High-Temperature Grease Guide

There are many criteria to consider when selecting a high temperature grease for hot, grease-lubricated equipment.

The selection must include consideration of oil type and viscosity, oil viscosity index, thickener type, stability of the composition formed by the oil and the thickener), additive composition and properties, ambient temperature, operating temperature, atmospheric contamination, loading, speed, relubrication intervals, etc.

With the variety of details to resolve, the selection of greases that must accommodate extreme temperature conditions poses some of the more challenging lubrication engineering decisions.

Given the variety of options, the potential for incompatibility problems and high prices for a given high-temperature product, the lubrication engineer must be selective and discriminating when sourcing products to meet high-temperature requirements.

High-Temperature

‘High’ is relative when characterizing temperature conditions. Bearings running in a steel mill roll-out table application may be exposed to process temperatures of several hundreds of degrees, and may experience sustained temperatures of 250oF to 300oF (120oC to ±150oC).

Automotive assemblers hang painted metal parts on long conveyors and weave them through large drying ovens to dry painted metal surfaces. Operating temperatures for these gas-fired ovens are maintained around 400oF (205oC).

In these two cases, the selection criteria differ appreciably. In addition to heat resistance, the grease to be used in a hot steel mill application may require exceptional load-carrying capability, oxidation stability, mechanical stability, water wash resistance and good pumpability, and at a price suitable for large-volume consumption. With all of the important factors to consider, it is useful to have a grease selection strategy.

Selection Strategies

A reasonable starting point for selecting a high temperature grease is to consider the nature of the temperatures and the causes of product degradation. Greases could be divided by temperatures along the lines in Table 1.

There is general correlation between a grease’s useful temperature range and the expected price per pound. For instance, a fluorinated hydrocarbon-based (type of synthetic oil) grease may work effectively as high as 570oF (300oC) in space applications but may also cost hundreds of dollars per pound.

The grease’s long-term behavior is influenced by the causes of degradation, three of which are particularly important: mechanical (shear and stress) stability, oxidative stability and thermal stability. Oxidative and thermal stresses are interrelated. High-temperature applications will generally degrade the grease through thermal stress, in conjunction with oxidative failure occurring if the product is in contact with air. This is similar to what is to be expected with most industrial oil-lubricated applications.

Large production facilities have a variety of grease-lubricated equipment, ranging from steady-state applications to applications that vary significantly in speed and load, and operate in aggressive (wet or dusty) environments.

If machine designers address equipment lubrication needs based strictly on a dynamic loading requirement, they might have to specify a wide variety of greases to meet the many existing needs. In this approach, the added system complexity would likely increase the cost and the risk of failure due to misapplication and cross-contamination.

To maximize grease lubrication effectiveness, minimize cost and minimize risk of application-induced failure, lubricant manufacturers have made an effort to formulate greases that cover a variety of applications. These greases range from slow to high speeds, and from low to high loads, in an effort to provide a single product to meet a multitude of requirements. The result is general purpose grease.

What is General Purpose Grease?