Mitigation of Electrical Discharge Damage in Electric Vehicle Bearings: Comparative Study of Multi-Walled Carbon Nanotubes and Alumina Nanoparticles in Lubricating Grease

The electrified environments encountered in electric vehicles (EVs) in terms of parasitic currents present significant challenges for the performance of EV bearings and their lubricants. This study investigates the effectiveness of various concentrations (0.1 wt.%, 0.2 wt.%, 0.3 wt.%, and 0.4 wt.%) of multi-walled carbon nanotubes (MWCNT) and alumina (Al2O3) as two different nanoparticles incorporated into lithium grease, specifically focusing on their ability to mitigate the bearing surface damage caused by varying magnitudes of bearing DC discharges. A specialized test rig was developed to evaluate the electrical discharge characteristics, vibration response, and extent of surface wear on bearings lubricated with both lithium grease without additives and when infused with each nano-additive. Microscopic examination was employed to qualitatively and quantitatively evaluate the surface degradation of each test bearing. The results of this study demonstrate that the addition of nano-additives into the lubricating grease of bearings subjected to electrical loads resulted in a reduction in electric discharge voltage thresholds and levels. This reflected on the mitigation of surface damage in terms of surface roughness and vibration amplitudes by up to 70.67% and 65.19% in the case of MWCNTs. In contrast, alumina nanoparticles yielded a reduction in vibration amplitude and surface wear by 44.89% and 37.5%, respectively.