FUCHS LUBRITECH GMBH Highperformance Biodegradable Lubrication of German

FUCHS LUBRITECH GMBH High-performance, Biodegradable Lubrication of German / European Railway Systems - Today 01. 2022 / *

FUCHS LUBRITECH GMBH High-performance, Biodegradable Lubrication of German / European Railway Systems - Today 1 Introduction 2 Problems - Wheel/Rail contact - Tribo-System Switch/Point 5 Application - Switch lubrication - Wheel flange lubrication 6 Test Methods 3 Requirements 7 Results 4 Solutions - Lubricant formulation 8 Future Aspects 9 Summary 01. 2022 / *

FUCHS LUBRITECH GMBH Lubricant consumption World‘s lubricant consumption: 37. 000 tons Consumption in Germany: 1. 200. 000 tons Total loss lubricants: 40. 000 tons Railway Systems: 5. 000 tons Total loss lubricants: Ä Concrete release agents Ä Two-stroke engine oils Ä Chain saw oils Ä Chain- and Wire rope lubricants Ä. . . Ä Switch lubricants Ä Wheel flange lubricants Ä Rail lubricants 01. 2022 / *

FUCHS LUBRITECH GMBH Problem: Wheel/Rail contact is essential, because Ätraction forces Äbraking forces Äelectric signals are transferred in this contact. No lubrication in the Traction Area A Lateral forces caused by Äcentrifugal effects in curves Ädynamic interaction between vehicle and track ÄVibrations/Shock loads due to gauge variations lead to further contact zones B. Zone B needs effective lubrication to reduce friction and wear. 01. 2022 / *

FUCHS LUBRITECH GMBH Problem: Wheel/Rail contact Influence of Lubrication on Wheel flange wear Wear area Lubricated 01. 2022 / * Loss of Material when reprofiling Not Lubricated

FUCHS LUBRITECH GMBH Problem: Switches belong to the most important elements of the rail track, because failures influence directly the network operation, safety and availability of the network. Switches of the common slide chair design are extremely demanding in the tribological point of view, because the lubricant has to fulfil strong and partly opposite requirements. 01. 2022 / *

FUCHS LUBRITECH GMBH Requirements Generally: Ä Environmentally harmless Ä Low water pollution Ä High biodegradability Ä No toxic components Ä Should be solvent-free Ä etc. These requirements are not homogeneously regulated. Regarding biodegradability, the test method according to CEC L-33 -A-93 standard is commonly used. Additionally different OECD-guidelines are used. 01. 2022 / *

FUCHS LUBRITECH GMBH Requirements Wheel flange lubrication: primary: Ä Reduction of friction between wheel and rail flange to reduce the risk of derailment and to minimise rolling noises generated in these contact zones. Ä Reduction of wear of wheel and rail to minimise maintenance work and life cycle costs and to increase the availability of the rolling stock. secondary: Ä High adhesion (gets more and more important for high speed trains) Ä Lubricity and sprayability should be independent from temperature Ä Independence from the lubricating system used Ä Good resistance against ageing Ä Long storage time 01. 2022 / *

FUCHS LUBRITECH GMBH Requirements Switch lubrication: primary: Ä Reduction of friction to achieve low adjusting forces and safe operation Ä Excellent corrosion protection, which is also effective under extreme weather conditions and in very thin lubricant layers secondary: Ä Good applicability Ä High creeping power for lubrication of inaccessible areas Ä Lubricity should be independent from temperature Ä Excellent EP- and damping properties (Shock loads during overrunning) 01. 2022 / *

FUCHS LUBRITECH GMBH Solution Basics of lubricant formulation: In these applications normally soft free-flowing greases are used, which can contain special solid lubricants. It is important, that all single components are checked regarding their environmental potential, even though the base oil is by far the biggest portion of the lubricant. Base oils: Regarding biodegradability we can choose from the following fluids: Ä Native esters Ä Synthetic esters Ä Low-viscous Polyglycols Ä Low-viscous synthetic hydrocarbons 01. 2022 / *

FUCHS LUBRITECH GMBH Solution Beside the biodegradability the following properties have to be considered with the base oils: Ä Lubricity Ä Flow behaviour at low temperatures Ä Thermal resistance Ä Solubility / Miscibility of additives Ä Compatibility with materials Following the thickeners, which can be used in biodegradable lubricants: Ä Lithium soap Ä Calcium soap Ä Li-/Ca-Mix soap Ä Inorganic thickeners, e. g. Bentonite 01. 2022 / *

FUCHS LUBRITECH GMBH Solution Additives and Solid lubricants: EP additives play an important role, because wheel flange lubrication, as well as switch lubrication is working under boundary or extreme mixed friction conditions. Selection of additives must be done also with regard to the strong requirements of environmental aspects and must fulfil all the tribological demands as well. Long-term experience in practical applications has shown, that special solid lubricants can be extremely helpful in these applications. Mostly special graphite types as well as combinations of the socalled white solid lubricants are used. 01. 2022 / *

FUCHS LUBRITECH GMBH Solution Synergetic combination of the mentioned components to ready formulations: *AC = Anti-corrosion, AW = Anti-wear, AO = Anti-oxydant, EP = Extreme Pressure **FSS = solid lubricants 01. 2022 / *

FUCHS LUBRITECH GMBH Application Generally: Ä to make sure that you have the right quantity of lubricant right in time at the right place Switch lubrication: Ä normally manually, e. g. with brush Ä sometimes with portable lubricators 01. 2022 / *

FUCHS LUBRITECH GMBH Application Wheel flange lubrication: Ä with automatic lubricators, which spray extremely small quantities of lubricant onto the wheel flanges Ä Regarding the controlling system, lubricators are divided into path controlled time controlled curve controlled systems. Ä normally only the first wheel set is lubricated, all the following axles are lubricated indirectly 01. 2022 / *

FUCHS LUBRITECH GMBH Application Wheel flange lubrication, example: Type Vogel SP 9 01. 2022 / *

FUCHS LUBRITECH GMBH Application Wheel flange lubrication, example: Type De. Limon RE 01. 2022 / *

FUCHS LUBRITECH GMBH Application Wheel flange lubrication, example: Type BEKA Fluilub 01. 2022 / *

FUCHS LUBRITECH GMBH Application Wheel flange lubrication, calculation example: Width of the spray jet on the wheel flange: Wheel diameter: Lubricant quantity per spray cycle: 20 mm 900 mm 30 mg Thickness of lube film on the first wheel set: ca. 0, 5 µm Spray pattern from test rig trial 01. 2022 / *

FUCHS LUBRITECH GMBH Application Wheel flange lubrication, calculation example: Lubricant quantity per cycle: Travelling distance per cycle: Total distance: Lubricant consumption at each side: 30 mg 500 m 1000 km 60 g Spray pattern from test rig trial 01. 2022 / *

FUCHS LUBRITECH GMBH Test methods Friction value Ä Tannert Ä Timken Ä Almen-Wieland Wear Ä FBT welding load Ä FBT wear Ä Timken Adhesion power Ä Tannert Ä Timken. Retention Ä Fling-off test 01. 2022 / * Corrosion protection Ä Erichsen Ä Water resistance Ä Emcor Environment Ä CEC L-33 -A 93 Ä OECD 301 AE Ä RAL-UZ 64 System test Ä De. Limon RE Ä De. Limon Railjet Ä Vogel SP 8 Ä Vogel SP 9 Ä Saxonia SSL-3 Ä Rebs Ä Woerner Ä Beka Fluilub Ä SRS Clicomatic Ä Portec

FUCHS LUBRITECH GMBH Results: Field test Biodegradable, High-Performance Lubricant Conventional Lubricant Used E-Lok: BR 111, D Total test distance: 1, 9 Mill. km remark: sh and a are not influenced by the lubricant Wear in mm / 100. 000 km 01. 2022 / *

FUCHS LUBRITECH GMBH Results: Field test 1991: Changing over from a conventional, mineral oil based grease to a high performance, biodegradable lubricant. Flange wear Surface wear Cracks 01. 2022 / * Flange/surface wear Flat surfaces Others Causes for Wheel Flange Wear on Locomotive Wheels (source: Austrian Railway)

FUCHS LUBRITECH GMBH Results: Field test 01. 2022 / * Conventional Biodegradable

FUCHS LUBRITECH GMBH Future Aspects Ä Searching for more suitable raw materials Ä New trends in environmental legislation Ä New materials for wheels and rails Ä New designs of carriages and bogies Ä Higher wheel loads Ä Higher velocities Ä Further optimisation of the status quo 01. 2022 / *

FUCHS LUBRITECH GMBH Summary Biodegradable lubricants for wheel flange and switch lubrication in German / European Railway Systems Ä have overrun their conventional ancestors and completely removed in many applications Ä perform much better and at the same time help our environment by: Reduction of driving power (up to 15%) Reduction of wear, noise and friction Increase of the maintenance intervals Reduction of maintenance works Reduction of lubricant consumption Reduction of the risk of derailment Increase of Reliability, Availability, Maintainability, Safety (RAMS) Decrease of Life Cycle Costs (LCC). . . 01. 2022 / *

FUCHS LUBRITECH GMBH Thank you very much for your kind attention. www. fuchs-lubritech. de 01. 2022 / *