MEAM Seminar: “Lubrication and Tribology Trends and Challenges in Passenger Electric Vehicles”

It is becoming more difficult and expensive to continue developing internal combustion engine (ICE) powered vehicles to meet the increasingly tight emissions goals addressing global climate change. Over the last few years, automobile manufacturers have been turning their attention toward electrification as the most practical and cost-effective way of providing personal transportation options that will meet future emission standards. Multiple sources are now predicting that over the next few decades, electric vehicles (EVs) will represent the fastest growing segment of passenger vehicle production.

The engine lubricants used in conventional ICE-powered personal vehicles represent one of the largest segments in the global lubricant market. It has become increasingly evident that the trend toward vehicle electrification will transform this market. However, EVs still require the use of lubricants and other fluids to function properly. It is likely that fluids specifically developed for EVs will play an even bigger part in enabling future EV technology than their earlier counterparts did during the development of ICE-powered vehicles.

This presentation will examine the trends in passenger EVs from the perspective of the unique lubrication, tribology and thermal management challenges they pose. It will also provide some insights gained from examining the layout and parts of three commercial EVs. While EV drivelines are mechanically simpler than their ICE vehicle counterparts, they expose the lubricant to a broader range of operating conditions. Also, the range anxiety concern expressed by consumers places an even bigger focus on friction reduction compared to ICE vehicles. Thermal management of different EV components has emerged as another technical challenge. Current fluids are not truly optimized to meet the competing requirements and there is room for future development of both the cooling systems and the fluids used in them.

We have now seen the first round of mass-produced EVs enter the market. Each manufacturer has developed their individual platforms and it is not clear if we have yet reached the most optimized vehicle architecture. Currently there are very few standards or even test methods to characterize the various fluids used in EVs. This will no doubt change over the next few years. We can also expect to uncover some unanticipated lubrication and tribology challenges that will require innovation and practical solutions from both vehicle manufacturers and lubricant suppliers.