3333 N.

Mayfair Road • Milwaukee, WI 53222-3219 • +1 414-778-3344

Technical
Paper Series

I00-9.8

Hydraulic Fluid Evaluation by ASTM

D2882: Procedures to Significantly
Improve Precision of Experimental
Results

Dr. George E. Totten, Union Carbide Corporation

Roland J. Bishop, Jr., Union Carbide Corporation
G. Michael Gent, Conestoga Inc.

Presented at the International Exposition for Power Transmission

and Technical Conference
4-6 April 2000
 LEGEND

Sample Identification Number: I00-3.2

I = Volume number (only one volume)

00 = 2000, year of the conference
3 = Conference Session Number
2 = Second paper in the Session’s presentation order

All papers presented at the 2000 International Exposition for Power Transmission
and Technical Conference are available in one volume, Proceedings of the 48th
National Conference on Fluid Power.

No part of this publication may be reproduced by any means, in an electronic

retrieval system or otherwise, without the prior written permission of the author(s).

Statements and opinions advanced in this paper are that of the author(s) and are
his/her responsibility, not those of the National Fluid Power Association. For permis-
sion to publish this paper in full or in part, contact the author(s) directly.
 I00-9.8
HYDRAULIC FLUID EVALUATION BY ASTM D2882:
PROCEDURES TO SIGNIFICANTLY IMPROVE PRECISION OF EXPERIMENTAL RESULTS

George E. Totten and Roland J. Bishop, Jr. Union Carbide Corp., Tarrytown, NY
G.Michael. Gent, Conestoga Inc., Pottstown, PA

ABSTRACT ASSEMBLED FOR ASSEMBLED FOR

RIGHT HAND ROTATION LEFT HAND ROTATION

The ASTM test method D-2882 (Standard Test

Method for Indicating the Wear Characteristics of
Petroleum and Non-Petroleum Hydraulic Fluids in a
Constant Volume Vane Pump) is widely used to
evaluate hydraulic fluids. Performing this method can
be difficult due to problems with the pump hardware and
the written procedure. This paper discusses the
problems and suggests possible remedies.

INTRODUCTION Figure 1 - ASTM D-2882 Pump Assembly.

Since 1986 Conestoga USA, Inc. has been active in

the manufacture of lubrication and wear test specimens
and testing apparatus with an emphasis on the
hardware used with the ASTM D-2882 test method.
There are two main goals for this work. The first goal is
the improvement of the written method so that it will ~ L e n 0d ~ont~lal!ev~
include improvements developed by the testing
community and clearly present recommended practice FlowCounter HeatExchanger
to the first-time user. The second goal is to reduce
operational and repeatability problems by improvement
of the pump hardware. 15Gallon
In 1995 a survey was conducted to determine
Reservoir
exactly which techniques were then in current use.
Various laboratories which performed the ASTM D-2882
test were asked to share the details of their practices • 25 MicrometerFiller
(Nominal)
and test conditions so that a basis for revisions to the D-
2882 method could be established [1,2]. The i

information gathered made it clear that no laboratory Screen

which responded to the survey ran the D-2882 test as
prescribed by the written method. In all cases, users •E•
bmJ
I PressureRegulater
1
Drain
had modified the procedure to avoid operational
Pressure Temperature
problems or to enhance precision.
Gauge k
Operational problems with the pump hardware
specified for use in the D-2882 test method have two
damaging effects. (1) They can prevent completion of
the test and (2) they can diminish the precision of the Drain V105C Thermoregulator
results. The large amount of time and expense required
to select and prepare the test cartridge
Figure 2 - Typical ASTM D-2882 Hydraulic Circuit
has forced the testing community to take remedial steps,
not described in ASTM D-2882, to prevent pump
failures. Rotor failure, bushing failure, ring cracking and The objectives of this paper are to summarize the
survey results with additional commentary on key areas
inconsistent wear are the major problems to be
overcome. Figure 1 shows the brake-out of the pump and to report on the status of research conducted by
assembly. A typical hydraulic test circuit is shown in Conestoga USA, Inc.
Figure 2.

287
 DISCUSSION

A. S U R V E Y OF R E S U L T S AND C O M M E N T A R Y

1. Rotor Failure - Rotor failure occurs when one or

more rotor segments break. Rotor failure will ruin the
entire pump cartridge and can also damage the shaft,
bearings and housing often necessitating their
replacement. To date, rotor failure cannot be prevented
by inspection and current preparation techniques.
However, rotor failure has been reduced by careful vane
selection and preparation, rotor inspection and
preparation, proper pump alignment and by other means
to prevent excess rotor segment stress.

2. Bushing Failure - Bushing failure typically occurs

when a leakage path between the pressure and suction
ports is opened due to wearing away of the bushing face
by the vanes or rotor. As a result of this action, the test
fluid becomes contaminated with debris and should be
dumped. Recirculating bushing debris and heat build-up
in the pump (owing to the drop in flow from the pump
and the internal case drain used on the V-104) may
have a detrimental effect on the wear specimens,
possibly preventing their further use. Bushing failure
due to direct wear by the vanes or rotor has been
reduced by insuring that the vanes and the rotor slots
are machined so that the vanes properly track the ring
and no unbalanced forces cause the vanes to be driven
against the bushing faces. Other steps which reduce
bushing failure include bushing selection and
preparation, maintaining adequate clearances in the
cartridge and the use of various torquing techniques. As
shown in Figure 3, a vane is in contact with the rotor and
ring along three lines. For the vane to be in balance,
the following three lines must be parallel: (A) the line
defined where the rotor slot trailing face meets with the
vane surface, (B) the line defined where the rotor slot
leading face meets the vane bottom edge, and (C) the
line defined where the vane chamfer meets with the ring
surface.
3. Ring Cracking - Ring failure occurs when the
ring wall thickness is too thin to resist the expansive
forces acting on the ring and excess diametrical
clearance between the ring and the housing bore
permits the ring to expand until cracking occurs. Wear
resulting from cracked rings should be considered
questionable. Ring cracking can usually be avoided by
keeping the diametrical clearance between the ring and
housing to a minimum by rejecting housings with overly
large bores or by using shim stock to take up the
clearance.
Fiqure 3 - Vane Lines of Contact.
4. Inconsistent W e a r - Inconsistent wear may be
caused by variation of the material condition of the wear
parts and variation of the cam profile and the vane
chamfer. Inconsistent wear may also be related to the
fineness of the filter used as well as to the percentage of
pump displacement which passes through the filter, the
remainder being unfiltered, uncooled recirculating
internal case leakage. Cavitation damage may cause
erratic results. Test specimen variations are checked
during the selection and preparation procedures.
Maximizing pump flow without reducing pump internal
clearances to a point where bushing damage occurs will
assure that the fluid entering the pump will be as clean
and as cool as conditions allow. Cavitation damage can
usually be avoided by assuring that there is no air
ingestion into the system, that the pump inlet is
unrestricted and that the fluid has sufficient time in the
reservoir to release any entrained air.
5. Vane Selection and Preparation - The ASTM D-
2882 test protocol directs the user to deburr the vanes
with an oil stone, assuring that the vanes are free in the
rotor slots and that the vane length is less than the rotor
width. The survey showed that vanes require even
more attention. Vanes are routinely rejected on the
basis of obvious faults, such as marred surfaces (Figure
4) and improper chamfer (Figure 5) [3]. Dimensional
inspection results in further rejections if the vanes are
found to be out of parallel or undersized (Figure 6).
Selection is followed by hand deburring of all edges and
flats except the chamfer which is on the vane wear
surface. Demagnetization before weighing is
recommended.

288

Figure 4 - Some Vanes Showing Side Defects.
Ficlure 5 - Some Vanes Showing Improper Chamfer.
6. Cam Ring Selection and Inspection - The
ASTM D-2882 test protocol advises the user to check all
components for manufacturing or material irregularities.
The only preparation mentioned is to deburr sharp
edges with an oil stone. Respondents to the survey go
further. Pump rings were visually inspected and rejected
for coarse surface finish, machining chatter or improper
profile. Some laboratories polished the cam surface
with abrasives, while others performed a "pre-test" (7
hours at 2000 psi with a reference fluid) to "hone" the
289
ring and screen out unsuitable parts. A dimensional
check could be made of the outer diameter to insure that
there will be a close fit with the pump housing to avoid
ring cracking. Ring edges could be deburred by hand
and the faces may be lapped if found to be wavy or if the
ring thickness needs to be reduced. Some users
performed checks of the ring hardness and surface
finish before use. Rings which are less than 180 grams
may have a larger cam profile which will allow greater
extension of the vanes from the rotor slot, thus
increasing the stress at the base of the rotor segment
where rotor failure typically occurs. Light rings have also
been associated with ring cracking and are discarded by
some users.
.F.o ~.~'
T
,Icl.ooo<
d/ l B[OOO,"l
Figure 6 - Desired Vane Dimensions
Figure 7 - Pump Bushing
7. Bushing Selection and Preparation - The
ASTM D-2882 test protocol suggests that the bushings
be polished on their working face until the outer rim is
flat and free of tool marks. Survey respondents tended
to follow this practice to greater or lesser degrees.
Some users conically lap the entire surface of the
bushing, while others use a very light polish only to verify
the concave nature of the face. The back face should
be checked to insure that it is convex and parallel to the
working face. Also, if possible, check that the bushing
bore is perpendicular to the face. Figure 7 shows the
desired bushing configuration.
8. Rotor Selection and Preparation The ASTM
D-2882 protocol advises the user to deburr any sharp
edges, check for cracks and gives detailed suggestions
for polishing the terminal holes and the sides of the
rotor. Survey respondents recommended additional
steps. A visual inspection is made to check for
machining marks in the slots and for other surface
irregularities. Dimensional checks are performed to
determine that the sides are flat and parallel and that the
outer diameter taper is not excessive (fig. 8). The sides
may be polished to correct a flatness or parallelism
deficiency or to reduce the width if desired. If possible, a
check for slot run-out should be made as illustrated in
Figure 8. Slot run-out and taper of the outer diameter
will both cause the vane to be unstable and will
contribute to bushing wear and rotor failure. Used rotors
should be checked for unacceptable slot wear prior to
reuse.
c~ImCK FOR
OD TAPER
\
CHE~CK
SLOT RUN
/y// "/~ I / I / l l l l l l ~l /z/z/W//
Ficlure 8 - Rotor on V-Blocks for Inspection.
9. Housing Inspection and Rebuild - The ASTM
D-2882 test protocol advises that the housing and head
be inspected for deterioration and replaced if any is
found. The shaft and bearings are to be replaced every
five tests, the seals every test. The survey produced
very few comments about the housing, shaft and
bearings. What comments were received indicated that
it was typical to leave the seals in place until the
bearings and shaft were replaced unless leakage
became evident. Housing replacement is used as a last
resort solution when operational troubles can not be
traced to any other source. Conversely, if troubles start
immediately after installation of a new housing or head,
they should be discarded and replaced again. The
faces of the housing and head should be flat so that a
good fluid seal can be made between the housing and
the bushings. The faces should be examined
periodically for surface irregularities which may prevent a
good fluid seal. The bores which receive the bushing
shanks govern the location of the rotor and should be
perpendicular to the housing and head faces and
-
concentric when the pump is assembled. Housing and
head bores which are not true to the faces can make it
impossible to torque the head without binding the shaft
or attain an acceptable flow rate. If possible, it is
advantageous to inspect the housing and head to
determine if the housing and head faces (surfaces A
and B, Figure 9) are parallel to the respective surfaces
where the holes for the head bolts are drilled. If they are
parallel, then torquing the head may be facilitated by
maintaining a consistent gap between the head and the
housing.
"GAP"
~"OrS[
OUT
Figure 9 - Pump Housing
10. Survey of Results From Other Subjects
A) No reporting lab used the 100-140 in-lb torque
level mentioned in the ASTM D-2882 protocol. 40-70 in-
Ib was the average range used with the highest value
quoted being 90 in-lb. Some labs use feeler gages to
check that the gap is even between the body and head
and some insert sized spacers into the gap and tighten
the head firmly against the spacers.
B) Though disallowed by the ASTM D-2882 method,
it is common practice to reuse bushings and rotors.
C) No laboratory polled used the D-2882 flushing
procedure (Stoddard solvent, 120oF, 1000 psi). Flushing
procedures varied and reflected the type of fluid being
tested.
290

D) Every laboratory polled used 10 IJm rather than
the 20 IJm filter specified in D-2882. Indications are that
repeatability has improved at those labs which upgraded
their filtration.
E) Some labs have reduced test pressure to 1900-
1950 psi to reduce the occurrence of rotor failure.
11. General Comments on Selection and
Preparation - While the survey pointed out the wide
variety of inspection and preparation techniques in use,
it also showed that the finished parts tolerances fell
within a reasonably narrow band. Survey respondents
rated parts preparation and inspection as the most
important factor contributing to the successful
completion of the test. In the revised D-2882 method it
will be desirable to standardize the selection and
preparation procedures to insure that reproducibility
does not suffer as a result of each laboratory having its
own set of standards and procedures. The D-2882
method will be difficult to standardize since it is so
heavily reliant on operator inspection and hand dressing,
the availability of accurate inspection tools, and operator
skill.
B. HISTORY AND CURRENT STATUS OF THE
DEVELOPMENT OF ALTERNATE TEST
C O M P O N E N T S [1]
In 1985 a research project was started with the
goals of identifying the reasons for the problems with the
D-2882 test hardware, and developing methods to
overcome the problems by improved parts selection and
preparation procedures.
It was reasoned that standardization of the shape of
the vanes (Figure 6) would assure that the root cause of
bushing wear produced by these vanes could be traced
to other components in the pump. The need for large
quantities of identical vanes and the high reject rate for
the Vickers vanes, made in-house production of
alternate vanes a necessity. Using these vanes
appeared to reduce incidents of bushing wear but did
not stop pump failures.
The next pump components to be evaluated and
standardized were the housing and shaft. Several
problems were identified. Bores for the bushing shanks,
the cartridge bore and the bearing seats were not
necessarily concentric, nor were the body and head
faces perpendicular to the bores. In a housing with these
deficiencies, it may be impossible to get the bushings to
seal properly against the housing faces while keeping
the rotor true to the axis of the pump. Initially these
problems were corrected by re-machining all of the
bores and faces. It proved to be more practical to
design and machine an alternate pump housing. The
291
new design also permitted up-sizing of the bearings, the
addition of external case drains, and the inclusion of
mounting feet as part of the casting. A housing with true
faces also permitted precision torquing by examining for
any cocking of the head with the use of feeler gages. A
mating shaft was also designed and produced with the
splines carefully machined true to the axis with smooth,
straight sides so that the rotor would be driven evenly
with no tendency to wear into a bushing face. In
addition, a precision ground motor coupling pair was
produced so that pump alignment could be quickly and
accurately made using a straight edge and feeler gages.
After removal of performance variables from the
vanes, housing and drive components, potential bushing
problems were next addressed. By custom machining
the bushings, it was possible to make the bushing shank
with a larger outside diameter in order to fit more snugly
with the housing bore. Since the bushing incorporates
the journal bearing which supports the rotor, the
bushings should not be allowed to shift relative to the
housing. The suction ports were eliminated from the
outer bushing since they serve no purpose in that
position and can only be a source of internal leakage.
All pump rings were inspected to determine if the
cam surface might be at an angle to the faces, causing
the vanes to wear into the bushings. No faults which
would cause the persistent bushing and rotor failures
being experienced was identified. However, rings were
custom machined to fit a standard housing without the
necessity of having to wrap the OD with shim stock to
prevent cracking and which would have consistent
weight, cam profile, hardness and surface finish.
After eliminating the aforementioned variables from
the vanes, housing, shaft, bushing and ring, pump
failures continued and it was speculated that the rotor
(Figure 8) might be the major factor contributing to pump
failure. Prior to this point, the outer diameter of the rotor
was measured and reground if necessary to eliminate
any taper which might influence vane movement. Other
deficiencies inspected for included machining marks on
the slot faces, ragged broaching marks down the length
of the terminal holes and slots cut off center of the
terminal holes. It was now discovered that the rotor
slots might not be ground parallel to the rotor journals,
creating a condition which would definitely drive the vane
toward the bushing face. Since this deficiency could not
be corrected, work was begun to produce an alternate
rotor. To date three alloys have been evaluated: 4340
steel with a TiN coating; a maraging steel (VascoMax C-
300) [4], nitrided and non-nitrided; and H-11 tool steel,
non-nitrided. All three have failed at D-2882 or at slightly
elevated conditions and were used in conjunction with
the other alternate pump components. Current work is
progressing with H-11 tool steel and various heat
treatments.
 CONCLUSIONS

1. Operational problems with the D-2882 test

method can be reduced by careful attention to parts
selection and preparation.

2. The ASTM D-2882 method as written does not

adequately describe the preferred techniques used to
successfully perform the test.

3. Until a reliable high strength rotor has been

produced, users of the D-2882 method should consider
alternative strategies such as lowering test pressure or
reducing the throw of the vanes (using a smaller
displacement cam ring) to decrease the stress on the
rotor segment.

REFERENCES

1. Gent, G.M., "Review of ASTM D-2882 and Current

Possibilities", in Tribology of Hydraulic Pump Testing,
ASTM STP-1310. Ed by G.E. Totten, G.H. Kling and
D.J. Smolenski, American Society for Testing and
Materials, Philadelphia, 1995, p. 96-105.

2. "ASTM Conference: D-2882-90 Collaborative

Investigation", Report available from Conestoga USA,
Inc., Box 3052, Pottstown, PA, 19464.

3. Totten, G.E., Bishop R.J. and Webster, G.M., "Water-

Glycol Hydraulic Fluid Evaluation by ASTM D-2882:
Significant Contributors to Erroneous Results", SAE
Technical paper Series, Paper Number 961740, August,
1996.

4. Teledyne Vasco Company, VascoMax C-300.

292