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Red and Tackygreasecompatibility

When a grease mixture is introduced into a machine, such as a motor bearing, it will undergo significant mixing and working in a relatively short period of time. This compares to the 60 double strokes utilized to mix and work the binary mixture evaluated in the standard.

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The following test results for binary grease mixtures were obtained using the previously described methods and the grease mixing test stand to mix and work the samples. The first example is of two common polyurea-thickened greases. This mixture was chosen for a company looking to consolidate the number of greases in its facility. One area of the facility used a particular grease in all electric motors, while the remainder utilized another grease. The goal was to consolidate to one product for all motors. Unfortunately, it would not be possible to completely clean out all of the grease being replaced from the motors. Therefore, it became necessary to verify that one polyurea grease could be added directly to a motor containing the other. According to most grease compatibility charts, polyurea greases are compatible with each other, and such a transition would be allowed.

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A number of organizations rely on compatibility charts to make important maintenance decisions. These charts are readily available in published papers, periodicals and Web pages. Unfortunately, very few charts give any reference for the origin of the data or any research utilized to establish the compatibility relationships described. Significant concerns have also been raised about some of these charts after greases presented as compatible have proven to be quite incompatible.

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IMPORTANT — CAREFULLY READ: THESE TERMS OF USE ARE A LEGAL CONTRACT BETWEEN YOU AND AMERICAN AIR FILTER COMPANY, INC.  BY CLICKING THE “ACCEPTED ICON” ASSOCIATED WITH THIS PAGE, OR REGISTERING FOR USE OF THIS SITE, WHICH WILL SERVE AS YOUR SIGNATURE, YOU AGREE TO CONDUCT TRANSACTIONS ELECTRONICALLY AND TO BE BOUND BY THESE TERMS. IF YOU DO NOT AGREE TO THESE TERMS, YOU SHOULD EXIT THIS PAGE WITHOUT ACCEPTING AND REFRAIN FROM ALL FURTHER USE OF THIS WEBSITE.

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Table 4. The rheological values for the two worked reference samples and the 50-50 worked mixture, with the values of concern in yellow

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It is interesting to note that these grease compatibility charts focus only on the family of thickener involved. However, there are three components to any formulated grease: the base oil, the additives and the thickener. When mixing oils, the key considerations are the viscosity of each product, the base oil type and the thickener. Somehow, though, these critical parameters are overlooked when utilizing grease compatibility charts. This is somewhat understood, since the most common reason for grease mixing problems is related to differences in the grease thickener, but that is not the only issue.

These terms of use are entered into by and among (i) American Air Filter Company, Inc. (“AAF”, “we” or “us”), (ii) you, the individual accessing this Website as a representative of a customer of AAF or other entity for which AAF has approved access, and (iii) our customer, a potential customer or other person or entity for which AAF has approved access (collectively, “Customer”). The following terms and conditions, together with any documents they expressly incorporate by reference (collectively, these “Terms of Use”), govern your access to and use of www.aafintl.com/aafvisionairclean, including any content, functionality and services offered on or through www.aafintl.com/aafvisionairclean (the “Website”), whether as a guest or a registered user.

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Greases are manufactured from both mineral oil and synthetic oil bases. Some synthetic base oils are incompatible with mineral oils and other types of synthetics, just as in the mixing of lubricating oils. Therefore, it is important to consider the type of base oil in the grease when determining compatibility. If the grease thickeners are compatible but the base oils are not, the resulting mixture can be problematic. Viscosity is critical when selecting any lubricant. Likewise, when greases are mixed where the base oil viscosities are significantly different, the resulting mixture will not be optimized for the application.

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It can be difficult to avoid mixing greases in a plant environment, but several steps can be taken to minimize the impact and likelihood of mixing incompatible greases.

Mixing of greases with incompatible thickeners can result in the most immediate and obvious changes that interfere with effective lubrication. Many mixtures will initially soften, often to the point of migration through seals or away from lubricated surfaces. Some mixtures will cause the thickener to release the oil, with the separated phase running freely from the bearing, gear or housing. Other mixtures harden initially and lead to component load issues and poor grease motility. This potential effect is not easily determined. Simply mixing two greases together to observe changes may not provide any obvious difference. 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.

In accordance with the Online Copyright Infringement Liability Limitation Act of the Digital Millennium Copyright Act (17 U.S.C. §512) (“DMCA”), the written notice (the “DMCA Notice”) must include substantially the following:

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. This includes employees and contractors who may be working in the facility. Provide labels and color codes where possible to prevent confusion.

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Identify the minimum number of products required to meet the design of the equipment in use and consolidate to that number. Do not stock additional products for convenience or brand loyalty. This increases the likelihood of mixing.

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No waiver by AAF of any term or condition set forth in these Terms of Use shall be deemed a further or continuing waiver of such term or condition or a waiver of any other term or condition, and any failure of AAF to assert a right or provision under these Terms of Use shall not constitute a waiver of such right or provision.

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Table 4 shows the rheological values for the two worked reference samples and the 50-50 worked mixture. The areas highlighted in yellow indicate values of concern.

Table 5. (Top) The expected and actual yield stress values for the 50-50 mixture and the reference greasesTable 6. (Bottom) The expected and actual recoverable compliance values for the 50-50 mixture and the reference greases

These Terms of Use, our Privacy Policy, Terms and Conditions of Sale, and all other applicable license agreements or terms of use that may apply to any feature or function made available through the Website constitute the sole and entire agreement between you and American Air Filter Company, Inc. with respect to the Website and supersede all prior and contemporaneous understandings, agreements, representations and warranties, both written and oral, with respect to the Website. In the event of any inconsistency between these Terms of Use and the terms of any other applicable document referenced herein, the more restrictive terms shall control to resolve such inconsistency.

Basic housings are available in 1H1W, 1H2W and 1H3W configurations, allowing up to three filters or adsorbers to be removed from a single access door. Each configuration may be provided with a separate slide-in pre-filter track behind the same door or with a separate access door. Pre-filters may be 2, 4 or 6 inches deep. Units may be joined in parallel or series to build systems with capacities ranging from 1,000 CFM to 30,000 CFM (based upon 1,000 CFM per 24”x24” filter) or 1,000 CFM to 30,000 CFM (based upon a filter face velocity of 250 ft/min).

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Manufactured under stringent quality assurance controls, KF-Series housings are subjected to thorough inspections and leak tightness tests before leaving the factory, and are guaranteed to pass both DOP and Freon in-place tests.

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In this case, each of the values for the 50-50 mixture is significantly different than the expected numerical average of the unmixed greases. This demonstrates a change in properties due to mixing and raises concerns about this mixture’s performance in the long term. It could be expected that the mixture may be subject to softening, oil separation and a tendency to channel when allowed to persist in a mixed state in the motor housing. 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.

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The resulting mixture is analyzed by Fourier transform infrared (FTIR) spectroscopy to note any reaction or unexpected oxidation of the components in the grease. 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.

These variations reveal an obvious formulation difference between the greases (most likely involving anti-wear additives), but this alone would not be sufficient to disqualify the mixture for compatibility if the resulting product still functioned effectively with regard to wear resistance.

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Mobilgreasecompatibility chart

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SKFgreasecompatibility chart

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Polyureagreasecompatibility

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Shellgreasecompatibility chart

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PTFEGreaseCompatibility

Taken together, these tests may provide a more comprehensive picture of the potential effects of mixing two grease products together and help users avoid reliability issues from grease mixing, even for products that might otherwise appear to be compatible on charts.

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Greasecompatibility Chart pdf

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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. While reacting additives will not settle to the bottom in grease, as is the concern in oil, the changes can cause problems, impacting additive effectiveness and in some cases creating corrosive conditions in the grease. Additive compatibility with the metallurgy of the lubricated component must also be considered.

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Rich Wurzbach, President, MRG Laboratories, York, PA, has 25 years of experience in the development of Predictive Maintenance programs and the applications of diagnostic technologies for industrial equipment. His expertise lies in the applications of Infrared Thermography and Lubricant Analysis, and the integration of various diagnostic technologies for equipment assessment. He can be reached at rwurzbach@mrgcorp.com.

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A selection of 17 compatibility charts was recently evaluated for differences. Table 1 shows the labels used in these charts and how many times these descriptions appear in the charts. Seventeen occurrences would indicate that a grease category was present in each of the charts found, and there were only three such products.

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If the wrong grease has been inadvertently added to a machine or consolidation is required that will transition the use of a product in a machine, perform simulated mixing and working of the mixtures as well as dynamic properties testing to evaluate the mixture’s performance. For those mixtures that prove to be incompatible, the extra effort must be taken to thoroughly clean all traces of grease from the housing, supply lines and bearings/gears to ensure long life and reliable machinery operation.

Without limiting the foregoing, we have the right to fully cooperate with any law enforcement authorities or court order requesting or directing us to disclose the identity or other information of anyone posting any materials on or through the Website. YOU WAIVE AND HOLD HARMLESS AAF AND ITS AFFILIATES, LICENSEES AND SERVICE PROVIDERS FROM ANY CLAIMS RESULTING FROM ANY ACTION TAKEN BY AAF OR ANY OF THE FOREGOING PARTIES DURING OR AS A RESULT OF ITS INVESTIGATIONS AND FROM ANY ACTIONS TAKEN AS A CONSEQUENCE OF INVESTIGATIONS BY EITHER AAF OR SUCH PARTIES OR LAW ENFORCEMENT AUTHORITIES.

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Some studies have been performed to improve the mixing and working of grease to better simulate machine conditions. The electric motor test stand shown below was developed for the Electric Power Research Institute’s Effective Grease Practices guideline. This test stand consists of the end bell from a 60-horsepower electric motor mounted with a ball bearing in a stub shaft. The shaft is turned by a fractional horsepower motor, coupled to a turned-down shaft. The housing of the end bell is removed and replaced by a Plexiglas window to observe the condition of the grease under dynamic conditions. For the purpose of testing grease mixtures, the 25-75, 50-50 and 75-25 ratios are packed sequentially into the bearing by hand, and the adjacent housing area is packed half full. This is then run for 72 hours to achieve the 30 million plus perturbations of the grease. The conditions observed are noted, and the grease is removed from the bearing.

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A common area for grease mixing is in new and rebuilt equipment. Even when all plant personnel are given clear guidance on using the correct products, equipment may be returned to the facility with a grease that is different than what will be added while in service. New bearings, gears, motors, etc., often come supplied with a product that is incompatible with the grease being used to relubricate.

Finally, the grease is tested in a controlled stress rheometer to identify changes in flow and shear properties as compared to the original products. The values measured include the yield stress, which can predict the hardening or softening the grease may undergo; the oscillation stress, which can give insight into the likelihood of oil separation and other effects; and recoverable compliance, which can help to identify those mixtures that might experience “channeling” or “tunneling” in the equipment housing.

Table 3 reveals the differences in elemental spectroscopy values for the reference greases and the 50-50 mixture. The areas highlighted in yellow show the contrast between the greases and evidence of mixing.

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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. 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.

You understand that we cannot and do not guarantee or warrant that files available for downloading from the internet or the Website will be free of viruses or other destructive code. You are responsible for implementing sufficient procedures and checkpoints to satisfy your particular requirements for anti-virus protection and accuracy of data input and output, and for maintaining a means external to our site for any reconstruction of any lost data. WE WILL NOT BE LIABLE FOR ANY LOSS OR DAMAGE CAUSED BY A DISTRIBUTED DENIAL-OF-SERVICE ATTACK, VIRUSES OR OTHER TECHNOLOGICALLY HARMFUL MATERIAL THAT MAY INFECT YOUR COMPUTER EQUIPMENT, COMPUTER PROGRAMS, DATA OR OTHER PROPRIETARY MATERIAL DUE TO YOUR USE OF THE WEBSITE OR ANY SERVICES OR ITEMS OBTAINED THROUGH THE WEBSITE OR TO YOUR DOWNLOADING OF ANY MATERIAL POSTED ON IT, OR ON ANY WEBSITE LINKED TO IT.

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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. ASTM D6185 (Standard Practice for Evaluating Compatibility of Binary Mixtures of Lubricating Greases) involves the mixing of the intended greases in ratios of 25-75, 50-50 and 75-25. The resulting mixtures are evaluated for changes in dropping point, shear stability and storage stability. These last two parameters include measuring changes in the cone penetration value.

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Grease compatibility charts have been developed and circulated since the 1980s without much alteration. However, grease technology has changed significantly over the years, and there are many examples of performance that contradict several widely used compatibility charts. This article will describe the most common examples of incompatible grease mixing and how to determine if two greases are compatible.

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Upon observation, it becomes obvious that several of the charts are derived from the others. The various descriptions used imply that some may have been copied from the others. Many charts include a disclaimer, usually stating that it would be preferable to clean out all old grease and avoid any mixing, or that the charts are believed to be accurate at the time of publication. This underscores the challenge of finding a single authoritative chart to be used with confidence when making decisions regarding grease mixing.

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Several contradictions were discovered among the various charts. For example, one chart indicated that barium-complex grease is compatible with clay-thickened grease, while others suggested this mixture is incompatible. Some charts listed polyurea grease as being compatible or borderline compatible with calcium complex, but another chart showed calcium complex to be incompatible with polyurea.

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A mixture of greases introduced in a common ball bearing operating at 1,750 revolutions per minute will see nearly 30 million mixing and working events in just three days of operation. This mixture will be subjected to continuous dynamic forces, and its performance and possible degradation will be influenced by this more than the static response seen in cone penetration or dropping point measurements. The ability of this testing to adequately predict in-service mixtures may be reasonably questioned.

The three products that appeared in each of the tables were aluminum complex, lithium complex and calcium complex. However, the commonality ends there. A total of 25 different product descriptions were found in the 17 tables. Some may have been referring to the same product categories but failed to use common nomenclature, so it is difficult to determine where there might be an overlap.

While this standard has greatly improved the uniformity to which greases can be tested for compatibility, it should be noted that the three evaluation tests are static in nature. Although there is some mechanical working of the grease prior to testing, this is minimal mechanical perturbation.

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Rich Wurzbach, President, MRG Laboratories, York, PA, has 25 years of experience in the development of Predictive Maintenance programs and the applications of diagnostic technologies for industrial equipment. His expertise lies in the applications of Infrared Thermography and Lubricant Analysis, and the integration of various diagnostic technologies for equipment assessment. He can be reached at rwurzbach@mrgcorp.com.

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Grease compatibility charts may seem to be a convenient way to make decisions based on actual or potential grease mixing. However, the unreliability of these charts and the complex interaction of base oils, additives and grease thickeners require that a more certain approach be employed for optimal equipment performance. The efforts to avoid mixing where possible and to test mixtures for compatibility issues as well as taking the appropriate actions will be an investment in reliability that will pay dividends.

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The KF-Series non-bag-in/bag-out housing is a high efficiency, side servicing filter housing that has been designed to give the user maximum quality and performance in a non-bag-in/bag-out configuration. This housing is designed for applications in which the bag-in/bag-out procedure is not necessary for filter change-out, but high quality side servicing filter housings are still required. Depending on the user’s requirements, the KF-Series housing may have an assortment of filter arrangements, including pre-filters, HEPA filters, and carbon adsorbers.

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LithiumGrease

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Many custom options are available, including static pressure taps, test ports, transitions, dampers, and in-place test sections that allow the operator to perform individual filter system efficiency tests without having to enter the system or otherwise disrupt its operation.

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Table 2 shows the product information for both greases tested. These greases are very comparable based on their consistency and viscosity of the base oils.