steel wire rope grease free sample

Wire rope forms an important part of many machines and structures. It is comprised of continuous wire strands wound around a central core. There are many kinds of wire rope designed for different applications. Most of them are steel wires made into strands wound with each other. The core can be made of steel, rope or even plastics.

Wire ropes (cables) are identified by several parameters including size, grade of steel used, whether or not it is preformed, by its lay, the number of strands and the number of wires in each strand.

A typical strand and wire designation is 6x19. This denotes a rope made up of six strands with 19 wires in each strand. Different strand sizes and arrangements allow for varying degrees of rope flexibility and resistance to crushing and abrasion. Small wires are better suited to being bent sharply over small sheaves (pulleys). Large outer wires are preferred when the cable will be rubbed or dragged through abrasives.

There are three types of cores. An independent wire rope core (IWRC) is normally a 6x7 wire rope with a 1x7 wire strand core resulting in a 7x7 wire rope. IWRCs have a higher tensile and bending breaking strength than a fiber core rope and a high resistance to crushing and deformation.

A wire strand core (WSC) rope has a single wire strand as its core instead of a multistrand wire rope core. WSC ropes are high strength and are mostly used as static or standing ropes.

Wire ropes also have fiber cores. Fiber core ropes were traditionally made with sisal rope, but may also use plastic materials. The fiber core ropes have less strength than steel core ropes. Fiber core ropes are quite flexible and are used in many overhead crane applications.

The lay of a wire rope is the direction that the wire strands and the strands in the cable twist. There are four common lays: right lay, left lay, regular lay and lang lay. In a right lay rope the strands twist to the right as it winds away from the observer. A left lay twists to the left. A regular lay rope has the wires in the strands twisted in the opposite direction from the strands of the cable. In a lang lay rope, the twist of the strands and the wires in the strands are both twisted the same way. Lang lay ropes are said to have better fatigue resistance due to the flatter exposure of the wires.

Wire ropes are made mostly from high carbon steel for strength, versatility, resilience and availability and for cost consideration. Wire ropes can be uncoated or galvanized. Several grades of steel are used and are described in Table 1.

Steel cable wire is stiff and springy. In nonpreformed rope construction, broken or cut wires will straighten and stick out of the rope as a burr, posing a safety hazard. A preformed cable is made of wires that are shaped so that they lie naturally in their position in the strand, preventing the wires from protruding and potentially causing injury. Preformed wire ropes also have better fatigue resistance than nonpreformed ropes and are ideal for working over small sheaves and around sharp angles.

Lubricating wire ropes is a difficult proposition, regardless of the construction and composition. Ropes with fiber cores are somewhat easier to lubricate than those made exclusively from steel materials. For this reason, it is important to carefully consider the issue of field relubrication when selecting rope for an application.

There are two types of wire rope lubricants, penetrating and coating. Penetrating lubricants contain a petroleum solvent that carries the lubricant into the core of the wire rope then evaporates, leaving behind a heavy lubricating film to protect and lubricate each strand (Figure 2). Coating lubricants penetrate slightly, sealing the outside of the cable from moisture and reducing wear and fretting corrosion from contact with external bodies.

Both types of wire rope lubricants are used. But because most wire ropes fail from the inside, it is important to make sure that the center core receives sufficient lubricant. A combination approach in which a penetrating lubricant is used to saturate the core, followed with a coating to seal and protect the outer surface, is recommended. Wire rope lubricants can be petrolatum, asphaltic, grease, petroleum oils or vegetable oil-based (Figure 3).

Petrolatum compounds, with the proper additives, provide excellent corrosion and water resistance. In addition, petrolatum compounds are translucent, allowing the technician to perform visible inspection. Petrolatum lubricants can drip off at higher temperatures but maintain their consistency well under cold temperature conditions.

Various types of greases are used for wire rope lubrication. These are the coating types that penetrate partially but usually do not saturate the rope core. Common grease thickeners include sodium, lithium, lithium complex and aluminum complex soaps. Greases used for this application generally have a soft semifluid consistency. They coat and achieve partial penetration if applied with pressure lubricators.

Petroleum and vegetable oils penetrate best and are the easiest to apply because proper additive design of these penetrating types gives them excellent wear and corrosion resistance. The fluid property of oil type lubricants helps to wash the rope to remove abrasive external contaminants.

Wire ropes are lubricated during the manufacturing process. If the rope has a fiber core center, the fiber will be lubricated with a mineral oil or petrolatum type lubricant. The core will absorb the lubricant and function as a reservoir for prolonged lubrication while in service.

If the rope has a steel core, the lubricant (both oil and grease type) is pumped in a stream just ahead of the die that twists the wires into a strand. This allows complete coverage of all wires.

After the cable is put into service, relubrication is required due to loss of the original lubricant from loading, bending and stretching of the cable. The fiber core cables dry out over time due to heat from evaporation, and often absorb moisture. Field relubrication is necessary to minimize corrosion, protect and preserve the rope core and wires, and thus extend the service life of the wire rope.

If a cable is dirty or has accumulated layers of hardened lubricant or other contaminants, it must be cleaned with a wire brush and petroleum solvent, compressed air or steam cleaner before relubrication. The wire rope must then be dried and lubricated immediately to prevent rusting. Field lubricants can be applied by spray, brush, dip, drip or pressure boot. Lubricants are best applied at a drum or sheave where the rope strands have a tendency to separate slightly due to bending to facilitate maximum penetration to the core. If a pressure boot application is used, the lubricant is applied to the rope under slight tension in a straight condition. Excessive lubricant application should be avoided to prevent safety hazards.

Some key performance attributes to look for in a wire rope lubricant are wear resistance and corrosion prevention. Some useful performance benchmarks include high four-ball EP test values, such as a weld point (ASTM D2783) of above 350 kg and a load wear index of above 50. For corrosion protection, look for wire rope lubricants with salt spray (ASTM B117) resistance values above 60 hours and humidity cabinet (ASTM D1748) values of more than 60 days. Most manufacturers provide this type of data on product data sheets.

Cable life cycle and performance are influenced by several factors, including type of operation, care and environment. Cables can be damaged by worn sheaves, improper winding and splicing practices, and improper storage. High stress loading, shock loading, jerking heavy loads or rapid acceleration or deceleration (speed of the cable stopping and starting) will accelerate the wear rate.

Corrosion can cause shortened rope life due to metal loss, pitting and stress risers from pitting. If a machine is to be shut down for an extended period, the cables should be removed, cleaned, lubricated and properly stored. In service, corrosion and oxidation are caused by fumes, acids, salt brines, sulfur, gases, salt air, humidity and are accelerated by elevated temperatures. Proper and adequate lubricant application in the field can reduce corrosive attack of the cable.

Abrasive wear occurs on the inside and outside of wire ropes. Individual strands inside the rope move and rub against one another during normal operation, creating internal two-body abrasive wear. The outside of the cable accumulates dirt and contaminants from sheaves and drums. This causes three-body abrasive wear, which erodes the outer wires and strands. Abrasive wear usually reduces rope diameter and can result in core failure and internal wire breakage. Penetrating wire rope lubricants reduce abrasive wear inside the rope and also wash off the external surfaces to remove contaminants and dirt.

Many types of machines and structures use wire ropes, including draglines, cranes, elevators, shovels, drilling rigs, suspension bridges and cable-stayed towers. Each application has specific needs for the type and size of wire rope required. All wire ropes, regardless of the application, will perform at a higher level, last longer and provide greater user benefits when properly maintained.

Lubrication Engineers, Inc. has found through years of field experience, that longer wire rope life can be obtained through the use of penetrating lubricants, either alone or when used in conjunction with a coating lubricant. Practical experience at a South African mine suggests that life cycles may be doubled with this approach. At one mine site, the replacement rate for four 44-mm ropes was extended from an average 18.5 months to 43 months. At another mine, life cycles of four 43-mm x 2073 meter ropes were extended from an average 8 months to 12 months.

In another study involving 5-ton and 10-ton overhead cranes in the United States that used 3/8-inch and 5/8-inch diameter ropes, the average life of the ropes was doubled. The authors attribute this increased performance to the ability of the penetrating lubricant to displace water and contaminants while replacing them with oil, which reduces the wear and corrosion occurring throughout the rope. A good spray with penetrating wire rope lubricant effectively acts as an oil change for wire ropes.

In these examples, the savings in wire rope replacement costs (downtime, labor and capital costs) were substantial and dwarfed the cost of the lubricants. Companies who have realized the importance of proper wire rope lubrication have gained a huge advantage over those who purchase the lowest priced lubricant, or no lubricant at all, while replacing ropes on a much more frequent basis.

This grease comes in cartridges that only work with our Controlled-Use Food-Grade Lever-Grip Grease Guns to make sure that the right grease is used in food-processing areas. It is NSF registered H1 for incidental food contact.

EnviroLogic® EHD Grease is a biodegradable, lithium complex grease fortified with extreme pressure (EP) additives and polymers.  Specifically developed for high load performance in a variety of marine and industrial equipment applications such as jack up platforms where incidental environmental exposure of the lubricant is cause for concern.  It is formulated to meet US EPA Vessel General Permit (VGP) criteria for environmentally acceptable lubricants.

EnviroLogic® EHD Grease demonstrates excellent water resistance and extreme pressure protection over an extremely wide temperature range.  It is formulated to provide steel and copper corrosion protection for use in harsh environments.

The oil/grease that is added to the steel wire rope during production is only sufficient to protect the steel wire rope during the storage period and initial use. The steel wire rope must be lubricated regularly.

Thorough lubrication is extremely important for the steel wire rope’s life expectancy, as the purpose of lubrication is partly to protect the steel wire rope against rust, and partly to reduce friction between the wires and the strands in the steel wire rope. Friction is also thereby reduced between the steel wire rope and the surfaces with which it comes into contact.

The lubricant used must be free of acids and must not have a destructive effect on the steel wires, the fibre core and the environment. The lubricant must have a consistency that enables it to penetrate the core and the strands. The steel wire rope must be cleaned before lubrication.

To achieve maximum lubrication effect, the lubricant should be applied during operation, at a sheaf or on the drum, as this is where the steel wire rope opens up and makes it easier for the lubricant to penetrate.

Randers Reb has developed a special lubricating oil, Randers WIRE OIL Type 01, which satisfies the special requirements for lubrication of steel wire ropes. The oil has excellent penetrative and lubrication qualities. It is also water-resistant and contains additives that dissolve rust and prevent further formation of rust during storage and operation. The oil is easily applied with a brush.

The following guidelines cover possible points that should be checked in conjunction with the inspection of steel wire rope. This is not a complete manual, nor is it an alternative to the relevant norms and standards.

All steel wire ropes become elongated when loaded (see also “Steel Wire Rope Elongation”, page 8-28). The elongation of a steel wire rope during its lifetime can be divided into three phases:

Phase 1: The new steel wire rope becomes longer quite naturally during its initial period of use. This partly because of the loading, and partly because the steel wire rope settles.

Phase 2: When the steel wire rope has settled and for most of its lifetime, the steel wire rope does not become much longer. Elongation during this phase is mainly due to wear.

Phase 3: The steel wire rope suddenly becomes longer very quickly. This means that the steel wire rope is deteriorating rapidly due to such causes as advanced wear and fatigue. The steel wire rope must be replaced immediately.

Every noticeable reduction of the steel wire rope’s dimensions in comparison with its original dimensions indicates a deterioration in the steel wire rope. The reduction may be due to such causes as:

Rust is just as important a factor as wear and tear in terms of evaluating the steel wire rope’s condition. Rust is normally caused by poor maintenance of the steel wire rope and promotes quicker fatigue in the wires (fragility/creation of cracks).

A “bird’s nest” (the strands rising in the same place) is created by such actions as the steel wire rope being subjected to torsion (rotated), sudden unloading, running through sheaf grooves that are too small and/or winding on a drum that is too small (fig. 44). The steel wire rope must be replaced immediately.

Local wear and tear is most often caused by poor winding. All fittings and splicings must also be inspected for wear or broken wires, loose or split strands, wear or cracks in fittings, etc.

If the wire fractures are serious, the steel wire rope must be replaced immediately. If you are in any doubt as to whether the steel wire rope should be scrapped or not, please contact your local salesman or our Technical Department as soon as possible.

With Alibaba.com, you can rest easy that you will be able to find the exact wholesale wire rope grease for the applications you have in mind. As one of the largest marketplaces for B2B shopping in the world, we have a huge network of wholesalers that have listed all sorts of lubricating jelly products and more.

For personal lube listings, we have a range of safe-to-use wire rope grease products. This includes pre seed lubricant options that are great for couples trying to conceive and mimics the body’s natural lubricants. For older women, we have options for menopause dryness. These vaginal moisturizers are designed specifically to prevent discomfort and add pleasure. For those with sensitive skin, we have specialist lube for sensitive skin products.

wire rope grease are also needed for home appliances and industrial lubricants. For home use, we have products for gun lubrication, sewing machine lubricants and more. These petroleum based lubricants can be used anywhere in the home where moving parts rub together. Squeaky door hinges will be a thing of the past with the options available here.

Wire rope forms an important part of many machines and structures. There are many kinds of wire rope designed for different applications. The wire rope’s performance is influenced by several factors, including type of operation and environment which can accelerate corrosion, oxidation, and wear. Hence, proper, and adequate lubricant application in the field is paramount. Essentially, wire rope lubricants have three principal functions, and it is to reduce friction, provide wear protection and corrosion protection.

Wire ropes, sometimes referred to as cables in gauges less than 3/8 in. dia., are connective elements used in static and dynamic work environments servicing industry and infrastructure needs. Common static wire-rope applications can be found in the main support systems for suspension bridges or as tensioned cable used to support tall, free-standing structures such as microwave cell towers. Popular dynamic applications include mining-cage hoists, elevator hoists, draglines, and cranes in which the wire rope moves under tension and load to lift, hoist, and transfer motion and power.

Originally developed in early 19th century Germany for the mining industry as a better alternative to existing metal chains and hemp rope—regular failure always proved catastrophic—wire rope is still manufactured in a similar manner from multiple strands of metal wire laid (wound) in a helical pattern around a center core. The center core can be made from hemp rope, plastic, fiber, or steel (specific to aircraft cable).

The multi-strand fabrication method provides tremendous tensile strength (100,000 to 350,000 psi, depending on the grade of wire steel) for lifting and hoisting while delivering flexibility of movement needed for traction and movement recovery over pulley or drum surfaces. In addition, stranded wire provides superior resistance to crushing and abrasion that can result from the extreme working conditions in which wire rope is often employed.

Wire ropes are gauged (sized) based on the number of strands surrounding the core and the number of wires used per strand. For example, an 8×19 wire rope will consist of 8 strands laid around the core, with each strand consisting of 19 wires. With 152 individual wires rubbing against each other as the rope moves over the drum or sheave pulley, friction and wear will result. That must be combatted with an effective lubrication strategy designed to maximize reliability and optimize life cycle.

In addition to load and movement, wire ropes are often subjected to weather and operating conditions that can introduce contamination and place heavy demands on the rope lubricant. Lack of a lubrication strategy can exasperate the situation and cause the wire rope to fail prematurely.

Dynamically loaded wire ropes typically fail from fatigue, wear, corrosion, and/or core shrinkage. Fatigue is a result of repetitive work cycles, subjecting the rope to constant bending, torsional twisting, and tension. These stresses eventually lead to broken wires within the strands. These same cyclic stresses also lead to high contact pressures between the wires that, in turn, set up a friction-and-wear cycle when the rope is inadequately lubricated. In addition, poorly lubricated ropes will allow solid contaminants between the wires as they open and close around the pulley. This contamination then sets up as three-body abrasion, causing accelerated wear inside the rope.

Because wire ropes are made from steel and can be subjected to outside elements such as moisture and acidic chemicals, unless a galvanized-steel rope is employed, successful corrosion abatement will rely solely on a quality lubrication program.

Core shrinkage starts to occur when the initial lubricant charge dries out, resulting in a reduced diameter and loss of support for the surrounding strands. This, in turn, can cause the strands to overlap one another, leading to nicked and cut wires.

Wire-rope lubricant is automatically applied by using a pressure boot clamped on the rope in a tensioned straight section. Lubricant is gently pressured into the wire rope as it passes through the boot. Photo courtesy Lubrication Engineers Inc., Wichita, KS; lelubricants.com

New wire ropes are lubricated at the factory. The lubrication gradually depletes, once the rope is placed in service, at a rate that depends on the load and working conditions. When setting up a wire-rope lubrication program, the first rule of thumb is to ensure the field lubricant is compatible with the original lubricant charge.

Considering the four common failure modes, a good lubricant must be able to coat the outside of the wire rope and get in between the wires to provide a lubricant film between all of the moving wires. The lubricant also must provide adequate corrosion protection. Because most wire ropes fail from the inside, it is important to always use a penetrating lubricant first. Penetrating oils are petroleum-based and contain solvents that allow these lubricants to “creep” into the core and ensure the strands and core are fully coated with a heavy lubricating film. Once in place, the solvent eventually evaporates, leaving only the oil film.

In extreme operating environments, the wire rope may also require a coating oil to protect the outside surface, sealing out moisture and protecting the inner strands and core. This coating oil also protects the outer rope surface from wear and damage.

The correct choice of lubricant is based on the application, load, rope construction, and working environment, all of which will require expert assistance from your local lubricant supplier.

If a new lubricant is to perform correctly, a full wire-rope cleaning must take place prior to re-lubrication. Ropes tend to pick up dirt in service and old lubricants can harden on the rope exterior. Cleaning ranges from a wire-brush-and-solvent cleaning, if only light surface debris is present, to a full steam clean for heavily soiled wire ropes.

Wire-rope lubricant can be applied manually or automatically in the field. Most manual applications are performed with a brush, spray, or even a dip-tank process, depending on the length and size of wire rope. If the lubricant is to be manually applied, always strive to do so at a directional change point, such as a pulley sheave or drum, when the rope strands naturally open up to accommodate flexibility.

For automatic application, a device known as a pressure boot is used. It is clamped on a tensioned straight section of the rope and lubricant gently pressured into the wires as the rope passes through the boot.

SWEPCO 150 Superior Wire Rope Grease is a semi-fluid grease, especially formulated for lubrication and protection of expensive wire ropes and cables. High performance synthetic base stocks and state-of-the-art overbased calcium sulfonate chemistry provide industry leading extreme pressure, antiwear and corrosion protection. Coats exteriors to eliminate abrasive wear and corrosion. Prolongs the life of wire rope, sheaves, pulleys, drums, guides, pins and rollers in a variety of applications, including cranes, hoists, marine tow and mooring lines, dockside cables, aerial tramways, dredges, draglines, mining, elevators and many other applications in construction, mining, transportation and manufacturing.