Impact of ultra-low viscosity fluids on drivetrain functionality and durability

Abstract

Increasing automotive powertrain electrification is impacting drivetrain complexity and the profiles of the fluids needed. Since the millennium, drivetrain fluid viscosities have been reduced for better efficiency, but this new challenge is driving them to unprecedented low levels. This paper assesses some of the potential implications of ultra-low viscosity fluids on drivetrain functionality and durability. Model formulations have been prepared from a variety of base fluids combined with additive packages. These have been evaluated in typical automotive drivetrain rig tests, as well as with some selected functional tests. In addition, the thermo-oxidative stability and electrical and thermal properties of the fluids were compared. Based on the results, the impact of low viscosity fluids on drivetrain functionality and durability varies depending on the performance parameter evaluated. For example, gear scuffing and bearing wear is highly dependent on additives, whilst gear and bearing fatigue is mainly affected by fluid viscosity. However, by carefully balancing base fluids and additives, acceptable component and fluid durability can be achieved. With respect to new electric drivetrain performance needs, the thermal properties of the finished fluid are essentially dependent on the base fluid composition, whilst its electrical properties are more influenced by additive chemistry, with some secondary impact from base fluid composition.