Influence of molecular weight and free NCO content on the rheological properties of lithium lubricating greases modified with NCO-terminated prepolymers

In this work, the use of reactive diisocyanate-terminated polymeric materials as rheology modifiers of lubricating greases has been studied. Particularly, the influences that free NCO content, molecular weight and functionality of the reactive prepolymers exert on the rheological response and microstructure of lubricating greases were analyzed. With this aim, NCO-terminated prepolymers were prepared from several di and trifunctional polyols and polymeric MDI. Afterwards, the reaction between terminal isocyanate groups and the hydroxy group located in the hydrocarbon chain of the 12-hydroxystearate lithium soap, used as thickener, was promoted during processing of lubricating greases. Polymeric materials used as additives and final lubricating greases were characterized by FTIR, DSC and GPC techniques. The effectiveness of these reactive additives was tested by performing small-amplitude oscillatory shear (SAOS), as well as standardized mechanical stability tests, on final greases. The rheological response was related to the microstructure of these greases, characterized by means of atomic force microscopy (AFM). From the experimental results obtained, it may be concluded that the effectiveness of these polymeric additives to modify the rheology of greases is due to the progress of the reaction between terminal isocyanate groups and the hydroxy group of lithium soap. However, a large dependence on both free NCO content and prepolymer molecular weight was found. Experimental results confirm that a balance between prepolymer molecular weight and NCO content is necessary to reach an optimal rheological modification of lithium greases. Moreover, this balance is a function of grease ageing, due to the progress of the reaction promoted.