Falex

Four-Ball Extreme Pressure Test Machine

Falex Four-Ball Extreme Pressure Test Machine
ASTM D2596, D2783

The Falex Four-Ball Extreme Pressure Test Machine is used

to measure the extreme pressure properties of lubricants
under High Hertzian 3 point contact in pure sliding or pure
rolling motion. The machine is used to determine the load
carrying properties of a lubricant under these tribological
conditions at high test loads. Three determinations are
made: load-wear index, last non-seizure load and weld
point.

The Falex Four-Ball E.P. Test Machine rotates a 1/2 inch

diameter ball in contact with three similar balls held
stationary. The rubbing surfaces are covered with the fluid
lubricant or grease under test. In the ASTM tests, the upper
ball is rotated at 1800 rpm and the lubricant is at ambient
temperature. An axial force between 6 and 1000 kilograms
is applied through the three stationary balls to the rotating
ball. A series of 10 second duration tests is run at increasing
load increments using a new set of test-balls for each load.
The size of the wear scars obtained on the three lower balls
from each test is measured and averaged. The test is
generally terminated at the load where the rotating ball welds
to the three stationary balls. The LWI gives the formulator a
good idea of the wear protection at increasing loads. The last non-seizure load (LNSL) indicated a transition
from elastohydrodynamic to boundary lubrication and metal to metal contact.

This test machine is available in two models; a Single Speed or Variable Speed version. The variable speed
version allows for testing with continuously variable speeds and can be used for both US and European test
speeds. An optional friction measuring attachment can be purchased that records the force required to
prevent cup rotation. Coefficient of friction can then be calculated under the conditions of test. A
Temperature Control is also available as an option. Computer based data acquisition systems are available
for measuring the width of the wear scar using a CCD camera with digital image display and for acquiring
the friction signal and automatically calculating the LWI from the scar data.

An optional disk adapter can be used to replace the stationary three ball holder. This allows for the use of a
variety of materials, not generally available in ball form. Also available are adapters for performing rolling
contact fatigue test and for shearing lubricants using a tapered roller bearing. The Mechanical Taper Roller
Bearing Shearing device, also known as the KRL, has shown good correlation in determining shear loss of
polymer containing multi-viscosity gear oils used in heavy duty manual transmissions and differentials. The
Falex Four-Ball E.P. Test Machine meets the requirements of ASTM D2596 and D2783.

The Falex Four Ball Extreme Pressure Test Machine is designed to provide a wide range of test loads, up to
1000 kg. This tester should only be used for determining levels of extreme pressure properties of lubricants.
ASTM test methods caution against using the Four-Ball E.P. Test Machine for wear testing due to its wide
available test load range will inherently lack sufficient precision test loads required for conductivity wear
tests. It should be noted that the Four Ball Wear Test Machine should be used for administering test loads
with high precision accuracy. The Falex Four Ball EP Test Machine has been shown through cooperative
interlaboratory testing to meet the precision requirements of the ASTM test methods. In order to meet your
ASTM, ISO and DIN requirements, insist on the Falex Four-Ball EP test Machine.

The Falex Four-Ball Extreme Pressure Test Machine has been used for over 50 years with over 200
machines now in service. It has gained wide acceptance with industry and government.
 SYSTEM COMPONENTS
F-1518 STANDARD FALEX FOUR-BALL EXTREME PRESSURE TEST MACHINE
Standard items included with machine:
• 2 HP Motor • Mounting Table
• Upper Ball Chuck • Unloading Mechanism
• Loading Weight Holder • Ball Holder Assembly
• Digital Shut Off Timer • Loading Weights
• Multi-position Load Lever • Accessory Drawer
• Test Cup Tightening Bracket • 0-100 in-lb Torque Wrench

SPECIFICATION & FEATURES

LOAD:
20 to 800 kg
Applied through lever arm consisting of 20 indicated stations. Dead weights consisting of (8) 5kg, (3) 2
kg, and (3) 1 kg slotted weights included with machine. Optional electro-pneumatic load system
(eliminates dead weights).

SPEED:
1800 rpm
20 to 3600 rpm with optional Variable Drive Motor System (F-1518-3)

MOTION:
Sliding rolling

FRICTION:
Measure and record friction with optional Electronic Friction Measurement System (F-1518-1)

TEMPERATURE:
Controlled from ambient to 175°C with optional Temperature Control System (F-1518-3)

SPACE REQUIREMENTS:
72 in (L) x 60 in (W) x 65 in (H) (183 cm x 152 cm x 165 cm)

POWER REQUIREMENTS:
220 Volts, 60 Cycles (50 Cycles optional), Single Phase, 15 Amps

SHIPPING INFORMATION:
900 lb. (408 kg) 56 in x 36 in x 65 in (142 cm x 91 cm x 165 cm)

TEST PROCEDURES:
ASTM D 2596 “Standard Test Method for Measurement of Extreme-Pressure Properties of Lubricating
Grease (Four-Ball Method)
ASTM D 2783 “Standard Test Method for Measurement of Extreme-Pressure Properties of Lubricating
Fluids (Four-Ball Method)
IP 239 “Determination of Extreme Pressure and Antiwear Properties of Lubricants - Four Ball Machine
Method”
IP 300 “Rolling Contact Fatigue Test for Fluids in a Modified Four-Ball Machine
CEC L-45-T-93* “Viscosity Shear Stability of Transmission Lubricants (Taper Roller Bearing Rig)”[RRL]
*Requires F-1518-5 Mechanical Shear Stability Adapter
 OPTIONS & ACCESSORIES
F-1518-1 ELECTRONIC FRICTION MEASUREMENT SYSTEM
Includes Load Cell, Digital Indicator, Panel Mounted High Response Recorder, 4-1/2" wide chart.

F-1518-1A CHART PAPER

(2 chart packs per box)

F-1518-2 TEMPERATURE CONTROL SYSTEM

Includes Heaters, Digital Temperature Controller and Modified Ball Holder Assembly, Automatic
Temperature Start-Up, Maximum Temperature 175° C.

F-1518-3 VARIABLE DRIVE MOTOR SYSTEM

2 HP Variable Speed Motor and DC Controller with 1% full scale speed control accuracy. Panel mounted
Digital Speed Indicator. Maximum spindle speed 3600 rpm. 2 pulley ranges.

F-1518-4 DISC ADAPTER

Permits use of 1/4" diameter by 1/16" thick disks in place of lower balls for alternate material
combinations.

F-1519-6 DISC FIXTURE

For punching 1/4" diameter disc from 1/16" sheet stock (must be used with arbor press).

F-1518-5 MECHANICAL SHEAR STABILITY ADAPTER

Mechanical shearing adapter incorporating a tapered roller bearing. Uses 40 ml test fluid. Widely used in
Europe and currently under DIN standardization. Meets CEC L-45-T-93 Viscosity Shear Stability of
Transmission Lubricants (Taper Roller Bearing Ring)(KRL test).

F-1518-5A MECHANICAL REFRIGERATION BATH

Thermostability maintains test temperature of 60°C for the Mechanical Shear Stability Adapter.

F-1518-6 BALL CUP ASSEMBLY

Includes parts for clamping 3 lower balls

F-1518-6A BALL CUP ASSEMBLY

Same as F-1518-6 but with Thermocouple for F-1518-2.

F-1518-7 BALL CHUCK

Holds upper rotating ½ inch diameter ball during testing.

F-1518-8 THERMOCOUPLE
F-1518-9 PITTING DETECTION DEVICE
Used when determining onset of fatigue when evaluating materials under rolling four-ball conditions.
Requires purchase of F-1518-9A.

F-1518-9A ROLLING FOUR-BALL CUP ASSEMBLY

Accommodates lower rolling specimen race (F-1518-9B) for testing under rolling conditions. Includes
one lower specimen race (F-1518-9B).

F-1518-9B LOWER ROLLING FOUR-BALL SPECIMEN RACE

Replacement lower specimen race for evaluating materials under rolling conditions. Requires Rolling Four-
Ball Cup Assembly (F-1518-9A).

F-1518-10 SPARE PARTS KIT

Recommended spare parts kit for two years operation, includes gear belt (1), thrust bearing (1), and 5
amp fuse (3)
 OPTIONS & ACCESSORIES continued
F-1518-11 PROGRAMMABLE LOADING MEACHANISM
Electro-pneumatic load system for applying test laods. Eliminates the use of dead weights.

F-1519-31 SCAR MEASUREMENT SYSTEM

Binocular microscope with scaled eyepiece and light. Accurate to 0.1 mm. Ball cup stand and single ball
holder. Allows reading of ball scar without removal from ball cup.

F-1519-31A HIGH PRECISION SCAR MEASUREMENT SYSTEM

Includes binocular microscope with X-Y base and digital display of measurement accurate to 0.001 mm.
System includes ball cup stand with single ball holder. Allows reading of ball scar without removal from
ball cup.

F-1518/19-31B HIGH PRECISION SCAR MEASUREMENT SYSTEM with CCD

CAMERA
Includes a CCD camera with X-Y base and digital display of ball scar and capability of measurement on
screen to 0.01 mm. System includes ball cup stand with single ball holder and CCD camera with USB
port for recording scar diameters to Falex computerized data acquisition system or host computer. Allows
for reading ball scar without removal from ball cup. Includes software to capture and record scar widths
on the monitor and to automatically calculate Load Wear Index.

F-1518-35 COMPUTERIZED DATA ACQUISITION SYSTEM

A Windows® based system that can acquire store all signals available with Four Ball EP or Wear test
machines such as torque/friction, test fluid temperature, speed, and load with appropriate sensors. Optional
sensors quoted on request. Software calculates coefficient of friction for four ball wear tests with appropriate
sensors. This system will also calculate Load Wear Index for extreme pressure tests with manual entry of
the scar diameters or can be integrated with the Falex Scar Measurement System with CCD Camera (F-
1518/19-31B). The test data is stored in files compatible with commercial programs, e.g. Microsoft Excel®.
Files may be viewed and data displayed on a color monitor. Real time and historical trending may be
displayed. Captures data at a maximum rate of 10 per second (10 Hz). Includes PC with CD R/W for data
storage, 19” color monitor, keyboard, color printer, mouse and software to run associated programs.

F1518-35A DATA ACQUISITION SYSTEM SOFTWARE

Software only, for use on host supplied computer for calculating Load Wear Index from manual input of scar
diameters or with Falex Scar Measurement System with CCD Camera (F-1518/19-31B)

TEST SPECIMENS
F-1519-50 FALEX TEST SPECIMEN BALLS
AISI E 52100 steel. 500/box
Balls conform to ASTM D2596 and, D2783.

Test balls and disks are available in a wide variety of materials, surface finishes and hardnesses. Please
contact a Falex Corporation technical sales representative for pricing and availability.

The Mechanical Shear Stability

Adapter (F-1518-5) includes a
cooling plate, and taper roller bearing
assembly which allows testing to
CEC L-45-T-93, “Viscosity Shear
Stability of Transmission Lubricants
(Taper Roller Bearing Rig),” [KRL
test]. Used for simulating shearing
action in manual gear boxes
OPTIONS & ACCESSORIES continued

FALEX CORPORATION

Falex is the world’s

largest manufacturer
of test equipment
specializing in the
measurement of
friction and wear.

Falex offers innovative test

equipment, custom
equipment design and
manufacturing, test specimen machining, test equipment repair and rebuilding, qualified field
service, and individual training and instructional seminars. In addition, the Falex Test Laboratory
is available for material and fluid product testing on an individual fee basis or by special contract
arrangements.

Falex Corporation Falex Tribology N.V. - Belgium

1020 Airpark Drive Technologielaan 11-0001
Sugar Grove, Illinois 60554 U.S.A B-3001 Heverlee
Phone: (630) 556-3669 Phone: +32-16-407965
FAX: (630) 556-3679 Fax : +32-16-405128
Email: falexcorp@aol.com Email office@falexint.com
www.falex.com www.falexint.com
.