Demand for sustainability and efforts to lower carbon emissions, water-lubricated bearings as an eco-friendly alternative to traditional oil-based system. However, transitioning from oil-to water-lubricated bearings in compressors under high pressure–velocity (PV) conditions poses challenges due to water’s low viscosity and poor lubricity. In this study 69 experimental datasets from literature-comprising 157 data points are analyzed, with PV values calculated using Hertzian contact models across various bearing geometries. \(k\) -means clustering, guided by the elbow method, was applied to PV, coefficient of friction (COF) and specific wear rate (SWR) data to identify performance regimes. Compressors are typically assumed to operate within a PV range of 100 to 300 MPa.m/s, based on representative operating conditions for compressor bearings. This assumption considers journal bearings with line contact, shaft diameter ranging from 85 to 212 mm, surface speeds between 16.01 and 55.5 m/s, and applied load of 12 kN. These demanding conditions impose the need for advanced materials and surface engineering strategies to ensure reliable performance. Within this context, polymers perform adequately at low PV (<100 MPa.m/s), whereas higher PV (>100 MPa.m/s)-typically of compressor applications necessitate the use of advanced coatings such as hydrogenated diamond-like-carbon (H-DLC) and surface texturing. Tribo-corrosion is highlighted as a critical issue due to mechanical and electrochemical interactions in water-based systems. Given the need for the high reliability and minimal downtime in modern compressor systems, early detection of wear and lubrication degradation is crucial. Advanced condition monitoring techniques-particularly acoustic emission and ultrasonic reflection offer the sensitivity needed to support effective predictive maintenance. These findings guide material selection and system design for developing robust, high-performance water lubricated bearing applications.

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Tribological Challenges of Switching to Water-Lubricated Bearings in Compressors

  • Chandrasekar Natarajan,
  • Zaihao Tian,
  • David Buckney,
  • Julian Wharton,
  • Robert Wood

摘要

Demand for sustainability and efforts to lower carbon emissions, water-lubricated bearings as an eco-friendly alternative to traditional oil-based system. However, transitioning from oil-to water-lubricated bearings in compressors under high pressure–velocity (PV) conditions poses challenges due to water’s low viscosity and poor lubricity. In this study 69 experimental datasets from literature-comprising 157 data points are analyzed, with PV values calculated using Hertzian contact models across various bearing geometries. \(k\) -means clustering, guided by the elbow method, was applied to PV, coefficient of friction (COF) and specific wear rate (SWR) data to identify performance regimes. Compressors are typically assumed to operate within a PV range of 100 to 300 MPa.m/s, based on representative operating conditions for compressor bearings. This assumption considers journal bearings with line contact, shaft diameter ranging from 85 to 212 mm, surface speeds between 16.01 and 55.5 m/s, and applied load of 12 kN. These demanding conditions impose the need for advanced materials and surface engineering strategies to ensure reliable performance. Within this context, polymers perform adequately at low PV (<100 MPa.m/s), whereas higher PV (>100 MPa.m/s)-typically of compressor applications necessitate the use of advanced coatings such as hydrogenated diamond-like-carbon (H-DLC) and surface texturing. Tribo-corrosion is highlighted as a critical issue due to mechanical and electrochemical interactions in water-based systems. Given the need for the high reliability and minimal downtime in modern compressor systems, early detection of wear and lubrication degradation is crucial. Advanced condition monitoring techniques-particularly acoustic emission and ultrasonic reflection offer the sensitivity needed to support effective predictive maintenance. These findings guide material selection and system design for developing robust, high-performance water lubricated bearing applications.