05.04 - 02 - Mr. Hirano - Engine Oil Requirements From An OEM Point of View

Engine Oil Requirements
from an OEM Point of View

- Prevention of Diesel Turbocharger Compressor Deposit -
4th – 5th April, 2017 in Stuttgart

UNITI Mineral Oil Technology Congress
Satoshi Hirano
TOYOTA MOTOR CORPORATION
Paul Decker-Brentano
TOYOTA Motorsport GmbH
4th - 5th April, 2017 UNITI Mineral Oil Technology Congress 2017 in Stuttgart 1
Agenda
1. Background
2. Mechanism of Diesel Turbocharger Compressor Deposit
3. Test Engine and Test Conditions
4. Reference Engine Oils
5. Test Results and Discussion
6. Summary
7. Acknowledgements
Agenda
1. Background
6. Summary
7. Acknowledgements
1. Background
• Turbocharger is a requisite element for modern diesel

engines to meet ;
– Stringent emission regulations
– Engine performance requirements such as fuel economy, power
output
• Turbocharger cannot get away from simple physics

– PV = nRT
– Increasing engine performance requires higher outlet pressure
and results in higher outlet temperature
1. Background
DI + TC DI + NA
Turbocharger is an
essential device to
PM meet emission
DPF regulations.
EGR DI +TC + Common Rail

SCR
NOx
Fig. 1 Trade-Off between NOx and PM,
and Improvements by Engine/After-treatment Hardware
1. Background
Temperature (T1)
Pressure (P1) Compressor Turbine
After-Treatment
Air Cleaner
Temperature (T3)
Intercooler Pressure (P3)
Muffler
Blow-By
D-Throttle
Intake Exhaust
Fig. 2 Diesel Engine with Turbocharger

1. Background
Compressor Side Turbine Side

Recover Exhaust Gas Higher Temp
Energy and Utilize it to
compress Intake Air
PV = nRT
When the inlet air is
compressed,
its temperature goes up.
Fig. 3 Cross Section of Turbocharger

1. Background
Turbocharger Map
Engine Torque Curve
Pressure Ratio
Torque/L
Boosted by
Turbocharger
Engine Speed Air Flow Rate
Fig. 4 Comparison of Typical Torque Curves and Turbocharger Map

1. Background
Turbocharger Efficiency
Drivability Compressor Outlet Temp. (T3)
Fuel Economy
Maximum
Power Output
Torque
Engine Speed
Fig. 5 Engine Operation and Compressor Outlet Temperature (T3)
1. Background
Concerned Areas for Deposit Formation
Turbine Housing
Water Cooling Jacket
Diffuser
Intake Air
+
Ventilation Gas
with Oil Mist
Diffuser
Bearing Housing
Scroll
Compressor Housing Variable Nozzle
Fig. 6 Deposit Formation in Turbocharger Compressor

Agenda
1. Background
6. Summary
7. Acknowledgements
2. Mechanism of Diesel TCC Deposit
New oil Mo
New oil
Transmittance [a.u.]
P
S
Zn
Ca
Deposits Deposits Fe, Cu, Si etc.

No Oxidation
Mo
Oxidation degradation P S
components: 1710 cm -1 Similar
Zn
2000 1500 1000 Composition
Ca
a.u. = arbitrary units [cm-1]
Simply Concentration of Oil + Soot

Fig. 7 IR Analysis and Elemental Analysis of New Oil and Deposit
New Engine Oil
Evaporated portion
GC Signal
Extracted Oil Portion

from Deposit
Adjustment of scale
300 400 500 600 700 800

Boiling Temp.(oC) by GC Distillation
Fig. 8 Distillation Characteristics by GC Distillation Analysis

(ASTM D6352)
It was confirmed that the concentration of sooted oil by evaporation
is the major mechanism of deposit formation in the turbocharger
compressor. (SAE 2013-01-2500)
Small particle of soot- High temperature

containing engine oil from and high flow speed
crankcase ventilation In the compressor
Evaporation
Concentrated and thickened
Attaches on surface
Deposit formation
Compressor Diffuser Surface
Fig. 9 Mechanism of Deposit Formation

Engine Oil Base Oil Volatility

Formulation Less Residual
Factors Base Oil by
Compressor Outlet Evaporation
Temperature (T3)
Solidification of
Oil Mist Particle
Soot Accumulation
in Engine Oil
Thickening
Engine
Effects
Operation
Factors Viscous Components
in Engine Oil*
* Not confirmed yet
Fig. 10 Cause Effect Diagram of Turbocharger Compressor Deposit

T3 Temperature
T3 Temperature
Deposit Deposit
No Deposit No Deposit
Soot Concentration GC Distillation (496oC)
Soot Concentration
Oil Soot
Concentration
Deposit
No Deposit T3 Engine Oil

Temperature Volatility
GC Distillation (496oC)
Fig. 11 Trade-Off Diagrams of Three Major Deposit Factors

Agenda
1. Background
6. Summary
7. Acknowledgements
• Test Engine
– Toyota 1KD-FTV
– Inline-4, 2,982 cc
– Max Torque = 305Nm @ 3,600rpm (w modified ECU for test)
– Max Output = 118KW @ 3,600rpm (w modified ECU for test)
• Test Cycle (Steady State)

– Duration = 100hrs
– Engine Speed = 3,600rpm
– Engine Torque = 290Nm
– Turbocharger Compressor
Outlet Temperature = 190oC
– Soot at EOT = 3.5 +/- 0.5%
(CEC L-82-97 (UV))
Engine Bench Build Up Intake Air Conditioner

Fig. 12 1KD-FTV Engine Bench at ISP
Temperature (T1)
Pressure (P1) Compressor Turbine
Facility
Exhaust
System
Temperature (T3)
Intercooler Pressure (P3)
Blow-By
Inlet Air
Conditioner
D-Throttle
Intake Exhaust
Fig. 13 1KD-FTV Engine Bench at ISP

Agenda
1. Background
6. Summary
7. Acknowledgements
• Reference Engine Oil Selection

– Chosen from Commercial Products from the European Market
with known Performance Claims
– ACEA Sequences, OEM In-house Specifications
• Low Reference Engine Oil

– ACEA C2
– SAE 0W-30
• High Reference Engine Oil

– ACEA C3, API SM/SL
– BMW LL-04, dexos2, MB229.31/229.51/229.52,
VW502 00/505 00/505 01
– SAE 5W-30
Agenda
1. Background
6. Summary
7. Acknowledgements
• Test Matrix
– Ran 4 High Reference Oil tests and 3 Low Reference Oil tests
with randomized test order
– The same engine hardware was used for all tests
– Turbocharger was replaced with new one for every test
– The turbocharger unit was disassembled and rated by visual
cleanliness rating
High Reference Oil Test
Low Reference Oil Test
Fig. 14 Test Sequence

Fig. 15 Turbocharger Deposit Rating Areas

Fig. 16 Turbocharger Deposit Rating Scale

Fig. 17 Turbocharger Deposit Examples

Fig. 18 Average Oil Consumption

Fig. 19 Soot Concentration at the EOT Used Oil

Average S. Deviation Average S. Deviation

Average (1+2) 8.4 1.2 Average (1+2) 66.1 5.9
Average (1+2+3+4) 5.5 1.9 Average (1+2+3+4) 61.5 6.4
Average 1+2+0.5*(3+4) 6.5 1.4 Average 1+2+0.5*(3+4) 63.0 6.1
Fig. 20 Turbocharger Deposit Ratings

Fig. 21 Soot Concentration and Deposit Rating
Agenda
1. Background
6. Summary
7. Acknowledgements
6. Summary
• The mechanism of the turbocharger compressor deposit

was proposed based on the deposit analysis and prove-
out tests. (see details in SAE 2013-01-2500)
– Engine oil volatility, soot concentration, and turbocharger
compressor outlet temperature are 3 key factors.
– Viscous components in engine oils may have the similar impact
for oil thickening.
• Based on the mechanism, the preventative engine test

for protecting turbocharger was developed.
– Anticipating more demands on improving over-all engine
performance by increasing the boost by turbocharger.
6. Summary
• High and Low Reference Oils were chosen from

commercially available products in the European market.
– High Reference : ACEA C3 + OEM specs, SAE 5W-30
– Low Reference : ACEA C2, SAE 0W-30
• The test procedure could discriminate high and low

reference oils with repeatable results.
• This test will provide good tool to formulate better

engine oils suitable for future diesel engines at improved
performance level.
Agenda
1. Background
6. Summary
7. Acknowledgements
7. Acknowledgements
ISP Salzbergen GmbH & Co. KG

Dr. Tono Nasch
Managing Director
Mr. Michael Schulz

Manager Engine and Vehicle Testing
Mr. Johannes Villinger

Project Engineer, Engine Testing
Thank you for kind your attention !

05.04 - 02 - Mr. Hirano - Engine Oil Requirements From An OEM Point of View

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Engine Oil Requirements

from an OEM Point of View

4th – 5th April, 2017 in Stuttgart

• Turbocharger is a requisite element for modern diesel

• Turbocharger cannot get away from simple physics

EGR DI +TC + Common Rail

Fig. 2 Diesel Engine with Turbocharger

Compressor Side Turbine Side

Fig. 3 Cross Section of Turbocharger

Engine Torque Curve

Engine Speed Air Flow Rate

Fig. 4 Comparison of Typical Torque Curves and Turbocharger Map

Compressor Housing Variable Nozzle

Fig. 6 Deposit Formation in Turbocharger Compressor

Deposits Deposits Fe, Cu, Si etc.

Simply Concentration of Oil + Soot

New Engine Oil

Extracted Oil Portion

300 400 500 600 700 800

Fig. 8 Distillation Characteristics by GC Distillation Analysis

Small particle of soot- High temperature

Fig. 9 Mechanism of Deposit Formation

Engine Oil Base Oil Volatility

Fig. 10 Cause Effect Diagram of Turbocharger Compressor Deposit

No Deposit T3 Engine Oil

Fig. 11 Trade-Off Diagrams of Three Major Deposit Factors

• Test Cycle (Steady State)

Engine Bench Build Up Intake Air Conditioner

Fig. 13 1KD-FTV Engine Bench at ISP

• Reference Engine Oil Selection

• Low Reference Engine Oil

• High Reference Engine Oil

High Reference Oil Test

Low Reference Oil Test

High Reference Oil Test

High Reference Oil Test

Low Reference Oil Test

Low Reference Oil Test

High Reference Oil Test

Fig. 14 Test Sequence

Fig. 15 Turbocharger Deposit Rating Areas

Fig. 16 Turbocharger Deposit Rating Scale

Fig. 17 Turbocharger Deposit Examples

Fig. 18 Average Oil Consumption

Fig. 19 Soot Concentration at the EOT Used Oil

Average S. Deviation Average S. Deviation

Fig. 20 Turbocharger Deposit Ratings

Fig. 21 Soot Concentration and Deposit Rating

• The mechanism of the turbocharger compressor deposit

• Based on the mechanism, the preventative engine test

• High and Low Reference Oils were chosen from

• The test procedure could discriminate high and low

• This test will provide good tool to formulate better

ISP Salzbergen GmbH & Co. KG

Mr. Michael Schulz

Mr. Johannes Villinger

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