ZDDP replacement? Hydrogen Wear: Revolutionary Lubricant Technologies

customboss · March 23

This document from Lube-Tech magazine explores the underreported phenomenon of hydrogen wear in machinery, distinguishing it from hydrogen embrittlement and tracing its discovery to Russian research. It highlights how hydrogen infiltration during friction leads to surface deterioration and premature failures, exemplified by gearbox issues in wind turbines also known as White Etching Cracking. The article then introduces a revolutionary approach based on copper filming technology, stemming from the "wearlessness effect," which uses copper ions to create a protective film on metal surfaces, effectively preventing and reversing hydrogen wear and other wear mechanisms. This technology, developed by NEOL, offers benefits like extended machinery lifespan, reduced maintenance, and environmental advantages by replacing traditional harmful additives like ZDDP, with real-world applications in mining and other industries demonstrating its effectiveness. The piece concludes by emphasizing the importance of addressing hydrogen wear for the longevity of both current and emerging hydrogen-based technologies.

https://www.lube-media.com/wp-content/uploads/Lube-Tech-153-Overcoming-hydrogen-wear-through-revolutionary-new-lubricant-technologies.pdf

customboss · March 23

Briefing Document: Overcoming Hydrogen Wear with Revolutionary Lubricant Technologies

Source: Excerpts from "Overcoming hydrogen wear through revolutionary new lubricant technologies," Lube: The European Lubricants Industry Magazine, No. 153.

Authors: Leyla Alieva (CEO and Co-founder, NEOL Copper Technologies) and Dr. Sergei Mamykin (Tribologist and Copper Filming Technology Developer, NEOL Copper Technologies).

Main Theme: The article highlights the largely underreported phenomenon of "hydrogen wear" in machinery and presents a revolutionary solution based on "copper filming technology" developed by NEOL Copper Technologies. This technology not only combats hydrogen wear but also reduces other forms of wear, improves efficiency, and offers a more environmentally friendly alternative to traditional lubricant additives like ZDDP.

Key Ideas and Facts:

1. Introduction to Hydrogen Wear:

Mechanical wear is a significant cause of failure in industries where surfaces meet and move. Traditional wear mechanisms include adhesive, abrasive, corrosive, and surface-fatigue wear.
A less recognized but critical mechanism, particularly in the West, is hydrogen wear.
The science behind hydrogen wear was pioneered by Russian engineer Professor Dmitry N. Garkunov in the 1960s, who discovered the selective transfer of copper ions during friction and identified hydrogen as the primary cause of metal surface deterioration. These findings led to the concepts of "the wearlessness effect" and "hydrogen wear of metals."

2. Distinguishing Hydrogen Wear from Hydrogen Embrittlement:

Hydrogen embrittlement is a well-known reduction in metal ductility due to absorbed hydrogen, often causing singular sharp cracks in hydrogenous media under high temperature, pressure, loads, deformation, and cathodic processes. It's a common issue for steelmakers.
Hydrogen wear, in contrast, occurs specifically during sliding and rolling contacts in rotating machinery like gears and hydraulics. High contact pressures lead to increased hydrogen absorption, causing internal pressure and crack formation. Repeated cyclic stresses cause these cracks to grow and produce wear particles.
Dr. Sergei Mamykin defines hydrogen wear as the "self-organised destruction in the material’s top layer during friction; it is characterised by a considerable non-equilibrium of processes and by joint impact of co-factors that contribute to absorption of hydrogen in the top layer and destruction of this layer."

3. Factors Influencing Hydrogen Wear:

The intensity of hydrogen absorption is influenced by the medium's composition and state, metal surface treatment and chemical composition, atomic structure, stresses and deformations (especially metal lattice deformation), hydrogen saturation time, and hydrogen desorption conditions.
Hydrogen adsorption on the friction surface, driven by temperature gradients, can diffuse deep into the surface, making top layers fragile and increasing deterioration.
Hydrogen wear is increasingly significant in various industries, including transportation, aviation, farming, mining, chemical production, and microbiological production equipment.
Hardened steel under alternating loads is particularly susceptible to hydrogen wear, affecting components like crankshafts, piston rings, and bolted joints.
The thermal, electrical, and magnetic effects of friction, which control hydrogen concentration in metals, are now recognized as factors determining deterioration.

4. Hydrogen Wear in Wind Turbine Gearboxes (WEC):

Gearbox failures in wind turbines within five years of operation are a major concern and the most expensive failure mode.
Researchers have identified a combination of non-metallic inclusions, sliding, and hydrogen as contributing factors.
Western researchers have termed this phenomenon White Etching Cracking (WEC), acknowledging that its exact cause is unclear but suggesting lubricants may play a role. The description of WEC is noted as "near-identical to the description of hydrogen wear."
ExxonMobil's 2020 report speculated on hydrogen activity in the subsurface but admitted that "the scale of this tribochemical reaction…is not well understood."
Despite extensive investigations, a viable solution for WEC in wind turbines has yet to be found.

5. Copper Filming Technology: A Solution to Hydrogen Wear:

Research in Russia and China has long indicated that advanced lubricants can prevent hydrogen wear.
Combining Garkunov's discoveries of "the wearlessness effect" and "hydrogen wear of metals" provides both the cause and the solution for mechanical wear.
Dr. Mamykin defines the "wear-free effect" as "a type of friction that can be described as a non-oxidising thin metal film (servovite film) that emerges spontaneously in the contact area; the film possesses low shear resistance and cannot accumulate dislocations through deformation. On top of this film, an additional protective film (surf film) can be formed, entering in a chemical bond with it; the latter film is made of degradation products left from hydrocarbon lubricants."
Selective transfer of copper ions can reduce the weight and dimensions of friction units by 15-20% due to increased load capacity, while also increasing efficiency, reliability, service life, and overhaul periods.

6. Mechanism of Copper Film Formation and Wear Reduction:

Professor Garkunov found that copper films formed during friction do not oxidize and can transfer to the counter body, creating a copper-copper sliding interface.
Experiments, including those by Dr. Matthias Scherge in 2016, demonstrated that stable copper additives in lubricants provide long-lasting friction reduction, wear protection, and extended service life.
The formation of copper tribofilms involves:
Instantaneous reduction in the coefficient of friction.
Formation of a solid lubricant composed of copper monolayers.
Plastic flow of the copper tribofilm combined with mechanical intermixing and tribochemical reactions.
Near-surface polymerization of monomers from the base oil creates a protective top layer that promotes hydrodynamic lubrication and prevents oxidation. This confirms "self-sustained friction reduction and wear protection."
Thin copper films provide sufficient protection in real-world, ultra-low wear regimes.

7. Practical Applications and Benefits of Copper Filming Technology:

Copper filming technology can solve hydrogen wear and reduce other wear mechanisms.
Hydrogen's tendency to cause wear upon metal-to-metal contact can be harnessed at an elementary level for surface "polishing" before being terminated by copper ions.
Copper ions embedded in the crystal lattice of iron alloys "heal" damaged areas and form an even copper film, virtually ceasing hydrogen wear and other wear mechanisms.
This leads to increased machinery efficiency and longevity, reduced maintenance and replacement costs, and lower fuel consumption.
Copper filming technology eliminates the dependence on toxic phosphorus and sulfur compounds like ZDDP.

8. Environmental Advantages and Comparison to ZDDP:

ZDDP, while effective, has negative environmental effects and potential neurotoxicity due to its zinc and phosphorus content.
Copper-based lubricant additives contain ultra-low to no SAPS (sulphated ash, phosphorus, and sulphur), are easily recyclable, and can be biodegradable. They also act as effective detergents.

9. Real-World Test Studies:

Sandvik CG820i Gyratory Crusher: A one-year trial using CuGlideTM powered industrial gear oil showed excellent viscosity control, thermal and oxidative stability, no increase in oil acidity, no wear on gear parts, effective cleaning of the crusher, and removal of metal debris.
CAT 777E Haul Trucks: A 500-hour field trial with CuGlideTM powered no-SAPS synthetic 10W-40 HDDEO showed minimal wear, efficient removal of lead-containing deposits, excellent oxidation and nitration control, potential annual fuel savings of £46,200 to £99,600 per truck, and improved vehicle performance.
Bench Tests: Tests on various small engines demonstrated improved fuel-saving performance, engine performance, no-wear protection, reduced emissions, and eco-friendliness.

10. Future-Proofing Hydrogen Technologies:

As hydrogen technologies emerge in the transportation industry and beyond, the phenomenon of hydrogen wear will become increasingly critical.
Protecting and maintaining hydrogen technology is paramount due to the high production cost of hydrogen.
Ignoring hydrogen wear in emerging industries will likely lead to failure.

11. Conclusion:

Hydrogen wear is a significant factor in premature machinery damage.
Copper filming technology offers a means to prevent and reverse hydrogen wear and other wear mechanisms.
This technology can improve fuel economy, machine performance, and longevity while being environmentally responsible.
The vision is a "greener world where machine parts don’t die" and a "new and self-sustaining industrial system."

Quotes:

"there is another wear mechanism that has gone largely underreported, at least in the West: hydrogen wear."
"Secondly, he found that hydrogen was the primary cause of metal surface deterioration." (referring to Professor Garkunov's discoveries)
"unlike hydrogen embrittlement, where a different law of hydrogen distribution applies, the phenomenon of hydrogen wear creates an unusual pattern of failure."
"Dr Sergei Mamykin, a global leader in the study of hydrogen wear, defines this pattern of failure as the ‘self-organised destruction in the material’s top layer during friction; it is characterised by a considerable non-equilibrium of processes and by joint impact of co-factors that contribute to absorption of hydrogen in the top layer and destruction of this layer.’"
"Western researchers have called this phenomenon White Etching Cracking, or WEC, and although they agree that its exact cause remains unclear, many suggest that lubricants may play a significant role."
"Tellingly, their description of WEC is near-identical to the description of hydrogen wear."
"Dr Sergei Mamykin, who has been developing revolutionary copper filming technology for more than 30 years, defines the wear-free effect as ‘a type of friction that can be described as a non-oxidising thin metal film (servovite film) that emerges spontaneously in the contact area; the film possesses low shear resistance and cannot accumulate dislocations through deformation. On top of this film, an additional protective film (surf film) can be formed, entering in a chemical bond with it; the latter film is made of degradation products left from hydrocarbon lubricants.’"
"Simply put, the system has become self-organising."
"By definition, the more hydrogen technology we adopt the more attention we need to pay to the hydrogen wear phenomenon, and if emerging industries don’t account for this phenomenon, then we are surely on a fast track to failure."

Implications:

This article presents a compelling case for the significance of hydrogen wear and introduces copper filming technology as a promising solution.
The successful real-world application examples highlight the potential for significant cost savings, improved efficiency, and reduced environmental impact across various industries.
The discussion of wind turbine gearbox failures (WEC) suggests that copper filming technology could offer a much-needed solution to a critical industry challenge.
The emphasis on future hydrogen technologies underscores the importance of addressing hydrogen wear proactively.
The article positions NEOL Copper Technologies as a leader in this innovative field.

customboss · March 23

TAKEAWAY FOR GM TRUCK OWNERS :

I THINK THAT THE METALLURGY ISSUES WITH GM VALVETRAIN COMPONENTS MIGHT BE SOLVED WITH THIS COPPER ADDITIVE VS ZDDP WHICH COULD BE CAUSING THE ISSUE BY A WATER/HYDROGEN MECHANISM FINDING WEAK SPOTS IN THE VALVETRAIN OF GM V8's in PRODUCTION.

Grumpy Bear · March 23

16 minutes ago, customboss said:

TAKEAWAY FOR GM TRUCK OWNERS :

I THINK THAT THE METALLURGY ISSUES WITH GM VALVETRAIN COMPONENTS MIGHT BE SOLVED WITH THIS COPPER ADDITIVE VS ZDDP WHICH COULD BE CAUSING THE ISSUE BY A WATER/HYDROGEN MECHANISM FINDING WEAK SPOTS IN THE VALVETRAIN OF GM V8's in PRODUCTION.

Did I just read that right.? Your putting valve train failure on the ZDDP? Questions if understood that as written.

Where were these ZDDP induced mass failures in roller cam applications for the last 4 or 5 decades before Ecotec3 motors? Would it seem reasonable that it was perhaps a change in the material or heat treat choices? Lower levels of ZDDP? Thinner films? Uneducated and willfully ignorant and uninterested public that doesn't do maintenance anymore? At best this is a hypothesis and it would be a really good one to put to the test.

29 minutes ago, customboss said:

CAT 777E Haul Trucks: A 500-hour field trial with CuGlideTM powered no-SAPS synthetic 10W-40 HDDEO showed minimal wear,

I'm not trying to work against you here but that paragraph is floating in air unhinged to a reference that would matter. BTW the article stated they used three engines EACH with 28,000 to 33,000 HOURS of operation or about a million miles per unit. Diesels. Yet no data is provided nor a blind referenced to the 'usual' 15W40 performance.

[Quote from link provided] By deepening our understanding of the hydrogen wear phenomenon, both the causes and solutions, we can improve fuel economy, improve machine performance, and eliminate wear almost completely – while helping to protect our planet.

Rather than settling for a polluted world with countless landfills of excessive machine waste, we should imagine a greener world where machine parts don’t die, where energy sources like wind turbines could last indefinitely, and where evolutionary lubricants can contribute to the dawn of a new and self-sustaining industrial system. More information about the science behind NEOL’s copper filming technology, and further insight into its real-world applications, can be found on the company website. [Close quote].

So this is an advertisement for a product not fully vetted?

I did take notice of this test oils base composition. Group III/IV and ESTERS.

Do we have current access to an oil KNOWN to use this technology? (Pragmatism)

customboss · March 23

CAUSING might be too strong but it’s not stopping it. The mechanism of hydrogen damage is exacerbated by water which ZDDP attracts.

Im writing as fast as I can with dementia so will make mistakes in translation.

customboss · March 23

30 minutes ago, Grumpy Bear said:

Would it seem reasonable that it was perhaps a change in the material or heat treat choices?

Absolutely and if you read all the papers presented I hope my summation reflected that.

customboss · March 23

31 minutes ago, Grumpy Bear said:

So this is an advertisement for a product not fully vetted?

Thats their summation and heck yeah they are marketing to survive, if you listen to other summations, Raif videos, and whatever know of crappy Soviet and Russian metallurgical issues I’ve been aware of for 50 years the copper replacement for ZDDP seems viable to a reasonable reader.

As far “esters” we had those as long as we’ve had engine wear and failures. They aren’t new. Poly Esters don’t replace AW additives nor are “esters” low cost for anyone but you and I. Lol

Grumpy Bear · March 23

Just now, customboss said:

Absolutely and if you read all the papers presented I hope my summation reflected that.

I'm still working on them. Quite the flood. I'm a pig in a pile of warm ****?

4 minutes ago, customboss said:

CAUSING might be too strong but it’s not stopping it. The mechanism of hydrogen damage is exacerbated by water which ZDDP attracts.

Now that is accurate and precise. Well done.

4 minutes ago, customboss said:

5 minutes ago, customboss said:

Im writing as fast as I can with dementia so will make mistakes in translation.

Take all the time you need. Perfection is not expected. Never has been. We are all flawed. Being willing to digress for the sake of accuracy it GOLDEN. Don't stop. Here to help, not hinder.

customboss · March 23

1 hour ago, customboss said:

COULD

Grumpy Bear · March 23

1 minute ago, customboss said:

Thats their summation and heck yeah they are marketing to survive, if you listen to other summations, Raif videos, and whatever know of crappy Soviet and Russian metallurgical issues I’ve been aware of for 50 years the copper replacement for ZDDP seems viable to a reasonable reader.

As far “esters” we had those as long as we’ve had engine wear and failures. They aren’t new. Poly Esters don’t replace AW additives nor are “esters” [ are not] low cost for anyone but you and I. Lol

Agreed! POE doesn't replace AW. It does enhance HTHS when properly formulated which goes to the first line of wear defense. It also has a useful component in 'lubricity'...translated "Slick like deer guts on a brass doorknob" because it is polar and thirdly, due to polarity a good solvent.

And yes, it has flaws...cost primary. I can compete with other polar additives but so does Ca and Mg and a few others, like borate esters. Balance is good and that balance is not as narrow as those trying to dismantle the status quo would be erroneously indicating.

Now to the point in bold in the quote; True! So.....we need to be conscience of that when recommending application specific and end user pocketbook friendly alternatives and make them aware of the adjustments they need to make in service schedules to compensate. Don't you think?

Grumpy Bear · March 23

3 minutes ago, customboss said:

COULD

Oh I got you. Cause get you. Not sure others may have caught the nuance. Clarity pause.

customboss · March 23

1 minute ago, Grumpy Bear said:

Agreed! POE doesn't replace AW. It does enhance HTHS when properly formulated which goes to the first line of wear defense. It also has a useful component in 'lubricity'...translated "Slick like deer guts on a brass doorknob" because it is polar and thirdly, due to polarity a good solvent.

And yes, it has flaws...cost primary. I can compete with other polar additives but so does Ca and Mg and a few others, like borate esters. Balance is good and that balance is not as narrow as those trying to dismantle the status quo would be erroneously indicating.

Now to the point in bold in the quote; True! So.....we need to be conscience of that when recommending application specific and end user pocketbook friendly alternatives and make them aware of the adjustments they need to make in service schedules to compensate. Don't you think?

CUFILM ….MIGHT… solve this issue. Reason I say this is from experience studying Soviet Military and poor steel quality forcing lubricant additives to compensate for that and former eastern bloc using barely refined group -1. Yeah NEGATIVE 1.

Grumpy Bear · March 23

3 hours ago, customboss said:

Thats their summation and heck yeah they are marketing to survive, if you listen to other summations, Raif videos, and whatever know of crappy Soviet and Russian metallurgical issues I’ve been aware of for 50 years the copper replacement for ZDDP seems viable to a reasonable reader.

Let me start with the later first. Viable? Agreed! Even exciting but currently useful?....not so much. Unless ....is there a current commercial candidate you can confirm uses this tech?

And to the former. Might I point out that your agreement also means you are aware that such conflicts will, by nature, add color to a result that is intended apart from not being completely true.

For instance the term "Harmful" used in the text to 'define' ZDDP is meant to convey the erroneous idea that it harms the MACHINE when in no real way is that EVER true at the concentrations used commercially when used as instructed; when what is actually true is that it CAN be harmful to the environment. A point PURPOSELY not clarified int the text...AKA...Marking. Strawman advertising smells and I have a nose for it. Hold that thought.

Since I can gain nothing personally nor monetarily from such an endeavor it guarantees I have no commercial or professional bias. Since that is true I am not conflicted nor is my "reading of the text" ever colored by such concerns. I thought that is why I was here. A neutral third party to keep the thing that killed BITOG credibility. :dunno: Using a information platform to promote and commercial interest. No one has influence over me and I none over them.

Anyway, we are trying something new we are ALL passionate about so a bit of bumping about in the dark to be expected.

customboss · March 23

6 minutes ago, Grumpy Bear said:

For instance the term "Harmful" used in the text to 'define' ZDDP is meant to convey the erroneous idea that it harms the MACHINE when in no real way is that EVER true at the concentrations used commercially when used as instructed; when what is actually true is that it CAN be harmful to the environment. A point PURPOSELY not clarified int the text...AKA...Marking. Strawman advertising smells and I have a nose for it. Hold that thought.

ZDDP does cause issues by nature of its chemical mechanism, forming a reactive layer, as time progresses or have too much ZDDP, it causes damage and pitting to the metal it was meant to protect. Have too much water in the oil volume and it excaerbates that damage. While its a primary cheap antioxidant its also aggressive in certain environments.

Its not unheard of for years to try to find an alternative to AW protection that is cost effective.

The CUFILM "marketing" is science based marketing with their young CEO writing to attract attention to the realities I just shared.

Before you decide they are liars, thieves etc allow the science to sink in. The product has been tested in HD mining fleets and in a Ford van tested by Rafe himself.

I did remember while reading the post above you added ZDDP to one of your engines. Why? How do you know its balanced?

No one here is selling anything. RETIRED AND DISABLED. Be careful you don't sell a needlessly critical POV without knowing the chemistry you challenge or defend. TRUTH is all I got.....