Lubricating grease compatibility and conversion
Guidance and example
The evaluation of lubricating grease compatibility is essential for ensuring optimal performance
and reliability in various mechanical applications. This document focuses on the ASTM D6185
standard, which outlines a systematic approach to assess the compatibility of binary mixtures of
lubricating greases. It details the basic procedures for conducting base compatibility tests, including
mixing greases in ratios of 50:50, 10:90 and 90:10. Key mechanical tests, such as dropping point
and worked penetration measurements, are presented as indicators of compatibility, as well as
secondary tests based on the specific application conditions. This document shares best practices
for grease conversion, including purging protocols and monitoring procedures to mitigate the
risks of equipment failure. Following these guidelines, end users successfully can manage grease
conversions and enhance the longevity and performance of lubricated components.
Compatibility testing of lubricating greases Concurrent testing may be relevant to investigate potential
incompatibility between base oils or additives. An example
The ASTM International standard D6185, “Standard Practice
is two greases with different additive chemistries for
for Evaluating Compatibility of Binary Mixtures of Lubricating
anti-wear and corrosion inhibition that compete for the
Greases,” provides a widely accepted protocol for assessing
same tribological interface may have a negative impact
the compatibility of grease thickening systems. Full details of
on performance. In this case, the user may want to add
this protocol can be accessed on the ASTM website at
supplemental testing for corrosion and/or wear. Other factors
[Link]/[Link]. The base compatibility
can influence incompatibility, including environmental
testing involves mixing greases in ratios of 50:50, followed by
conditions and application scenarios. For instance, greases
10:90 and 90:10, contingent upon whether the 50:50 mixture
operating in colder climates or in chiller rooms may exhibit
performance falls outside the range defined in the standard.
slower reaction rates compared to those in high-temperature
The primary indicators of thickener system incompatibility
applications. High-speed bearings can be particularly sensitive
are determined through grease worked penetration testing
to even minor incompatibilities, whereas low-speed bearings
at 100,000 strokes, worked penetration at 60 strokes after
may tolerate slightly more variation without adverse effects.
a thermal soak at 120°C for 70 hours, and dropping point
High-shearing conditions further complicate compatibility,
measure. Incompatible mixtures may exhibit penetration
necessitating careful consideration when selecting lubricating
consistency change by 1 to 2 NLGI grades, typically softening
greases. The product technical data sheet and intended
after working. The dropping point test provides an indication
application of the grease are relevant to guide the selection
of the temperature at which the thickener matrix is unable
of supplementary tests. A list of base test methods, including
to retain the base oil. Reduced dropping point can indicate
a list of supplemental tests, is referenced in the ASTM D6185
changes in thickener chemistry and physical structure.
standard. Most accredited grease-testing laboratories possess
Qualitatively, visual abnormalities – such as discoloration,
the capability to conduct these assessments.
cracking, separation and changes in texture – should be part
of the base testing observation.
Figure 1. Example base test
50:50 mixture
High-temp soak Worked 100,000
Dropping point
w/worked 60 penetration
No change No change Softens from
NLGI 2 to 1
Fails: Consider application risk & consider purge options
Figure 2. Example base test with supplemental test based on application need
50:50 mixture
Corrosion critical: Supplemental test
High-temp soak Worked 100,000
Dropping point EMCOR D6138
w/worked 60 penetration
No change No change No change
Repeat
90:10 mixture 10:90 mixture
Warning: Grease compatibility charts are for reference only
Numerous grease compatibility charts are available online, accessible via a simple search of common internet search engines.
It is important to note that these charts serve only as general references and should be utilized only as preliminary guidelines.
Compatibility charts do not account for the base oil or additive compatibility of the binary grease mixtures. They generally assume
that the change is limited to the thickener while the base oil and additives remain consistent, which is not always the case.
Grease conversion example To purge a bearing with a discharge or purge/relief port or
line, the new bearing grease typically is added while the
When converting from one grease system to another, best
equipment is operating if the addition can be completed
practice is to clean the component if possible. If cleaning is
safely. It typically is recommended to add the grease in small
not possible, one can verify grease compatibility using ASTM
quantities at frequent intervals as outlined below:
D6185 and assess application criticality. If the greases are
compatible, purge or flush out the old grease – ideally while • Remove the purge plug and/or verify the purge port
the machine operates – and monitor the process closely to is clean.
identify any issues.
• Add grease with two to three ¼ oz (5 g) shots or observed
If compatibility testing displays a test performance difference, current grease discharges from purge plug.
such as slight thinning of the grease or excessive dropping
• Leave the purge plug out for 30 to 60 minutes, allowing
point temperature reduction, best practice is to remove the
excess grease to purge out of the bearing. Reinstall the
bearing and clean out the old grease. If removal and cleaning
purge plug.
is not possible, some applications can purge the bearing
by increasing lubrication frequency. This option requires • Monitor the bearings for any temperature deviations or for
careful analysis of potential issues, including the application’s bleeding or leakage during this transition.
criticality from a failure/risk analysis. The associated risks may
outweigh the benefits of conversion, and it is the end user’s • Increase relubrication frequency until the discharge
responsibility to monitor, measure and validate the success of appears transitioned completely to the new grease. This
the purge. can be up to 8 times.
• Periodic monitoring is required. Consider the use of tools
Purging the bearing or component is only effective if
(e.g., ultrasonics) to monitor if possible.
the bearing has a discharge or purge/relief port. Filling
the bearing with grease without proper relief can lead to
Again, it is the user’s responsibility to evaluate risk of flush
immediate failure as the balls and rollers plow through the
conversion and to monitor, measure and validate the success
new grease. This can cause a rapid increase in temperature,
of the purge. If an automatic lubrication system is used,
with studies indicating temperatures can exceed 2x within
consult your technical service representative for conversion
minutes. The bearings can be forced out of the race path,
guidance.
resulting in immediate failure.
About MOLYKOTE® Greases
MOLYKOTE® Greases are suitable for a wide range of applications, including gears, all types of bearings,
conveyor systems, slides, drives, pumps, valves, seats and shafts. For information about the full portfolio
of MOLYKOTE® Greases for high-performance, severe-duty lubrication, visit [Link] or scan the
QR code at right.
About MOLYKOTE® Specialty Lubricants
Since 1948, customers around the world have trusted the MOLYKOTE® brand for performance and expertise to help
solve complex, technical design and lubrication challenges. Today, our greases, compounds, pastes, dispersions, oils
and fluids, and anti-friction coatings support customers’ innovation, performance and sustainability needs. To learn
more about our extensive product and service offering, to utilize our interactive product selection tool, or to locate a
distributor, visit [Link].
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