. . It is essential to prevent problems by specifying compatible products. . . . . . . . . This article will describe the most common examples of incompatible grease mixing and how to determine if two greases are compatible. Call the metalworking experts at Acculube - we'll help you get the most value . A selection of 17 compatibility charts was recently evaluated for differences. . . . . . Likewise, when greases are mixed where the base oil viscosities are significantly different, the resulting mixture will not be optimized for the application. . All greases contain a thickener (which helps with its physical state). Wide service-temperature range (-45C to 180C; for short periods up to 200C) Suitable for very high rotational speeds (DN value 750,000) Good oxidation . . . . Our high-quality additive chemistry will meet your specific needs for thickener compatibility, environmental responsibility and cost effectiveness. . . . Grease compatibility problems may be immediately apparent in observable changes to the lubricant. . . . . . When changing oil and grease lubricants, it is wise to work with an experienced supplier with extensive knowledge of compatibility issues and good testing resources. . Low noise. . Greases are manufactured from both mineral oil and synthetic oil bases. Motor Bearing Grease Google "grease compatibility chart" and you will find a bunch of charts that rate compatibility (based on change in worked penetration) of greases according to their thickener. . . . . . . Others need to be inert due to material compatibility, or they may be in aggressive environments where they are exposed to corrosive or acidic environments. Many mixtures will initially soften, often to the point of migration through seals or away from lubricated surfaces. . . More Than List Price How Evaluating Synthetic vs. There are only a few other thickeners that are not compatible with lithium complex, when using one of the Graco greases. The most likely result is a change in consistency or increased oil bleeding, especially under shear stress. . . . of Metalworking Fluids . The grease with 10% thickener flows in the shear stress range of about 50 Pa after passing through the yield point and then begins to slide as a single body. . It is understood that when oils are mixed, any incompatibility in the additive packages will result in poor performance and often additive reactions creating deposits. . Soap-based thickeners are produced from an acid base reaction. . . Selecting Diesel Engine Oil for Mixed Fleets . . . Vibratory Finishing Basics Irritant Contact Dermatitis: How to . . Contains no lead or nickel. As such, to verify whether two greases are compatible or not, Machinery Lubrication developed a Compatibility Chart based on thickener type. . Viscosity is critical when selecting any lubricant. Mixing incompatible greases in your machine can have major consequences. However, these charts rarely tell the whole story, even just in terms of the thickener compatibility. . . . . . . 3.2.4. . All personnel involved in applying grease to equipment should be trained and receive instruction on the proper product to use on each piece of equipment and the location. . a Proven Brand of Lubricant . In this case, each of the values for the 50-50 mixture is significantly different than the expected numerical average of the unmixed greases. For this reason, the mixture was not permitted at the facility, and the decision was made to keep two greases in place until the motors could be removed and thoroughly cleaned of the existing product. . Today, with not only the aforementioned thickeners - but also complex soaps, polyurea, calcium sulfonate and even more exotic thickeners used in many greases - the issue of compatibility has become much more complicated. . . . . . Testing should be conducted to determine if greases are compatible. The thickener defines the type of grease (see Fig. . . They are finding that the greases they have been using for years for on-highway, off-highway and industrial applications are in short supply. . . . . . Finally, the grease is tested in a controlled stress rheometer to identify changes in flow and shear properties as compared to the original products. . . Do not stock additional products for convenience or brand loyalty. . . That is to say, the charts being used to make significant engineering and design decisions are contradictory and do not indicate the source of information or research used to compile them. . . Unfortunately, it would not be possible to completely clean out all of the grease being replaced from the motors. . . . . . . Consistent lubrication frequency, without over- lubricating, also promotes a smooth transition. Therefore, you never need to add more grease to increase mobility. . . . Once two greases are determined to be compatible in the above three areas, further testing to determine the impact on other performance parameters of the products may be warranted. . . . A typical grease compatibility chart is shown in Figure 1. . . This is because the charts from the various manufacturers often disagree with one another on certain thickener-type combinations. . The resulting mixture is analyzed by Fourier transform infrared (FTIR) spectroscopy to note any reaction or unexpected oxidation of the components in the grease. . . . . . . In practice this rarely happens due to the amount of extra work it takes. . . . . . . . . Grease compatibility can be confusing to those who have to maintain equipment correctly even if most of the manufacturers can produce compatibility charts. . Lubricant Contamination Control Helps Prevent Varnish Formation in Machine Shops . Formulation or additive incompatibility - this is dependent on the robustness of the thickener structure and can occur even when the thickener systems are the same, for example lithium/lithium. . . . Meets requirements of FDA 21 CFR 175.300. . . . Sheer stabilized Polyurea is compatible with just about all thickeners (much more so than the non-sheet stabilized). . . . . . . Grease compatibility is often confusing to grease users, even though most grease manufacturers produce compatibility charts. . . . . . . . . . . . a grease with different thickener should especially proceed with caution. Grade #3 greases have good sealing properties to protect the equipment . . . . . . Table 4 shows the rheological values for the two worked reference samples and the 50-50 worked mixture. . This includes employees and contractors who may be working in the facility. . . . . . Calcium Sulfonate greases are an excellent alternative to traditional Lithium Complex for consistent performance in extreme conditions such as steel mills. Somehow, though, these critical parameters are overlooked when utilizing grease compatibility charts. Table 3 reveals the differences in elemental spectroscopy values for the reference greases and the 50-50 mixture. . . . . . . . . . 5. . The short answer is, "No". . . Low volatility. Greases based on simple lithium soaps (lithium stearate or lithium 12-hydroxy stearate) and lithium complex soaps may or may not be compatible with polyurea greases. . . Grease compatibility charts (such as the one pictured below) can only help compare the thickener types of greases. . See the above example for composition or formulation. . . These greases are very comparable based on their consistency and viscosity of the base oils. . . Acculube's Compatibility Chart For Commercial Greases, Talk with Us Today . Some polyurea thickeners are completely compatible with lithium and lithium complex thickeners, while other polyurea thickeners are definitely incompatible with the lithium and lithium complex thickeners. Grease compatibility and conversion guidance Tech topic Key insight Compatibility testing enables users to make informed decisions when converting from one grease to another. For Commercial Greases . . . . . . If the grease thickeners are compatible, but . . Don't Waylay Your Machine Tools with the Wrong Way Oil 4 The type of thickener influences grease properties such as temperature resistance, which relates to viscosity, and water washout, which is the ability of the grease to still perform and remain intact when submerged in water. . . Maintaining Gear Box Lubrication Compatibility testing is the only way to verify compatibility. . 3.3.2. . . . . . . . polyurea conventiona. . Mixing grease with incompatible thickener type can change the physical and chemical structure of the grease. . . . . . The reason being, some polyurea thickeners are completely compatible with lithium and lithium complex thickeners, while others are incompatible. Although there were significant disagreements between the various charts, they all had one thing in common - few provided any link or reference to research that was conducted to develop them. . . . lithium complex. The mixture's dropping point is not significantly lower than the dropping points of the individual greases. . . . Grease suppliers typically advise their customers to purge as much of their grease as possible through the grease-dispensing system and application to displace the previously used product. . . . . . . . The grease fitting also merits inspection for contaminants and should also be wiped clean. . . Table 3. . . . . It is recommended to match "like-for-like." If you plan to make a switch, it is best to completely drain your equipment before applying new grease. . . . . . . . . Copper phthalocyanine grease; Na terephthalamate grease; Thickener Compatibility. > . Goodbye, Tramp Oil Tramp Oil Contamination Is Not Inevitable . Grease labeling according to standards . . . If the grease thickeners are compatible but the base oils are not, the resulting mixture can be problematic. Even so, those charts have their limitations. . There are three typical grease thickeners used in grease lubricants, including: In an ideal scenario you would remove all of the old grease from the machine before introducing a new one. . . . . Mixing of greases with incompatible thickeners can result in the most immediate and obvious changes that interfere with effective lubrication. . . . . . Calcium Sulfonate Calcium-sulfonate greases have superior mechanical and shear stability compared to lithium-complex greases. You also need to consider the operating conditions of the grease (temperature, sheer rate, etc.) . . . . . Soaps can be grease thickeners, while non-soap thickeners include polyurea, organophilic clays (e.g., bentonite) and other materials. Mixing greases in a system can cause issues with thickener systems reacting with each other. . . . . . . . . Particulates in Cutting Fluid -- A Fine Mess . . . . . . Coolant Sump Odor; What to Do . . . When mixing oils, the key considerations are the viscosity of each product, the base oil type and the thickener. . with Optimal Water Quality In grease-lubricated applications, on the other hand, it is usually impossible to remove all of the old grease from the application when changing products. . . . . . . . . . . . . . 3.3. . . Fantastic put on and intense stress safety. . . . . . Consistency of the mixture following temperature elevation is comparable to the change in consistency of the individual greases under the same conditions. . . . . . . . . . . Incompatibility of thickener systems, which is the most commonly asked question. . . . . . . . Table 5. However, carefully mixing the greases in different ratios and subjecting them to mixing, working and heating cycles can reveal measureable changes in properties to predict their performance in a machine. You can not select more than 25 topics Topics must start with a letter or number, can include dashes ('-') and can be up to 35 characters long. . When changing grease thickener types in an application, always consult your lubricant supplier on the compatibility of a proposed product with one that's being replaced. Borderline The properties of the mixture may or may not be acceptable, depending on the nature of the application. . . . . . How Can Lubrication Best Practices . . . . JavaScript seems to be disabled in your browser. This document details the procedure for evaluating the basic compatibility of greases, which is determined by measuring the dropping point, the mechanical stability and the change in consistency of the mixture upon heating. Coolant Smell: Lubricant Solutions . . Specific properties of greases can dictate suitability for use. . . 2 is Cenex's Poly-Xtreme, a high-temperature polyurea grease. . . . . . However, there are three components to any formulated grease: the base oil, the additives and the thickener. . . Therefore, it is important to consider the type of base oil in the grease when determining compatibility. . . . . . . . . Table 2. A number of organizations rely on compatibility charts to make important maintenance decisions. . . . . . Thoroughly Clean Those Coolant Systems! . . . . . . In the case of lubricating oils, it is often possible to change the fluid completely; and when that is not possible, the compatibility of the fluids can be relatively easily determined. . . Reduce Foam: How to Prevent Foam in Oil . . The electric motor test stand shown below was developed for the Electric Power Research Institutes Effective Grease Practices guideline. thickener compatibility. . . . Conventional Oil Can Add or Subtract From Your Bottom Line Note: The compatibility charts should be used as a reference only.Compatibility testing is the only way to verify compatibility. (Bottom) The expected and actual recoverable compliance values for the 50-50 mixture and the reference greases. . "Base oil type and viscosity are the most . Different thickener systems can react with each other to modify . . . It provides a general assessment of grease compatibility based upon the structural stability of mixtures of different grease thickeners. . . . . . . . High load-carrying capacity. . . Many mixtures will initially soften, often to the point of migration through seals or away from lubricated surfaces. The upper operating limit for a grease is usually recommended to be 100-150F lower than the dropping point. . . . . . . . . . Managing the Turnover . Significant concerns have also been raised about some of these charts after greases presented as compatible have proven to be quite incompatible. . . . . . . How to make grease: The process to make anhydrous calcium soap grease. . . . . LGHP 2 is compatible with such greases. . . . . . . . Sometimes, though, conditions dictate a change from one lubricant to another. . Shows also excellent performance in combination with hot water . Chips Off the Old Block For example, one chart indicated that barium-complex grease is compatible with clay-thickened grease, while others suggested this mixture is incompatible. . When switching greases, it is important to understand thickener compatibility to make sure the new grease does not fail. . . . . . . . . Polyurea greases are also characterized by dropping points above 250 C and low oil separation. . A total of 25 different product descriptions were found in the 17 tables. . . + = Compatible = Test required - = Incompatible . . . . . But thanks to the polyurea thickeners that are far better than any lithium-complex grease. . While there are advantages to staying consistent with one lubricant product per task, this often means that improvements in performance - or cost - can't be realized. . . . This could mean that your grease is no longer the correct grade for the machine. . . One is to determine whether such mixtures meet the same specification requirements as the constituent components. . . . . . . . . . . . . . Lubricants often fail to perform as specified when combined with other products, even in small concentrations. . . Standard compatibility tests may consider the stability of the oil/thickener matrix by evaluating a grease's shear stability, dropping point, storage stability and high-temperature performance. . . 3.2.5. . . It is up to you to determine the tradeoffs between grease costs and performance gains/losses. . and Save Money? . . . . from every lubricant and other critical fluid you buy, and avoid the common pitfalls that can cost you money. . The compatibility of polyurea greases with soap-thickened greases is probably the most debated area of grease compatibility today. . . . . . The areas highlighted in yellow show the contrast between the greases and evidence of mixing. If research has demonstrated the unreliability of the different grease compatibility charts, it is important to discuss what additional steps can be taken to evaluate grease compatibility. Greases with same thickener type 2017 by Accurate Lubricants & Metalworking Fluids, Inc. located in Dayton, Ohio U.S. All rights reserved. . . . . . . . . and the proportions in which they are mixed. . . Grease of #2 consistency rated GC (for wheel bearings) and LB (for chassis) is good. . . The various descriptions used imply that some may have been copied from the others. . Relative Compatibility Rating In some cases, dissimilar thickener types are combined in a grease. . . . . . . Coolant Concentration NLGI Consistency number 3. . Acculube Compatibility Chart . . . . . However, grease technology has changed significantly over the years, and there are many examples of performance that contradict several widely used compatibility charts. . How Can Oil Leak Dye Pinpoint Leaks The remaining 10% to 20% of a finished grease is made up of thickeners and additives, both of which contribute to the . This table is to be used as a reference only. . Table 6. Technical Help Desk 6 Jun 2017. . . . . . . . . . Compatibility has a lot to do with which thickeners are used in the greases. Grease is a combination of thickener, oil, and additives. . . . . The full text of ASTM D6185 is available from ASTM International at www.astm.org. The conditions observed are noted, and the grease is removed from the bearing. This generally allows for smooth operation of equipment. . Vacuum pumps. . This type of thickener system can be referred to as a hybrid thickener or in some cases as a complex thickener. The two components of a lubricant are the base oil and additives; a grease adds one more component - the thickener. . . Performance Benefits. . . Grease compatibility charts have been developed and circulated since the 1980s without much alteration. . . . . . . Although there is some mechanical working of the grease prior to testing, this is minimal mechanical perturbation. It is necessary to perform compatibility testing on combinations of these greases to determine whether the greases can be mixed in service. . Why is Oil Testing Important for New Oil? The grease is also evaluated by elemental spectroscopy to assess unexpected final ratios of additives as compared to the anticipated averaging of values seen in the original products, adjusting for mixing ratios. . . Compatibility of grease mixtures is typically categorized as follows: . Polyurea greases offer excellent performance in industrial equipment. Unfortunately, very few charts give any reference for the origin of the data or any research utilized to establish the compatibility relationships described.
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