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The purpose of this study was to perform a complete experimental assessment of a family of oil ferrous wear debris sensor is performed. The family comprised the original sensor and its re-engineered evolution, which is capable of detecting both amount and size of wear debris particles trapped by the sensor and some predefined oil condition properties.

In this work, the first step was to perform a design of experiments for the sensor validation. A specially defined test rig was implemented, and different ferrous wear debris was collected. For each sensor, two different tests were performed. The first test was called a “void test”, where quantified amounts of debris were collided with the sensor without oil. The second one was a dynamic test, where the sensor was installed in the test rig and different amounts of wear debris were added at a constant rate. In addition, specific tests related with oil properties detection were studied.

The results show excellent correlation of the sensor output signal with the amount of wear debris and a satisfactory detection of debris size in all ranges. Also, the dynamic test presented adequate representativeness, and sensors performed well in this scenario.

This paper shows the practical implementation of this type of sensor and the usual detection range and rate of detection for different debris size and quantities.

This work has a great utility for maintenance managers and equipment designers to fully understand the potential of this type of sensor and its suitability for the application required.

As lubricating oils are used, their performance deteriorates and they become contaminated. The purpose of this paper is to investigate the lubrication performance of reclaimed 5 W-30 a fully synthetic used engine oil (UEO) with wear tests after refining it from a solvent-based extraction method using solvent (1-PrOH) and adsorbent materials such as cement, celite and deep eutectic solvent (DES).

The treated oil mixtures were prepared by blending engine oils with various adsorbent materials at 5% (w/w) in organic 1-PrOH solvent at a UEO: solvent ratio of 1:2 (w/w). The measurement of kinematic viscosity, density, the total acid number (TAN) and elemental analysis of oil samples was done by the ASTM standards D445/D446, D4052, D974 and D6595, respectively. Adsorbents and treated oil samples characterized by SEM-EDX, FTIR and UV analysis, respectively. Meanwhile, lubricating performance in tribological applications was evaluated through the wear test device using a rotating steel alloy 1.2379 cylinder and a stationary 1.2738 pin under 20, 40 and 80 kg load conditions. Worn surface analysis was done with SEM and 2.5D images.

It was found that when using the combination of cement and celite as an adsorbent in the reclamation of used engine oil demonstrated better lubricant properties. The properties of used engine oil were improved in the manner of kinematic viscosity of 32.55 from 68.49 mm²/s, VI (Viscosity index) value of 154 from 130, TAN of 3.18 from 4.35 (mgKOH/g) and Fe content of 11 from 32 mg/L. The anti-wear properties of used engine oil improved by at least 32% when 5% cement and 5% celite adsorbent materials were used together.

The paper is based on findings from a fully synthetic 5 W-30 A5 multi-grade engine lubrication oil collected after driving approximately 12.000 km.

The results are significant, as they suggest practical regeneration of used engine oil is achievable. Additionally, blending fresh oil with reclaimed used engine oil in a 1:1 ratio reduced wear loss by over 10% compared to fresh oil.

Reusing used engine oils can reduce their environmental impact and bring economic benefits.

This study showed that the properties of UEO can be enhanced using the solvent extraction-adsorption method. Furthermore, the study provided valuable insights into the metal concentrations in engine oil samples and their impact on lubrication performance. The order of the number of the grooves quantity and the possibility of the observed scuffing region trend relative to the samples was UEO > 5W-30 fresh oil > Treated oil sample with the adsorbent cement and celite together.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-06-2024-0209/