Graphene-based materials have great potential for tribological applications. Graphene’s unique properties such as low shear resistance, high stiffness, and thermal conductivity make it an attractive material for improving the properties of lubricants in a wide range of industrial applications, from vehicles to house refrigerators and industrial machinery such as gearboxes, large compressors, etc. The current review aims to give an engineering perspective, attributing more importance to commercially available graphene and fully formulated lubricants instead of laboratory-scaled produced graphene and base oils without additives. The use of lubricants with graphene-based additives has produced e.g., an increase in mechanical efficiency, consequently reducing energy consumption and CO₂ emissions by up to 20% for domestic refrigerators and up to 6% for ICE vehicles. Potential effects, other than purely friction reduction, contributing to such benefits are also briefly covered and discussed.

Electric vehicle (EV) transmissions operate at high speeds. High-speed operation puts higher demands on bearings, seals, and gears. Bearings in EV transmissions are prone to electrically induced bearing damage and may exhibit signs of pitting and fluting. Surface-initiated rolling contact fatigue is another common problem gaining increased attention lately. Most EV transmissions require a coupling between an oil-lubricated gearbox to an electrical motor that runs with minimal lubrication at very high rpm. The high mechanical and thermal stresses the seals are exposed to under starved lubrication conditions have a detrimental impact on their service life. Hence, proper lubrication is critical. In general, EV transmission fluids call for a somewhat different spectrum of properties compared to conventional ATFs. Gear tribology simulations open new ways to the design and optimization of lubrication for EV transmissions. Additionally, such simulations can also provide valuable insights into the effects of different oil properties on cooling and lubrication efficiencies, thereby helping in matching the lubricant and hardware characteristics for optimal performance. In the present communication, we demonstrate the effects of different lubricants and surface finishing technologies on the tribology of high-speed gears using tribological tests and advanced thermal elastohydrodynamic (TEHD) simulations. The important roles of lubricity additives and surface finish optimization are highlighted in conjunction with a move towards ultralow viscosity EV transmission fluids.

Improving fuel economy and reducing emissions is nowadays more important than ever. Apart from powertrain electrification, automotive manufacturers have constantly been seeking to improve the efficiency of the internal combustion engine. Downsizing and boosting have become common practice in the internal combustion engine (ICE) design. Increased power density and torque output of modern boosted engines, in combination with the introduction of automatic stop-start systems and ultralow viscosity lubricants tends to stress the engine beyond the limits foreseen in the classical design. This leads to wear problems. Each engine component comes with a unique landscape of competing manufacturing technologies, among which advanced surface finishing and coating methods play an important role. This presentation provides an overview of different industrial trends related thereto. The role of lubricant on the engine tribology is studied for different engine designs. The importance of in-design “pairing” of low-viscosity motor oils with the engine characteristics is highlighted filling the gap in the understanding of complex interactions between the crankcase lubricant and engine mechanics.

EV transmissions operate at high speeds, upto 30,000 rpm. High speed operation puts higher demands on bearings, seals, and gears. Bearings in EV transmissions are prone to electrically induced bearing damage and may exhibit signs of pitting and fluting. Surface-initiated rolling contact fatigue is another common problem gaining increased attention lately. Most EV transmissions require a coupling between an oil-lubricated gearbox to an electrical motor that runs with minimal lubrication at very high rpm. High mechanical and thermal stresses the seals are exposed to under starved lubrication conditions have a detrimental impact on their service life. Hence, proper lubrication is critical. In general, EV transmission fluids call for a somewhat different spectrum of properties compared to conventional ATF. Gear tribology simulations open new ways to the design and optimization of lubrication for EV transmissions. Additionally, such simulations can also provide valuable insights into the effects of different oil properties on cooling and lubrication efficiencies, thereby helping in matching the lubricant and hardware characteristics for optimal performance. In the present communication, we demonstrate the effects of different lubricants and surface finishing technologies on the tribology of high-speed gears using tribological tests and advanced thermal elastohydrodynamic (TEHD) simulations. Important roles of lubricity additives and surface finish optimization are highlighted in conjunction with a move towards ultralow viscosity EV transmission fluids.