Recent theoretical developments linking degradation to the thermodynamic concept of entropy have allowed a new approach to modeling all types of degradation. The theory has been successfully applied to wear, fatigue, and numerous other forms of degradation and experimentation has confirmed its applicability to modeling the mechanical degradation of lubricating grease. This paper overviews the mechanical degradation of grease, discusses past and present modeling techniques, shows how new techniques can be used to predict grease life, and provides suggestions for future research.

Because of the influential role of consistency in selecting a grease for a given application, accurate and meaningful methodologies for its measurements are vitally important. A new method, recently introduced, uses a rheometer to compress a grease sample to evaluate a relative consistency between a fresh and degraded grease; however, the results of this approach compared to a standard penetrometer and other methods of assessing consistency have not been studied. This paper takes a closer look at the relevant parameters involved in the rheometer penetration test and establishes a recommended procedure for its use. The consistency of various greases is then tested using this method and compared to results obtained from yield stress, crossover stress, and cone penetration tests. The results indicate that rheometer penetration may be used to assess the change in consistency for a given grease but should not be used to compare different greases. For this purpose, the crossover stress method is recommended, which is shown to correlate very well with cone penetration while using a simple procedure and allowing the use of a substantially smaller sample. A strong power law correlation between crossover stress and cone penetration was found for all greases tested and is presented in Figure 12.

Many grease-lubricated components operate in wet environments, making them susceptible to water contamination which degrades their performance, functionality, and useful life. Hence, selecting a grease with appropriate water-resistant properties can have a significant influence on the life of the machine. While industry standards attempt to evaluate a grease’s water resistance, research indicates that a more thorough understanding of water resistance is needed to properly match a grease to an application. This paper provides an overview of the interaction of grease and water, covers existing water-resistance standards, discusses the results of available experiments aiming to describe the effects of water on grease, demonstrates the need for more meaningful standards, and suggests additional measures for characterizing a grease’s water resistance.