Yes / The presence of lubricant droplets in the gas that flows through the piston assembly and crankcase of an internal combustion engine (generically termed oil misting) has important implications for performance, particularly lubricant supply to the upper piston assembly, oil consumption and lubricant degradation. A significant source of these droplets is thought to be oil shearing and blow-through by blow-by gas flows in the piston assembly. An experimental rig was developed to simulate the high velocity gas and lubricant film interactions at a top piston ring gap where the flow conditions are most severe. Flows of lubricant droplets were produced and characterised in terms of the proportion of the oil flow that formed droplets in the gas flow and the size distribution of the droplets produced. Considering various aspects of a commercial automotive crankcase formulation, the effect of lubricant viscosity was found to be particularly important. Of the lubricant additives evaluated, viscosity modifiers were found to have the greatest effect on the tendency to form droplets: Detailed study on a range of viscosity modifiers identified that the influence of their molecular architectures on viscoelasticity was the key mechanism.

Yes / Droplet flows, termed misting, are significant lubrication flow mechanisms to, in and around the piston assembly. Therefore, these are important in piston assembly tribology and engine performance. Crankcase lubricant degradation rate has been hypothesised to be influenced by lubricant droplet flows through the piston assembly and crankcase, but not previously confirmed. Lubricant was sampled from the sump, top ring zone (TRZ), and mist and aerosol from the crankcase during an extend-ed run. The physical and chemical degradation of these samples was characterised. Droplet flows were intermediate in degradation and fuel dilution between TRZ and sump. Flows with smaller droplet sizes were more degraded that those with larger droplets. The degradation of polymers was dependent on their molecular architecture.

Yes / The tribological performance of the piston assembly of an automotive engine is highly influenced by the complex flow mechanisms that supply lubricant to the upper piston rings. As well as affecting friction and wear, the oil consumption and emissions of the engine are strongly influenced by these mechanisms. There is a significant body of work that seeks to model these flows effectively. However, these models are not able to fully describe the flow of lubricant through the piston assembly. Some experimental studies indicate that droplets of lubricant carried in the gas flows through the piston assembly may account for some of this. This work describes an investigation into the nature of lubricant misting in a fired gasoline engine. Previous work in a laboratory simulator showed that the tendency of a lubricant to form mist is dependent on the viscosity of the lubricant and the type and concentration of viscosity modifier. The higher surface area-to-volume ratio of the lubricant if more droplets are formed or if the droplets are smaller is hypothesised to increase the degradation rate of the lubricant. The key work in the investigation was to measure the size distribution of the droplets in the crankcase of a fired gasoline engine. Droplets were extracted from the crankcase and passed through a laser diffraction particle sizer. Three characteristic droplet size ranges were observed: Spray sized (250–1000 μm); Major mist (30–250 μm); and Minor mist (0.1–30 μm). Higher base oil viscosity tended to reduce the proportion of mist-sized droplets. The viscoelasticity contributed by a polymeric viscosity modifier reduced the proportion of mist droplets, especially at high load.