubricants, and Fluids Applications
The Fuels, Lubricants, and Fluids Applications
Group in the Fuels and Lubricants Technology
Department performs a wide variety of fuel,
lubricant, and engine and fuel system
investigations for the Department of Defense,
government agencies and commercial clients.
The Fuels and Lubricants Technology
Department also operates the U.S. Army
TARDEC Fuels and Lubricants Research
Facility, an extension of the U.S. Army Tank
Automotive Research, Development and
Engineering Center in Warren, Michigan. Since
1957, this government-owned, contractoroperated facility physically located on the
grounds of Southwest Research Institute, has
provided fuel and lubricant research services to
the Army, Department of Defense, Department
of Energy and other government agencies.
Technical strengths and contracts include:
• Investigations of fuel/lubricant/engine
interactions
• Fuel and fluid flammability hazard
assessments
• Alternative fuels development and utilization
• Fuel injection system wear and performance
• Jet fuel use in diesel equipment
• Engine dynamometer evaluations
• Bench test development, fuel system materials
compatibility
• Field evaluations
Automotive Filtration Performance Testing
Oil filters are evaluated using SAE and ISO test
procedures, which involves systems tests for
resistance to flow, filter capacity, contaminant
22
• Fuels/hardware interactions and test rig design
• Aviation fuel research
• Aviation fuel stability and contamination effects
• Aviation fuel-derived deposition
• Customized test fuel blends
• Gas turbine combustor test facility
• Optical and laser combustion diagnostics
filtration problems. Theoretical and experimental
laboratory and field programs are also
conducted to support the development and
testing of novel filtration and particle
technologies.
The Section provides research, development,
testing and evaluation services in:
• Air filters and filtration systems
• Automotive air induction systems and
components
• Filter qualification to industry, military and
government specifications
• Mechanical pre-cleaners and inertial
separators
• Engine intake air/water separation testing
• Failure analysis of air filters, systems and
components
• Smaller-scale wind tunnel testing using blowing
dust and water sprays
• Contamination sensitivity assessment of
mechanical and electrical systems and
components
• Structural integrity of filtrations systems and
components (combined vibration and thermal
cycling)
• Field testing to develop vibration spectra for
laboratory filter testing
• Air filter test stand development and fabrication
• Air filter laboratory design, layout and
equipment specification
• Evaluation of equipment protection from
blowing and settling dust and blowing sand
• Novel filtration technologies
• Filtration specification development
• Filtration sensor system development
• Aerosol technology and mechanics
• Aerosol sampler development and testing
• Particle transport and multi-phase flows
• Small particle interactions and mass transfer
• Low and zero gravity separation studies and
technology investigations
• Dispersion studies using bioaerosol simulants
and tracers
• Near field particle transport and dispersion
• Real-time wear measurement in operating
engines and mechanical systems
• Thermal efficiency and heat rejection
evaluation of air and liquid-side heat exchangers
and radiators
Fuel Systems and Contamination Research
The Fuel Systems and Contamination Research
Section in the Fuels and Lubricants Technology
Department operates a 5,000-square-foot
laboratory dedicated to fuel contamination
research and testing. The facility consists of
more than 4,200 square feet of laboratory
space, containing 12 automated test cells. Of
these cells, nine are dedicated to
gasoline/flexible fuel testing, two to diesel testing
and one to hybrid fuel cell testing. Using an
automated fluid heating and cooling system, test
temperatures can be varied from -40° to 80°C
(-40° to 170°F).
Technical strengths include:
• Contaminant characterization
• Accelerated life testing or key-life testing
• Material compatibility
• Modeling and simulation
• Test procedure development
• Lubricity, friction and wear
• Environmental evaluation
• Filtration
• Emissions and safety issues
• Component and systems development
• Contamination research and advanced fuel
delivery
Filtration and Fine Particle Technology
The Filtration and Fine Particle Technology
Section in the Fuels and Lubricants Research
Division provides research, development and
testing services in many areas of air filtration;
contamination sensitivity assessment; particle
mechanics, transport and aerosol science; and
real-time engine and component wear as a
function of dust ingestion and exposure. The
section also performs evaluations of automotive
and heavy-duty engine and vehicle components
and systems, including testing, analysis and
design, with emphasis on real-world operation
and real-life laboratory simulation. In addition to
qualification and third-party comparative testing,
laboratory and field evaluation programs are
implemented to support component and systems
research and development. These programs aid
in developing strategies to solve specific
Laboratory and field test programs support
includes:
• Qualification and third-party comparative
testing
23
• Component and systems research and
development
• Aid in developing strategies for demonstrating
specific levels of performance
• Solving specific problems
• Performing standardized test to manufacturer,
industry, government and military specifications
• Developing and implementing specialized test
plans
• Advancing knowledge and understanding
• Filtration efficiency, dust capacity and life
measurement
Air Filter Test Stand Design, Development
and Fabrication
The Section develops designs and fabricates air
filter test stands for industry and government
clients worldwide. These stands include:
• Semi-automatic operation with real-time
display
• Closed loop control of dust feeding and airflow
management
• Post-test report generation
In addition, laboratory design, layout and
equipment specification services are also
provided.
24
Southwest Research Institute is an independent, nonprofit, applied engineering and physical
sciences research and development organization with 11 technical divisions using
multidisciplinary approaches to problem solving. The Institute occupies more than 1,200 acres
in San Antonio, Texas, and provides more than 2 million square feet of laboratories, test
facilities, workshops and offices for 3,000 employees who perform contract work for industry
and government.
We welcome your inquiries.
For more information, please contact:
Steven D. Marty, P.E., Vice President
(210) 522-5929
smarty.swri.org
Benefiting government, industry
and the public through innovative
science and technology
Southwest Research Institute
6220 Culebra Road • P.O. Drawer 28510
San Antonio, Texas 78228-0510
www.flrd.swri.org
www.swri.org
25
Rev. Nov 2013

Fuels and Lubricants Research Division

Transcription

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