. . . . With Polyurea Greases we are talking about a specific type of thickener for lubricating greases. . 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. . Grease Compatibility Chart Mixing greases in a system can cause issues with thickener systems reacting with each other. . . Some synthetic base oils are incompatible with mineral oils and other types of synthetics, just as in the mixing of lubricating oils. Charged 15% of the total base oil to an open kettle. Heat is applied to reach 50-60C (122-140F) with stirring. . . 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. . . a grease with different thickener should especially proceed with caution. . . . . . "Why Does This Sump Smell?" However, there are three components to any formulated grease: the base oil, the additives and the thickener. . . . How Can Oil Leak Dye Pinpoint Leaks . . When the base grease is the same, the name of the grease can be similar, but the two will not be identical; the thickeners can react with each other even if they are made by the same grease manufacturer. . . . . . For the best experience on our site, be sure to turn on Javascript in your browser. . . . . . Reduces wear in plastic-to-metal and rubber-to-metal contact. The tests that are conducted should be agreed upon between the user and grease supplier to assure that the properties that are critical to the proper function of the product in service are covered. . Many mixtures will initially soften, often to the point of migration through seals or away from lubricated surfaces. . . This type of thickener system can be referred to as a hybrid thickener or in some cases as a complex thickener. Best Practices for Mixing . . Grease Compatibility Chart. . Grease compatibility and conversion guidance Tech topic Key insight Compatibility testing enables users to make informed decisions when converting from one grease to another. 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. . Suitable for long-term lubrication by virtue of low oil evaporation and low tendency towards oxidation. . . . . . . . . . Sheer stabilized Polyurea is compatible with just about all thickeners (much more so than the non-sheet stabilized). 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. . . . Accurate Lubricants & Metalworking Fluids, Inc. 403 Homestead Avenue; Dayton, Ohio 45417 USA Phone: 937-461-9906 Fax: 937-461-9917 . Taking these precautionary measures to prevent the introduction of contaminants into the bearing will help ensure the proper operation of the bearing and performance to and beyond the rated life of the bearing. . . Uncommonly, even greases of the same type, although normally . Some mixtures will cause the thickener to release the oil, with the separated phase running freely from the bearing, gear or housing. . 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. . . . . Viscosity is critical when selecting any lubricant. This article will describe the most common examples of incompatible grease mixing and how to determine if two greases are compatible. . . Greases are considered to be compatible if the following conditions are met: Problems associated with grease compatibility can be minimized by specifying greases with similar thickening profiles, and by making sure that new greases are appropriate for the operating environment. . . . . . Soap-based thickeners are produced from an acid base reaction. . . To help users understand the implications of mixing greases, ASTM International (formerly the American Society for Testing and Materials) Committee D02.G developed ASTM D6185 Standard Practice for Evaluating Compatibility of Binary Mixtures of Lubricating Greases in 1997. . 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. . . . Selecting Diesel Engine Oil for Mixed Fleets . . Contact Us: 1.800.404.2570 or email us at sales@acculube.com, Think Twice Before Changing . . . . . Long bearing life Outstanding thermal and oxidation stability. . . from every lubricant and other critical fluid you buy, and avoid the common pitfalls that can cost you money. . . . Lubricants often fail to perform as specified when combined with other products, even in small concentrations. . . In these situations, component damage is likely the result of the chemical or structural interaction between the thickener or additive systems of . . Good chemical resistance. . . . Compatibility of grease mixtures is typically categorized as follows: Mechanical stability of the mixture is within the same consistency range as that of the individual greases. . . . . . . . . . Different thickener systems can react with each other to modify . . . . . . . . If this can not be carried out, Table 1: Grease Compatibility Generic Chart NOTE: This matrix is based on information commonly used in industry. . . More than 90 % of thickeners are soap based. . . Excellent for antifriction bearings, wheel bearings, factory sealed ball bearings, and some flexible couplings. The compatibility of greases is most often related to the thickener type. Shows also excellent performance in combination with hot water . . . The resulting grease carries unknown performance characteristics (load, temperature stability, shear, etc. . Table 2. . . . lithium 12 hydroxy. . . . High load-carrying capacity. Thickener products give the grease consistency and hold the lubricant in place, so it stays where it's supposed to, and the formation remains together. . Maintaining Gear Box Lubrication . . . . . . The portion of the grease that determines the compatibility is the thickener. More Than List Price How Evaluating Synthetic vs. In bygone days, when simple soaps and clay were the primary thickener types, compatibility . Thickeners vary depending on application (such as temperature, water resistance etc). 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. . . lithium. . 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. . Contains no lead or nickel. . . If the grease thickeners are compatible but the base oils are not, the resulting mixture can be problematic. Improved extreme pressure and water resistance are also strong characteristics, making these greases excellent choices for automotive and robotics applications. . . . . Proper care must be taken to ensure compatibility when changing from one grease system to another, including cleaning if possible, compatibility verification (including base oil), monitoring and assessing, purging and flushing of old grease, and even repurging as necessary. Provide labels and color codes where possible to prevent confusion. . . . . . . . . When switching greases, it is important to understand thickener compatibility to make sure the new grease does not fail. Thoroughly Clean Those Coolant Systems! . Grease Compatibility. . . This is because of the wide variety of materials that can be reacted to form a thickener that is termed polyurea. . . . . Why is a Breather Filter Important? . . . . . . . . . Grease performance and interactions Grease performance can be affected by interactions between: Thickener: Loss of structural stability. To add to the confusion, there are some grease specifications that are based solely on grease performance without regard to grease composition. . It is essential to prevent problems by specifying compatible products. . Particulates in Cutting Fluid -- A Fine Mess. . . . . . . . . . . . . . See the above example for composition or formulation. . . . . . . . Grease compatibility is often confusing to grease users, even though most grease manufacturers produce compatibility charts. . . Significant concerns have also been raised about some of these charts after greases presented as compatible have proven to be quite incompatible. . . . Therefore, it is important to consider the type of base oil in the grease when determining compatibility. 2). . . Incompatible The properties of the mixture are significantly different than those of the individual greases. . . . . Grease compatibility is on the minds of a lot of maintenance managers these days. . . . If corrective action is not taken quickly enough, this can result in damage to the machine. . . . . Therefore, you never need to add more grease to increase mobility. . . . . Incompatibility of thickener systems, which is the most commonly asked question. A number of organizations rely on compatibility charts to make important maintenance decisions. . Grease compatibility charts (such as the one pictured below) can only help compare the thickener types of greases. . . . . 2017 by Accurate Lubricants & Metalworking Fluids, Inc. located in Dayton, Ohio U.S. All rights reserved. . More than 90% of the thickeners used worldwide are soap based. . . . . . . . . . . "Thickener" is an umbrella term for a range of molecules, polymers or particles that are partially insoluble in lubricating oil that give the grease a semi-solid consistency. The various descriptions used imply that some may have been copied from the others. . . . They are finding that the greases they have been using for years for on-highway, off-highway and industrial applications are in short supply. . . Simply mixing two greases together to observe changes may not provide any obvious difference. There are three typical grease thickeners used in grease lubricants, including: . . . . . NLGI Consistency number 3. Grease compatibility charts may seem to be a convenient way to make decisions based on actual or potential grease mixing. Lithium complex is the thickener that is most compatible with other thickeners. . . . These charts are readily available in published papers, periodicals and Web pages. Incompatibility is a major issue when mixing greases something that can result from having too many types of grease in a plant. . . . There are only a few other thickeners that are not compatible with lithium complex, when using one of the Graco greases. Table 1. . Greases are classified into two major families: soap and non-soap thickeners. . . . polyurea. . . . . . . . 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 . . . Excellent high temperature performance. . Some grease is compatible with other grease type, while some may not be able to perform the same. . . The short answer is, "No". . Likewise, when greases are mixed where the base oil viscosities are significantly different, the resulting mixture will not be optimized for the application. . Non-soaps are split into two main categories. 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. polyurea conventiona. Figure 1. . Different types of greases are typically formulated with three grease components: base oil, thickener and additives. . . . . . Black cells indicate compatibility testing not performed. Sometimes these changes are not immediately apparent, and become obvious only with diminished equipment performance. . . Valves, packings, seals & O-rings. . . . In bygone days, when simple soaps and clay were the primary thickener types, compatibility was relatively straightforward. (Top) The expected and actual yield stress values for the 50-50 mixture and the reference greases . . . . . Soaps can be grease thickeners, while non-soap thickeners include polyurea, organophilic clays (e.g., bentonite) and other materials. . . . . . . . . . . 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. LGHP 2 is compatible with such greases. . . Grease, however, may be more difficult to purge. . . . Coolant Concentration . Grease is a combination of thickener, oil, and additives. . . 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 mixtures performance. Grease Compatibility Matters . . . . . . . . . . . 12-hydroxy stearic acid and hydrogenated castor oil added (the preferred ratio is 85:15 up to 50:50). Note: This chart is a general guide to grease compatibility. 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. In order to minimise issues arising from incompatibilities, ExxonMobil laboratories routinely test different grease technologies to assess their compatibility when mixed with other grease products in various ratios.The table below also gives an indication of the compatibility of various grease thickener combinations. . Even so, those charts have their limitations. . . 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. . . . . . . . . In an ideal scenario you would remove all of the old grease from the machine before introducing a new one. . . A significant portion of grease lubrication failures can be attributed to mixing greases in a system without taking into consideration compatibility. These last two parameters include measuring changes in the cone penetration value. . . It is wear resistant for use in a wide range of bearings.. NLGI viscosity grade is a rating of a grease's consistency. . . Generally, greases having the same or similar thickener types will be compatible. . . . . Technological advances have made grease compatibility a much more complicated proposition with the wide and complex array of thickeners used. . . (Bottom) The expected and actual recoverable compliance values for the 50-50 mixture and the reference greases. There are many types of chemical compounds that can thicken grease. If you are ever unsure if two greases are compatible be sure to test them before adding a new grease to your machine. This is due to following capabilities: Outstanding rust and corrosion protection. . . . Greases are considered to be compatible if the following conditions are met: The dropping point of the mixture is not significantly lower than that of the individual greases. . . to Prevent Rancidity Acculube Compatibility Chart 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. . . . . . Monitoring and Controlling . ). . 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. . . . Lubrication grease is a mixture of oil and soap or another thickener. Grease labeling according to standards . . of Metalworking Fluids The most likely result is a change in consistency or increased oil bleeding, especially under shear stress. . 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. . . . . . . Performance Benefits. . . . . . . . This is then run for 72 hours to achieve the 30 million plus perturbations of the grease. . I'm not sure I would trust data from Grainger. . . Thus, it is key you determine which thickener is best suited for use in your specific application Organic Soaps Mixed Soaps Complex Soaps The chart below summarizes the key characteristics of each thickener we have discussed. . . 1) SKF high performance, high temperature bearing grease LGHP 2 is not a common polyurea type grease. . . . . 5. 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. . . I=Incompatible, C=Compatible, and B=Borderline. . . . . . . 3.2.5. . . The explanation lies in the fact that with the deterioration of oil and thickener compatibility, the solubility of the latter decreases; the volume fraction of the thickener particles . The compatibility of polyurea greases with soap-thickened greases is probably the most debated area of grease compatibility today. . . . The Changing Attitude Toward Basic Maintenance, Home | Metalworking Lubricants | Heavy Duty Truck Lubes | Industrial Lubricants | . Acculube's Compatibility Chart For Commercial Greases, Talk with Us Today A total of 25 different product descriptions were found in the 17 tables. 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. . . . . . It is interesting to note that these grease compatibility charts focus only on the family of thickener involved. Water-Based Lubricants . The thickener (base), kind'a like a chemical sponge that holds oil in its pores, is the key to waterproofness and compatibility with other thickeners. However, these charts rarely tell the whole story, even just in terms of the thickener compatibility. . Excellent resistance to water, chemicals, and high and low temperatures. This is because the charts from the various manufacturers often disagree with one another on certain thickener-type combinations. Do not overgrease a system. . The following properties are impacted by the chosen thickener: Call the metalworking experts at Acculube - we'll help you get the most value When changing to a different oil, it is typically an option to discharge and change fluids completely. . . . . . . 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. . . . . . . . If you are a human seeing this field, please leave it empty. . . . . . For Commercial Greases Unlike the compatibility of oils, which is most often related to interactions of the additives in the products (and sometimes the nature of the base fluids themselves), the compatibility of greases is most often related to the thickener types of the products to be mixed (although base fluid compatibility is also important). 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. . . Maximize Fluid Performance . . . . . NLGI 3 grease has a semi-solid appearance and is a common lubricant in automotive, industrial, marine, and agricultural applications. . . . . This kind of lubricant is just perfect for dealing with compatibility. . . . . . . . . . . . . 1. . . . . These thickeners can be broken into three groups: Simple - A simple soap resulting from the reaction of a single acid, usually 12 HSA and a metallic hydroxide, usually lithium, aluminum, calcium or sodium. . . . . . . . A typical grease compatibility chart is shown in Figure 1. . . . Lubricant Contamination Control Helps Prevent Varnish Formation in Machine Shops Polyurea Greases are anorganic, non-soap based thickeners which are alternatives to the commonly known metal- and metalcomplex soap thickeners. . . . . . . . . Can a Lubrication Audit Show Us How to Grade #3 greases have good sealing properties to protect the equipment . Though manufacturers make grease compatibility charts available, information can be vague or contradictory. According to thickener type . 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. Grease compatibility is a straight forward concept when armed with the correct knowledge. . . . For the best experience on our site, be sure to turn on Javascript in your browser. New bearings, gears, motors, etc., often come supplied with a product that is incompatible with the grease being used to relubricate. 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. . Calcium Sulfonate Calcium-sulfonate greases have superior mechanical and shear stability compared to lithium-complex greases. 3.3.2. . . Compatibility testing is always the best option, since the base oil and elastomer must also be taken into consideration. Ongoing process maintenance with continuous monitoring by the supplier is also a strategy that will help insure success. . . . . . . . It is up to you to determine the tradeoffs between grease costs and performance gains/losses. . . Table 3. . . . lithium complex. . Thickener compatibility: Typically, grease lubricants are 70% to 90% finished grease and 10% to 20% thickeners. . . . Grease compatibility charts (such as the one pictured below) can only help compare the thickener types of greases. . . . . . 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 areas highlighted in yellow indicate values of concern. . . . . Compatibility testing is the only way to verify compatibility. . . . . . . . . . . . . . . . . . . . . The shaft is turned by a fractional horsepower motor, coupled to a turned-down shaft. . Table 1 shows the labels used in these charts and how many times these descriptions appear in the charts. . . . . . . Vacuum pumps. According to most grease compatibility charts, polyurea greases are compatible with each other, and such a transition would be allowed. If greases of different thickener types (both of which meet the performance requirements of the specification) get mixed in service, dire consequences can result. Grease thickeners can be divided into two categories, soap and non-soap. Too often the presumption is that "grease is grease". 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. . Compilation of 17 grease compatibility charts. Goodbye, Tramp Oil Tramp Oil Contamination Is Not Inevitable . . Also, while lithium thickener remains the most prolific, a greater variety of other thickeners are becoming available due to lithium demands for batteries. . . . The goal was to consolidate to one product for all motors. . . . Prevent Metal Corrosion Borderline The properties of the mixture may or may not be acceptable, depending on the nature of the application. Compatibility between greases is based on three factors: thickener type, base oil, and additives. . . Grease compatibility charts have been developed and circulated since the 1980s without much alteration. . 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 Grease Compatibility Charts found in company and . . . . . How to Choose an . . . . . . . . As such, to verify whether two greases are compatible or not, Machinery Lubrication developed a Compatibility Chart based on thickener type. . . David Turner works for Shell Global Solutions Inc. and is the co-chairman of the National Lubricating Grease Institutes technical committee. . 3. If the grease thickeners are compatible, but . . . . . . This table is to be used as a reference only. to Lubricate Plain Bearings? . . . . . . 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. Forgive my grease illiteracy. . . . . . . Motor Bearing Grease . . 3.3. What Is MQL (Minimum Quantity Lubrication) . . . . . . The full text of ASTM D6185 is available from ASTM International at www.astm.org. . . . . Mixing grease with incompatible thickener type can change the physical and chemical structure of the grease. . . . . . . . . . . How to Determine Grease Compatibility and Why It's Importantalso provides an indepth look at grease compatibility. . . Managing the Turnover To learn more about NLGI, visit www.nlgi.org. 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. . . . . Greases are manufactured from both mineral oil and synthetic oil bases. Lithium and calcium soaps were compatible with one another, and neither was particularly good when mixed with a clay-based grease. . . . . Mixing of greases with incompatible thickeners can result in the most immediate and obvious changes that interfere with effective lubrication. . . . . Other mixtures harden initially and lead to component load issues and poor grease motility. Technical Help Desk 6 Jun 2017. In order for a grease to change state, one thing that has to happen is the soap matrix needs to break down, to degrade. Low noise. . . . . the old grease with the new grease. Table 5. . . . . . . . . . . . . Grease labeling according to ISO standard . . Troubleshooting Tips for Machinists The mechanical stability of the mixture is within the range of consistency of the individual greases. . . . . clay non-soap . . . . . . . . . . Table 6. Most grease suppliers have data on certain grease combinations or are willing to perform the required testing for their customers. . . Consistency of the mixture following temperature elevation is comparable to the change in consistency of the individual greases under the same conditions. . . . This increases the likelihood of mixing. Table 4. . Therefore, it became necessary to verify that one polyurea grease could be added directly to a motor containing the other. . You then compare these mixtures to the original in terms of dropping point, shear stability, and consistency after prolonged storage at an elevated temperature. Reduce Your Environmental Footprint? . . . . . Use Fewer Lubricants, and Save Costs? The thickener determines the compatibility of greases. . . thickener compatibility. . Greases are not created equal - there are dozens of options to choose from, each type is designed to work better in a specific application. . . and How Can it Reduce Total Lubricant Costs? . . Particulates in Cutting Fluid -- A Fine Mess . Refer to Grease Compatibility and Grease Lubrication Practices for more information on grease compatibility. . . . Polyurea thickened greases have the excellent anti-oxidant capability. . . . . For example, one chart indicated that barium-complex grease is compatible with clay-thickened grease, while others suggested this mixture is incompatible. . . . . and the proportions in which they are mixed. These factors eventually lead to compromises in machine component life, and substandard equipment performance. grease. . . . . . . . . . . . . . The electric motor test stand shown below was developed for the Electric Power Research Institutes Effective Grease Practices guideline. . . . Elemental spectroscopy values for the reference greases and the 50-50 mixture. . . 3.2.3. . . . The housing of the end bell is removed and replaced by a Plexiglas window to observe the condition of the grease under dynamic conditions. . . . . . . lithium stearate. . . . Compatibility of grease mixtures is typically categorized as follows: Compatible The properties of the mixture are similar to those of the individual grease. . . . . . The grease fitting also merits inspection for contaminants and should also be wiped clean. Some studies have been performed to improve the mixing and working of grease to better simulate machine conditions. Polyurea greases are also characterized by dropping points above 250 C and low oil separation. . Identify the minimum number of products required to meet the design of the equipment in use and consolidate to that number. . . . . . Fantastic put on and intense stress safety. . . . Consistent lubrication frequency, without over- lubricating, also promotes a smooth transition. . . Table 3 reveals the differences in elemental spectroscopy values for the reference greases and the 50-50 mixture.

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