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Knowledge Center Prevent Gear Failure Across a Wide Temperature Range Test results show that modern gear oils formulated with carefully selected additives prevent micropitting and wear across the broadest temperature range.

Gear failure that results from micropitting and wear is expensive — and unnecessary. Today’s gear oils need to reliably prevent this gearbox damage so you can avoid costly downtime.

That’s tough enough in an ideal environment, let alone in industrial gearboxes operating at low speeds, high loads and low lubricant film thicknesses in the mixed or boundary friction regime (where the friction bodies are not fully separated by a lubricant film). In these critical lubricating conditions, damages like micropitting and wear seem inevitable.

That’s where additives come in. Additives in lubricants form a reaction layer that protects gears and rolling bearings against wear and micropitting. But not all additives are formulated equally. The problem is that some types of additives require a certain temperature to form this crucial layer.

So, how do you prevent gearbox damage, even at low temperatures?

To determine which gear oils best prevent micropitting and wear, we investigated their performance capacities through standardized testing. These standardized tests evaluated modern gear oils under critical lubricating conditions, high oil temperatures and, as a modification of the standard procedures, low oil temperatures:

  • FZG micropitting test – Conducted at oil temperatures of 90, 60 and 40°C, this test uses an FZG back-to-back gear test rig. The test investigates whether the advanced additives in modern gear oils achieve the necessary reaction layer to protect tooth flanks from micropitting across a wide temperature range.

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    Figure 5: FZG back-to-back gear test rig
  • FZG wear test – This test identifies whether the additive technology in modern gear oils build the reaction layer needed to reliably protect gears against wear in oil temperatures of 120, 90 and 40°C. It uses an FZG back-to-back gear test rig.
  • FE8 wear test – This test subjects modern gear oils to oil temperatures of 80 and 40°C and uses an FE8 rolling bearing test rig to demonstrate whether additives show reliable reaction layer formation to protect rolling bearings against wear.

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    Figure 6: FE8 rolling bearing test rig

Our latest white paper explores these test results and reveals the performance capacity of gear oil additive technology under different temperatures. Read it to learn how you can choose oils that best prevent micropitting and abrasive wear across the broadest range.

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