Dual-Film Synergistic Lubrication Mechanism of Sulfurized Oleic Acid Butyl Ester/Modified Castor Oil System in Machining GH4169 Nickel- Based Superalloy

Dual-Film Synergistic Lubrication Mechanism of Sulfurized Oleic Acid Butyl Ester/Modified Castor Oil System in Machining GH4169 Nickel- Based Superalloy | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Dual-Film Synergistic Lubrication Mechanism of Sulfurized Oleic Acid Butyl Ester/Modified Castor Oil System in Machining GH4169 Nickel- Based Superalloy jianning zhu, xiangpeng yu, jiajie tang, longbo xu, zhaocheng wei This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-8536159/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted 8 You are reading this latest preprint version Abstract GH4169 nickel-based superalloy is widely used in aerospace critical components manufacturing due to its excellent high-temperature strength, oxidation resistance, and corrosion resistance. However, its machining process often results in issues such as high cutting forces, severe tool wear, and poor surface quality. To address these challenges, a novel green dual-functional cutting fluid system was designed and formulated in this study. The system uses ethoxylated modified castor oil (E-S545) as the base oil and incorporates sulfurized oleic acid butyl ester (SOE) as an ash-free extreme-pressure additive, thereby constructing a composite lubrication system with synergistic physical adsorption and tribochemical reaction mechanisms.High-temperature tribological tests (100–500°C, 100–200 N) and actual turning experiments on GH4169 were conducted to systematically evaluate the friction-reducing, anti-wear, and thermal stability performance of the SOE/E-S545 system. The results showed that the formulated cutting fluid exhibited a remarkably low steady-state friction coefficient of 0.009 at 100°C and 100 N, due to the rapid formation of a dense and stable adsorption film. Even under extreme conditions of 500°C and 200 N, the friction coefficient remained as low as 0.324, demonstrating excellent high-temperature lubrication stability.Cutting experiments further verified that this system significantly reduced cutting forces (up to a 25% reduction) and slowed down the tool wear rate. The tool wear width gradually increased from 237 µm at 10 minutes to 350 µm at 50 minutes, with a uniform and stable wear morphology. SEM, EDS, and XPS analysis revealed that E-S545 formed a uniform physical adsorption layer on the metal surface, while SOE generated FeS and FeSO₄ tribochemical films under high temperature and high pressure. The two layers intertwined to form a continuous and dense "dual-film lubrication" structure, effectively suppressing oxidative wear and metal adhesion.The SOE/E-S545 system achieved excellent friction reduction and anti-wear performance under high-temperature and high-load conditions through a "physical adsorption + chemical reaction" dual lubrication mechanism. This system avoids the environmental hazards associated with traditional chlorine-containing extreme-pressure additives and provides a theoretical basis and formulation design idea for the green machining of nickel-based superalloys. GH4169 nickel-based superalloy sulfurized oleic acid butyl ester modified castor oil dual-film lubrication green cutting fluid Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Under Review Version 1 posted Editorial decision: Revision requested 20 Mar, 2026 Reviews received at journal 05 Feb, 2026 Reviewers agreed at journal 29 Jan, 2026 Reviewers agreed at journal 28 Jan, 2026 Reviewers invited by journal 14 Jan, 2026 Editor assigned by journal 14 Jan, 2026 Submission checks completed at journal 14 Jan, 2026 First submitted to journal 06 Jan, 2026 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-8536159","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":574882217,"identity":"22cdb8ac-22ae-4b2f-8d3f-a46e2418db2b","order_by":0,"name":"jianning zhu","email":"","orcid":"","institution":"Dalian Jiaotong University","correspondingAuthor":false,"prefix":"","firstName":"jianning","middleName":"","lastName":"zhu","suffix":""},{"id":574882219,"identity":"6f7abfce-188d-49f4-8970-e8a239cf17df","order_by":1,"name":"xiangpeng yu","email":"","orcid":"","institution":"Dalian Jiaotong 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Superalloy","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"journal-of-bio--and-tribo-corrosion","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jbtc","sideBox":"Learn more about [Journal of Bio- and Tribo-Corrosion](http://link.springer.com/journal/40735)","snPcode":"40735","submissionUrl":"https://submission.nature.com/new-submission/40735/3","title":"Journal of Bio- and Tribo-Corrosion","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"GH4169 nickel-based superalloy, sulfurized oleic acid butyl ester, modified castor oil, dual-film lubrication, green cutting fluid","lastPublishedDoi":"10.21203/rs.3.rs-8536159/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-8536159/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eGH4169 nickel-based superalloy is widely used in aerospace critical components manufacturing due to its excellent high-temperature strength, oxidation resistance, and corrosion resistance. However, its machining process often results in issues such as high cutting forces, severe tool wear, and poor surface quality. To address these challenges, a novel green dual-functional cutting fluid system was designed and formulated in this study. The system uses ethoxylated modified castor oil (E-S545) as the base oil and incorporates sulfurized oleic acid butyl ester (SOE) as an ash-free extreme-pressure additive, thereby constructing a composite lubrication system with synergistic physical adsorption and tribochemical reaction mechanisms.High-temperature tribological tests (100\u0026ndash;500\u0026deg;C, 100\u0026ndash;200 N) and actual turning experiments on GH4169 were conducted to systematically evaluate the friction-reducing, anti-wear, and thermal stability performance of the SOE/E-S545 system. The results showed that the formulated cutting fluid exhibited a remarkably low steady-state friction coefficient of 0.009 at 100\u0026deg;C and 100 N, due to the rapid formation of a dense and stable adsorption film. Even under extreme conditions of 500\u0026deg;C and 200 N, the friction coefficient remained as low as 0.324, demonstrating excellent high-temperature lubrication stability.Cutting experiments further verified that this system significantly reduced cutting forces (up to a 25% reduction) and slowed down the tool wear rate. The tool wear width gradually increased from 237 \u0026micro;m at 10 minutes to 350 \u0026micro;m at 50 minutes, with a uniform and stable wear morphology. SEM, EDS, and XPS analysis revealed that E-S545 formed a uniform physical adsorption layer on the metal surface, while SOE generated FeS and FeSO₄ tribochemical films under high temperature and high pressure. The two layers intertwined to form a continuous and dense \"dual-film lubrication\" structure, effectively suppressing oxidative wear and metal adhesion.The SOE/E-S545 system achieved excellent friction reduction and anti-wear performance under high-temperature and high-load conditions through a \"physical adsorption\u0026thinsp;+\u0026thinsp;chemical reaction\" dual lubrication mechanism. This system avoids the environmental hazards associated with traditional chlorine-containing extreme-pressure additives and provides a theoretical basis and formulation design idea for the green machining of nickel-based superalloys.\u003c/p\u003e","manuscriptTitle":"Dual-Film Synergistic Lubrication Mechanism of Sulfurized Oleic Acid Butyl Ester/Modified Castor Oil System in Machining GH4169 Nickel- Based Superalloy","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2026-01-20 08:47:50","doi":"10.21203/rs.3.rs-8536159/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"decision","content":"Revision requested","date":"2026-03-20T23:24:49+00:00","index":"","fulltext":""},{"type":"editorInvitedReview","content":"","date":"2026-02-05T11:45:20+00:00","index":"hide","fulltext":""},{"type":"reviewerAgreed","content":"230089181879740720734585888304223378890","date":"2026-01-30T03:12:02+00:00","index":"hide","fulltext":""},{"type":"reviewerAgreed","content":"277849963818815020272188116918696205734","date":"2026-01-28T15:19:44+00:00","index":"hide","fulltext":""},{"type":"reviewersInvited","content":"","date":"2026-01-15T04:45:10+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2026-01-15T01:50:01+00:00","index":"","fulltext":""},{"type":"checksComplete","content":"","date":"2026-01-15T01:48:44+00:00","index":"","fulltext":""},{"type":"submitted","content":"Journal of Bio- and Tribo-Corrosion","date":"2026-01-07T02:50:07+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"journal-of-bio--and-tribo-corrosion","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jbtc","sideBox":"Learn more about [Journal of Bio- and Tribo-Corrosion](http://link.springer.com/journal/40735)","snPcode":"40735","submissionUrl":"https://submission.nature.com/new-submission/40735/3","title":"Journal of Bio- and Tribo-Corrosion","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false}}],"origin":"","ownerIdentity":"437a57ee-faa7-4349-bce7-e06a3adcb13a","owner":[],"postedDate":"January 20th, 2026","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"under-review","subjectAreas":[],"tags":[],"updatedAt":"2026-04-08T00:08:27+00:00","versionOfRecord":[],"versionCreatedAt":"2026-01-20 08:47:50","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-8536159","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-8536159","identity":"rs-8536159","version":["v1"]},"buildId":"XKTyCvWXoU3ODBz1xrDgd","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}