Lube-Tech PUBLISHED BY LUBE: THE EUROPEAN LUBRICANTS INDUSTRY MAGAZINE
which indicate altered phases of steel. Several of the cracks made contact with the surface and would almost certainly have developed into full spalls had the test continued. These findings align with existing literature on WEC formation, particularly under the influence of electrical current and hydrogen diffusion.
Figure 11: Lubricant A cross sectioning analysis
In contrast, Lubricant B, the prototype containing the copper-based additive, demonstrated remarkable stability throughout the test. Vibration levels remained low and consistent, with no spikes or warning trends. Friction remained slightly lower than Lubricant A, indicating effective surface interaction and lubrication film maintenance even under high stress and temperature conditions.
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directional striations in the sliding direction were visible—normal in rolling-sliding contacts and not indicative of failure. More importantly, no subsurface damage was observed during serial sectioning. All seven slices across the wear track revealed structurally intact steel: no WEAs, no white etching cracks, no evidence of hydrogen embrittlement or subsurface material transformation. The roller surface was essentially unaffected by the high contact load, sliding motion, elevated temperature, and continuous electrical current.
Figure 13: Lubricant B post-test inspection
Figure 14: Lubricant B cross sectioning analysis Figure 12: Lubricant B performance data
Upon completion of the full test cycle, the roller lubricated with Lubricant B was examined. Surface microscopy showed a smooth wear track, free from pitting, scarring, or delamination. Only minor
This stark difference in performance strongly supports the hypothesis that the copper additive actively intervenes in the wear mechanism, not simply by forming a protective tribofilm, but by disrupting the electrochemical and thermally driven pathways that normally lead to hydrogen generation and diffusion.
By forming a conductive, low-shear film across the surface, the copper salt reduces the likelihood of electron bombardment and lubricant degradation
LUBE MAGAZINE NO.188 AUGUST 2025 35
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