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cover STory

Jean Van Rensselar / Contributing Editor

Trends in Industrial

Key cOncePTs

• Smaller gearboxes mean reduced oil reservoirs,


higher loads and more stringent demands on
lubricants.

• Because gearboxes are burdened with increas-


ingly hotter operating environments, improved
thermal stability in gear oils is an imperative.

• The trend toward lowering gearbox manufactur-


ing costs, while at the same time allowing for
increased in-use productivity, places ever more
stringent demands on gear oils.

26 Reserve booth space: Exhibit booth application forms available for STLE’s 2013
Gear Oils

Today’s machines are smaller, hotter


and overloaded—making proper
lubricant selection even more critical.

A n alarMing 30% of u.S. induSTrial


coMPanieS recently surveyed said
they experienced a lubricant-re-
lated gearbox failure within the
last year.1 These failures were
most likely related to extreme operat-
ing temperatures that created break-
point stress on such industrial gearbox
parts as seals, bearings and gear teeth.
The following are basic require-
ments for industrial gear oils:

• Appropriate viscosity
• Oxidative and thermal stability
• Solid load-carrying capacity
• Demulsibility (the ability to
shed water)
These higher operating tempera- • Resistance to foaming
tures are precipitated by the demand
for more power in a smaller footprint • Protection against rust and
and decreased oil volume. Today’s corrosion.
equipment also needs to handle in-
creased loads and deal with a host of The difference between automotive
contaminants, including water. Deal- and industrial gear oils is that indus-
ing with these demanding conditions trial gear oils must perform in condi-
requires gear oil that is formulated to tions and applications that vary sig-
reduce stress in a number of ways. nificantly. Examples are the highly

1
Study conducted by Shell and cited at:
http://www.gearsolutions.com/article/detail/5490/motion-impossible--without-the-right-lube.

annual meeting in Detroit. Contact Tracy VanEe at (630) 922-3459, tnicholas@stle.org. 27


contaminated conditions that exist in tures of these specifications and the al contact at the asperity scale where
mines and the highly aqueous condi- unique challenges posed by techno- plastic or elastic deformation creates
tions in steel mills. It’s not surprising logically advanced gearboxes require material loss that manifests as micro-
then that gear base oil and additive advanced gear oils to fully protect pits. Micropitting is a function of many
manufacturers need a thorough grasp components. things, including gear manufacture
of the performance requirements of While using the wrong lubricant and quality, EHL viscosity calculation/
advanced machinery and the end-us- for the job and incorporating certain selection, the EP additive package,
er’s needs. additives that promote micropitting base oil selection, debris/contamina-
Additives protect seals and improve can cause gearbox failure attributed to tion and operating parameters, includ-
thermal, oxidative and viscosity stabil- the lubricant, the two most common ing temperature and load.”
ity. They also provide micropitting re- culprits are excessive heat and water Micropitting starts with fatigue
sistance, bearing corrosion protection, contamination. cracks on the surface (or just below
foam resistance and enhanced demul- the surface) of the gear teeth. These
sibility and load-carrying capacity. MIcROPITTInG pits are caused by metal-to-metal con-
There are many gear oil standards While it’s fairly easy to spot micropit- tact of rough surfaces. But because
such as North America’s AGMA 9005- ted gear teeth with a basic flashlight cracks can form below the surface of
E02 EP, Europe’s DIN 51517-3 and (they appear dull, etched and/or the gear teeth, high-speed gears with
Germany’s SEBI 181 226. The newest stained with gray speckles and spar- smooth surfaces and good film thick-
is the Siemens (Flender) MD specifica- kles), micropitting can be difficult to ness also can become pitted.
tion. In addition, OEMs often use see under fluorescent lighting. STLE-member Ravi Shah, staff engi-
standard tests together with their own STLE-member Bob Shorter, indus- neer at Chevron, explains, “Typically,
requirements. There are also specifica- trial specialist for Chevron Global lubrication in this equipment is under a
tions for specific industries such as Marketing, explains, “Micropitting on hydrodynamic or elastohydrodynamic
food processing. The increasing stric- gear teeth is the result of metal-to-met- (EHD) regime. In the EHD regime,

TraiTs of a good gear oil*

low viScoSiTy. As the lubricant travels through the filter system, deMulSibiliTy. Water can get into the system (especially the
contaminants, (which may originate outside the system or result reservoir) in many ways, leading to corrosion and compromised
from inside wear) should be removed. Slow-moving, highly viscous performance. Because of this, gear oil must be formulated to
lubricants can be difficult to filter. They can cause pressure at quickly separate water through the range of temperatures found
the filter to increase. If sufficiently high, it will trigger a system in industrial gearboxes. This will extend the life of the oil and the
bypass and allow contaminant-laden lubricant to circumvent machinery.
the filters. Less viscous lubricants flow more easily through the
filtration system where contaminants are effectively removed. dedicaTed for induSTrial uSe. There are two types of industrial
This reduces the likelihood of machinery damage and increases gear lubricants. The first, so-called universal gear oils, are formu-
equipment life. lated so they can also be used in automotive gear applications.
Universal fluids (formulated for automotive and industrial use) may
Another benefit of using a lower viscosity gear oil is that it may contain components that are unnecessary for and/or harmful to
not need to be changed as often, resulting in less costly downtime. industrial gears. On the other hand, they may omit components that
Industrial gears operating under heavy loads require extreme- are critical to industrial use (demulsibility additives). Gear oils for
pressure protection for gear components, but mainstream industrial industrial applications are formulated with additives necessary for
gear oils do not always provide high extreme-pressure performance protection and optimal functioning.
at low viscosity grades. This means that not just any low viscosity
fluid will perform well. SMarT addiTiveS. Conventional additives that improve extreme-
pressure properties in gear oil are often susceptible to thermal
durabiliTy. Industrial gear oils formulated for extended durability instability, which encourages sludge. But additives are available that
keep gears operating correctly and protect equipment by prolong- improve thermal stability, discourage sludge formation and provide
ing life, minimizing downtime, maximizing productivity and reducing extreme-pressure protection. This allows high extreme-pressure
maintenance costs. performance and cleanliness throughout the full range of viscosities.

* Based on five factors cited by Lubrizol product manager Tim Cooper.

28 • FEBRUARY 2013 T R I B O LO GY & LU B R I CAT I O N T EC H N O LO GY W W W. ST L E .O RG


when the surface roughness of bearings gear oil but also of the
or gears matches the lubricant film gears themselves.
thickness, parts of the two surfaces
WATeR
Just 1% of water
come in contact with each other caus-
ing micropitting.” cOnTAMInATIOn in an industrial gear
“Surfaces subjected to heavy loads, “Contamination is a oil can reduce bearing
high temperatures and a lubricant that key interest for
doesn’t have a high enough viscosity some industrial cus- life by up to 90%.
will experience micropitting,” Shah tomers,” says Nelson
adds. “Presence of water will also aggra- Tam, Lubrizol’s in-
vate micropitting. Certain properties of dustrial product man-
lubricant basestocks and additives (i.e., ager for ROA (Rest of
antiscuff agents) affect micropitting, as Asia). “Their most com-
does viscosity. On the other hand, some mon problem is foaming
lubricants can stop the process.” and lowering of demulsibility
STLE-member Tim Cooper, Lubr- performance. Contamination is
izol’s industrial product manager for most common in gearboxes in ce-
Europe, Africa and the Middle East, ment plants and plants that handle
explains, “There are various theories coal—such as coal mines and coal- the
regarding the causes of micropitting,” fired power plants.” system
he says. “It is often talked about in re- Shah adds that contamination also in the first place. A secondary strategy
lation to the wind turbine industry, can occur in the proximity of sea/wa- is to limit the water’s ability to damage
but we see it in many other applica- ter sources and where the tempera- components. A good way to do that is
tions, too. In some cases, micropitting tures vary significantly between day- to opt for a lubricant designed to
may lessen over time, while in others time and nighttime. maintain its properties even when
it can ultimately lead to vibration, Abrasive dust particles can pene- small amounts of water enter the sys-
noise or even more destructive phe- trate the oil film and cause surface dis- tem.
nomena such as macropitting.” tortion and wear. Water contamina- “All industries are susceptible to
tion can rust gear surfaces and, in the contamination,” Shorter says. “Some
HeAT extreme, destroy the gear completely. of the worst environments are gener-
When it comes to heat-related issues, Consider that just 1% of water in an ally those industries that are dealing
gear oil serves two functions: it re- industrial gear oil can reduce bearing with climate elements.”
moves heat in the machinery generat- life by up to 90%.2 And the damage
ed by friction, and it protects itself and contamination can quickly esca- TRenDs
from viscosity breakdown due to heat. late. “The general trend is toward gears op-
The viscosity of a lubricant decreases The effectiveness of a gear oil is erating under heavier loads and higher
as the temperature increases. So the compromised when the oil and water temperatures, smaller sumps (lubri-
viscosity of the oil must be high do not separate and the oil becomes cant volume) and higher power den-
enough to provide an adequate lubri- diluted. Experts agree that using a sity,” Shah says. “The demand on the
cating film but not so high that it cre- gear oil that quickly separates from lubricant is significantly increased, re-
ates friction within the film itself. water is the most effective way of re- quiring better EP performance, micro-
With the constant pressure to in- ducing the risk and consequences of pitting resistance, oxidative proper-
crease operating loads, gearboxes are water contamination. Gear oil with ties, lower sludge-forming tendency
burdened with increasingly hotter op- improved water separation properties and better foam performance.”
erating temperatures. As a result, im- not only allows faster and easier water Today’s increasingly smaller gear-
proved thermal stability in gear lubri- draining, it also reduces the frequency boxes are made from lighter weight
cants is an imperative. Today’s gear of oil changes. materials. At the same time, they must
oils need to be formulated to with- Another way to manage water con- produce more power, be more durable
stand the entire temperature range tamination is to identify potential and more reliable. The bearing loads
that the gear could be exposed to contamination points early on and in- and speeds of the gear teeth are also
(both within the system and in the stitute measures to reduce the ingress trending higher. This means that a
ambient environment). This will not and counteract the effects. The strate- smaller gearbox with less lubricating
only help to maximize the life of the gy is to prevent water from entering oil needs to support gears with much

2
From: http://www.gearsolutions.com/article/detail/5490/motion-impossible--without-the-right-lube.

W W W. ST L E .O RG T R I B O LO GY & LU B R I CAT I O N T EC H N O LO GY FEBRUARY 2013 • 29


four Types of gear oils higher workloads. Not surprisingly, forming tendency and better foam per-
this results in higher temperatures, but formance. Some lubricants are moving
it also results in accelerated oxidation. to synthetics using Group III, IV and V
r&o inhibiTing gear oilS. Rust and Oxidation is a particular problem for components.3 There are two major
oxidation (R&O) inhibiting gear lubri- industrial gear oils because it contrib- considerations in the formulation of
cants perform well over a range of gear utes to sludge formation. new industrial gear oils:
sizes, speeds and outside temperatures. “Just like many other types of
They lubricate well if both the gears and equipment, industrial gearboxes are • Increased emphasis on cost
bearings are lubricated from the same experiencing a drive toward higher reduction (longer lubricant life)
reservoir. Because they do not adhere power densities that place greater de- • Design changes to improve
to the gear tooth surface, it’s best if mands on the lubricant,” Cooper ex- gearbox efficiency (smaller
the gear teeth are constantly relubri- plains. “In some cases, they are also gearboxes with less oil capacity).
cated. R&O inhibiting gear oils can be using steel qualities, which have prop-
conditioned with heat exchangers and agated the amount of micropitting fa- The good news is that newer oils
filters for consistent temperature and tigue in a range of applications and are formulated with high levels of ex-
cleanliness. industries. Other trends include ener- treme-pressure properties across a
gy-efficient oils and longer-life oils to spectrum of viscosities. This gives
eP gear oilS. Extreme-pressure (EP) extend drain intervals.” smaller gearboxes carrying high loads
gear oils are recommended for gear Cooper adds, “Oils today are for- extra protection. But additives to im-
drives subjected to conditions of high mulated with a greater level of durabil- prove extreme-pressure properties can
load, medium-to-high slide and high- ity in mind—resistance to micropit- decrease thermal stability, resulting in
power transmit. EP gear oils can contain ting fatigue, greater thermal stability the formation of sludge. Industrial
additives that are corrosive to brass and (very important) the realization gear oil additives do exist, however,
and bronze components. But EP gear that performance must be retained that provide the balance of thermal
oils that utilize chemistries noncorro- through the life of the oil. As an ex- stability and extreme-pressure protec-
sive to these components are available. ample, it’s no longer acceptable to tion. The combination of these two
These oils also perform well over a market oil that has good foam control factors adds value by prolonging the
range of gear sizes and speeds and or water-shedding properties when life of gearboxes and maximizing effi-
outside temperatures. Gear teeth must new but after a few months of service ciency.4,5
be continually relubricated. the properties fall away, leaving the Regarding the Asian market, Tam
gearbox operator with an underper- explains, “The general trends in Asia
coMPounded gear oilS. Compounded forming system.” are not different from other zones. But
gear oils lubricate gear drives where Even with regular lubricant main- more customers in Asia are looking at
the high sliding of gear teeth requires tenance, punishing operating condi- cost-effective products, which means
a friction-reducing agent to minimize tions of higher heat, higher loads, special and long-drain products—they
heat and improve efficiency (enclosed higher pressures and contaminants would like a product developed with
worm gear drives). Unlike R&O and EP can compromise a gear system. The lu- their own base oil. Asian customers
oils, they do not perform well over a bricants must withstand increasingly are always interested in long-drain in-
wide temperature range and have a high harsh environments that also quickly tervals, energy efficiency, low cost,
operating temperature of 180 F (82 C). deplete essential gear oil additives. OEM approval and high loading.”
Like R&O and EP oils, constant relubrica- The trend toward lowering gearbox
tion of the gear teeth is encouraged. neW GeAR OILs manufacturing costs, while at the same
As a result of increased demand on the time allowing for increased in-use pro-
SynTheTicS. Synthetic gear oils are lubricant, some lubricant companies, ductivity, places even more stringent
primarily used in applications where including Chevron, are developing demands on gear oils. This means high
mineral-based industrial gear oils are higher quality lubricants with im- load-carrying capabilities that main-
unable to perform. Synthetic gear proved EP, micropitting resistance, tain gearbox cleanliness will be the
lubricants can contain R&O inhibitive oxidative properties, lower sludge norm for gear oils.
additives and/or EP additives. Synthetic
gear lubricants offer advantages such 3
Group I is solvent dewaxed oil; Group II is hydroprocessing and refining oil; Group III is further
as improved thermal and oxidation sta- refined hydroprocessing and refining oil; Group IV is chemically engineered synthetic, including PAO
bility, lower volatility and evaporation (polyalphaolefin) oil; Group V is a blend of oils.
rates, improved energy consumption 4
DIN 51517 Part 3, U.S. Steel 224, ISO 12925-1 CKC/CKD, Cincinnati Machine, AGMA 9005-E02, and
and reduced flammability. GM LS-2 and David Brown S1.53.101.
5
From: http://www.machinerylubrication.com/Read/1292/industrial-gear-oils.

30 “Equipped with his five senses, man explores the universe around him and calls the adventure Science.” Edwin Hubble.
synTHeTIc fLUIDs
selecTing The correcT gear oil*
Synthetic industrial gear oil goes
where mineral gear oil can’t—at tem-
perature extremes, in exceptionally
high loads, in challenging operating There are two primary considerations for
environments and when there are spe- selecting the correct gear oil for an application:
cial requirements.
Shah explains, “Replacing fluid in a gear SPeed
gearbox located 100 meters high is not The now superseded Industrial Gear Lubrication Standards, AGMA 250.04, used
an easy task. As a result, synthetic center distance as the primary criterion for gear lubricant selection. The new
products are finding more and more version of this standard, designated AGMA 9005-D94 Industrial Gear Lubrica-
use in manufacturing wind turbine tion, has adopted pitchline velocity as the primary selection criterion. The
gearbox lubricants. The same is true of pitchline velocity determines the contact time between gear teeth. High ve-
other difficult and demanding applica- locities are generally associated with light loads and very short contact times.
tions involving factors such as high For these applications, low-viscosity oils are usually adequate. In contrast, low
loads, extremes of temperature or vi- speeds are associated with high loads and long contact times. These condi-
brations.” tions require higher viscosity oils. EP additives may be required if the loads
The most commonly used synthet- are very high.
ic industrial gear oils are ester oils,
synthetic hydrocarbon oils and polyg- TeMPeraTure
lycols. It’s important to note that while Ambient and operating temperatures also determine the selection of gear
synthetics have many advantages, in lubricants. Normal gear oil operating temperature ranges from 90 F to 100
some instances they do not perform as F (50 C to 55 C) above ambient. Oils operating at high temperatures require
well as mineral-based oils. good viscosity and high resistance to oxidation and foaming. Caution should
The specific advantages of synthet- be exercised with abnormally high temperatures. High operating temperatures
ics (which vary according to the base- indicate oils that are too viscous for the application, excess oil in the housing
stock) can include the following: or an overloaded condition. Each of these conditions should be investigated
to determine the cause and correct the problem. Oil for gears operating at
• Better viscosity protection in low ambient temperatures must be able to flow easily and provide adequate
high temperatures viscosity. Therefore, these gear oils must possess high viscosity indices and
• Better low-temperature proper- low pour points.
ties
*From: http://www.agroengineers.com/gears/gears-lubrication.shtml.
• Better thermal and oxidative
resistance
• Reduced volatility and evapora-
tion
• Better lubricity • Poor miscibility with mineral oils into conventional aspects of gear and
• Reduced flammability (depend- • Higher price (usually but not bearing lubrication (wear protection,
ing on the basestock) always). corrosion resistance, etc.) but also
takes into consideration compatibility
• Resistance to residues and Synthetic industrial gear oils can between the lubricant and every com-
deposits at high temperatures contain rust and oxidation-inhibiting ponent within the gearbox that it will
• Extended drain intervals additives and/or antiwear/EP addi- come into contact with. He adds,
• Reduced energy consumption. tives. “Synthetics offer an alternative “Thus there is a very strong emphasis
for the end-user, but Group II+, Group on elastomeric seal and paint compat-
Disadvantages may include the fol- III and Group IV base oils are all viable ibility with the oil. This can place limi-
lowing: choices,” Shorter says. “These base tations on the types and amount of ad-
oils often lead to longer lubricant life, ditive chemistry that can be deployed
• Reactions (such as corrosion
better performance and ultimately val- to deliver the necessary lubrication
and hydrolysis) in the presence
ue for the end-user.” properties.”
of water
Before Siemens MD approves oils
• Compatibility issues with sIeMens MD sPecIfIcATIOn for use in Flender helical-, bevel- and
materials such as some metals, Cooper explains that the latest Sie- planetary gear units, the manufacturer
paints and elastomers mens MD specification not only looks must warrant that the oils are of CLP

W W W. ST L E .O RG T R I B O LO GY & LU B R I CAT I O N T EC H N O LO GY FEBRUARY 2013 • 31


addiTional oeM gear oil specificaTions* quality according to DIN 51517-3.6
There are also many other application-
specific properties that must be met.
The qualification testing and sub-
In addition to standard specifications for industrial mission of the approval documenta-
gear oil, many gear manufacturers’ specifications tion must be conducted by the oil
contain additional demands, such as the following: manufacturer or marketer. This means
gearbox users cannot request an ap-
• Intensified scuffing tests proval.
• Micropitting tests at 140 F (60 C) and at 194 F (90 C) All tests must be conducted no
• A roller bearing wear test more than one grade above the lowest
• A low-speed wear test viscosity of the oil. The exception to
• A pitting test this rule is the Flender foam test,
• A test to determine load-carrying capacity which must be tested in the highest
• A filtration test viscosity grade. All test data must be
• A foaming test carried out on oil samples of the same
• Low-temperature tests (for behavior and flow) composition according to the formula-
tion table (which must be enclosed).
These additional bench tests attempt to replicate the extreme conditions to which In addition to the testing and perfor-
gearboxes and gear oils are subject and quantify the performance of the various mance requirements, the material safe-
formulations. ty data sheet (MSDS) and technical
data sheets (TDS), including the tem-
*From: http://www.fuchs-europe.com/uploads/media/renolin_industrial_gear_and_lubricant- perature-viscosity curves for each vis-
ing_oils_07-2009_01.pdf.
6
Except tests acc. ISO 6247 and DIN ISO 1817.

32 • FEBRUARY 2013 T R I B O LO GY & LU B R I CAT I O N T EC H N O LO GY W W W. ST L E .O RG


cosity grade, must be submitted for api/din classificaTion of gear oils
approval. The lubricants must be iden-

Gear oils are classified by the American Petroleum Institute using GL ratings:
tified by submission of an IR (infrared)
reference spectrum and ICP (induc-
tively coupled plasma) reference val-
ues for the viscosity grades requested n gl-1 – Designed for gearboxes operating at low sliding speeds. It does not
for approval.7 contain any EP additives and is often used in applications containing parts
All test data must be generated made of yellow metals. Additives can increase resistance to oxidation,
within a Siemens-approved laboratory protection from corrosion and freezing point.
for application-specific testing. Sie- n gl-4 – Designed for gearboxes and main hypoid gears operating at high
mens will not accept test data gener- rotation speeds and low torques.
ated in an unapproved laboratory.8 For
n gl-5 – Designed for gearboxes and main hypoid gears operating at high rotation
the approval of a viscosity range, oil
speeds with impact loads and low torque or at low speeds and high torque.
manufacturers must guarantee that the
performance level obtained in a test on
Gear oils are generally classified in Europe using the DIN 51517 standard. The following
a specific oil are consistent for that
DIN 51517 classifications of gear oils are used most often:
product independent of production lo-
cation or viscosity grade across the vis-
n din 51517 cglP – Contains additives that protect from corrosion, oxidation
cosity range. In addition, the oil man-
and wear at the mixed friction spots, as well as additives which improve
ufacturer has to warrant that the
characteristics of sliding surfaces.
required properties do not only apply
to fresh oil, but that they also do not n din 51517-3 clP – Contains additives which protect from corrosion, oxidation
deteriorate within permissible toler- and wear in the mixed friction zone (this is the Siemens MD specification).
ances through the entire period of use. n din 51517-2 cl – Contains additives that protect from corrosion and oxidation,
The period of use for mineral oils must suitable for average load conditions.
be at least 10,000 operating hours or
two years maximum, and for synthetic
oils at least 20,000 operating hours or
four years maximum, assuming an av- production must be noted in writing limited to five years.10, 11
erage oil operating temperature of 176 and sent to Siemens MD. Unaccept- The Siemens MD specification and
F (80 C). able changes will result in voided ap- its revisions are a giant step forward in
“Some of the challenges of the proval and removal of the oil brand ensuring the quality and performance
specification include extensive and ex- from the approved lubricant list. of critical industrial gear oils. OEMs,
pensive testing of lubricants against a Tam says, “Asian customers ask for formulators and end-users welcome
battery of tests outlined in the specifi- Siemens MD-approved products, and the tight regulation of basestock, addi-
cations,” Shah says. “Additionally, commercially we have a problem if we tives and end products.
sometimes there are differences in re- cannot deliver such products. It is par- With tougher operating conditions,
sults when run at different labs. It ticularly challenging for some custom- the demands on industrial gearboxes
would be helpful if these tests become ers who need approval in their own have reached levels that no one could
standardized DIN and/or ASTM tests.” base oil.” have anticipated even five years ago.
The formulations tested and ap- “The pending Revision 14 to the As OEMs and operators struggle to en-
proved by Siemens MD must be identi- Siemens/Flender specification ad- sure the reliability and longevity of
cal to the oils produced commercially dresses some of the technical challeng- equipment, new industrial gear oils
under the approved fluid name. Any es, but the certification/approval pro- that offer protection against high heat
changes to the approved formulations cess timeframe continues to be slow,” and contamination are a key weapon
beyond permissible tolerances within Shorter says.9 Lubricant approval is in their arsenal.

7
IR and ICP test machinery are used to identify the fingerprint of a lubricant.
8
The list of approved laboratories and contact details can be found using the fol-
lowing link: http://support.automation.siemens.com/ww/view/en/44240585. Jean Van Rensselar heads her
9
Revision 14 is designed to streamline the approval process.
own communications firm,
Smart PR Communications,
10
From: http://cache.automation.siemens.com/dnl/zc/zc3ndQ1aaaa_44241193_
faQ/en_Specification_for_oil_approval_SKP__rev_13.pdf. in Naperville, Ill. You can reach
11
Revision 13 includes the following changes: a second approval criterion for the foaming test;
her at jean@smartprcommuni-
temperature-viscosity curves for each viscosity grade must be submitted; some wording was changed. cations.com.

Tribo-dictionary: Tackifier (tackiness additive or agent) – a high molecular weight, fluid polymer added to greases to improve adhesiveness. 33

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