TLT: How long have you worked in a lubricant-related field, and what motivated you to study grease performance?
Kumar: I have been working in the tribological characterization of materials since 2015 when I joined the Material Characterisation Laboratory at the Indian Institute of Technology Delhi under my then supervisor Dr. Jayant Jain and co-supervisor Dr. Sujeet Kumar Sinha. My first research project involved nanowear analysis of magnesium-based nanocomposites with our then collaborator Dr. Manoj Gupta at the National University of Singapore. 

My attention shifted toward liquid lubrication when I joined the Martini Research Group at the University of California, Merced, in 2021. I worked on several challenging projects, but the one which fascinated me the most included the performance analysis of electric motor greases. This project was focused on improving the energy efficiency of electric vehicles by designing and testing operation specific greases for reducing friction and wear in electric motors to optimize electric vehicle performance. At Texas A&M University, I have been working with Dr. Hong Liang on forever chemicals, coatings and electric vehicle lubricants (last one in collaboration with STLE Fellow and STLE Past President Dr. Ali Erdemir). I became passionate about these projects due to their vast futuristic impact on green technology, public health and society. 

TLT: What has been your most rewarding accomplishment throughout your career in lubricants research?
Kumar: In my opinion, the most rewarding accomplishment of my career in lubricants research, thus far, was getting the opportunity to spread the awareness about the importance of grease research to a non-technical audience in the GradSlam (Three Minute Thesis) 2023 competition as one of the top 10 finalists at the University of California, Merced. I was able to inform a non-technical audience and aspiring scientists about the lubricants field and hopefully help foster a new generation of tribologists.

TLT: What is the No. 1 piece of advice you would give to a person who might be interested in starting a career in the lubricants industry?
Kumar: Be curious! As the famous author and speaker Hilary Hinton “Zig” Ziglar used to say, “Your attitude, not your aptitude, will determine your altitude in life.” It is always important to stay curious to look for answers when you get stuck on a research problem.
 
TLT: Throughout the different segments within your career, which one has been the most interesting, challenging and/or rewarding?
Kumar: My chapter with the Martini Research Group at University of California, Merced, was most interesting, challenging and rewarding all at the same time. It was a roller coaster ride! I worked on eight different projects with various industrial and academic collaborators. These projects covered different aspects of surface and tribological characterization, which helped me learn a lot of new things. My first project with Lawrence Livermore National Laboratory dealt with conformal contacts between two curved surfaces. My next project focused on studying vellum friction using a silicone-based elastomer probe to understand the tactile experience of interacting with medieval vellum. I also worked on jackfruit leather to compare the tactile and mechanical performance of jackfruit leather to examine it as an alternative to animal leather. In parallel, I was also working on performance characterization of electric motor grease and aerospace grease. I learned and grew so much as a young professional and a researcher in my time with the Martini Research Group. I acquired so many new skills and had the freedom to explore research topics from multiple angles, which widened my research spectrum. My new journey at Texas A&M University with Dr. Hong Liang has been equally fascinating and I acknowledge that as well.


Abhishek Kumar with a multifunction tribometer to analyze grease performance at the Martini Research Group at University of California, Merced.

TLT: What are some of the most technical lubrication-based concepts or topics you have encountered throughout your career?
Kumar: In grease lubrication, I consider the film thickness ratio that is the ratio of minimum film thickness of the grease to that of the base oil and how it affects the grease lubrication regime to be one of the most prevalent technical themes in my career. Comparing the performance of greases having different base oils and thickeners with temperature is a humongous task. Generally grease starts bleeding at around 80°C, and thickener microstructure degradation starts at around 120°C, which, in addition to grease viscosity, dictates the grease film thickness behavior with temperature. Therefore, it is important to consider the grease composition and its desired operating conditions in its entirety to optimize the overall system performance. 

TLT: What is the one thing you wish you would have learned earlier in your career?
Kumar: I wish I learned how to make professional connections! The value that being involved in the research community and networking events such as the STLE meetings and podcast offers is extremely crucial to improving your skills and prolonging your professional career. Connecting with other researchers working on different aspects of tribology helps to keep you informed about the emerging research topics and opens the door for your future endeavors. Concurrently, the poster sessions and talks provide a valuable platform to share and improve your current research, and exhibitions give an opportunity to personally meet and connect with industry experts.

TLT: What made you decide to work with grease?
Kumar: The decision to work with grease was driven by my passion for mechanics and engineering. Since a young age, I have always been fascinated by how machines operate and the intricacies involved in their functioning. As I pursued my education and gained experience in the mechanical engineering field, I found myself drawn toward the realm of lubrication and tribology.
Grease plays a vital role in ensuring the smooth operation and longevity of various mechanical systems. Its ability to reduce friction and wear in moving parts, as well as providing protection against corrosion, make it a crucial element in mechanical applications. I realized that by specializing in grease technology, I could contribute significantly to enhancing the efficiency and reliability of machines in various industries.

Additionally, I was intrigued by the constant advancements and innovations in the grease industry. New formulations and technologies were constantly emerging to meet the diverse and evolving needs of different machines and environments. This presented an exciting opportunity for me to stay at the forefront of technological advancements and continuously learn and improve my skills.

Moreover, working with grease offered me the chance to collaborate with a diverse group of professionals, including lubrication engineers, chemists and researchers, which added to the dynamic and intellectually stimulating aspect of the field.

TLT: Why is making grease considered an art?
Kumar: Making grease is considered an art due to the delicate balance of science and craftsmanship required in the process. While grease production involves chemical engineering principles and technical knowledge, it also relies on the skillful touch of experienced professionals to achieve optimal results. Making grease is often regarded as an art because it involves an amalgamation of formulation expertise; precision in mixing; customization for specific applications; balancing viscosity and consistency; understanding complex interactions within the grease between the base oil, thickener and additives, and between the grease and the contacting surfaces; continuous improvement and innovation in the formulation; quality control and consistency, etc.

Creating the right grease requires a deep understanding of the properties and interactions of various raw materials. Grease manufacturers must carefully select base oils, thickening agents and additives that suit the specific application and performance requirements. Achieving the perfect combination of these components is an art that involves trial, error and a keen sense of judgment.

The process of blending the base oils, thickeners and additives demands precision and finesse. Achieving uniform distribution of the ingredients and ensuring that no impurities are introduced into the mixture requires skilled hands and meticulous attention to detail.

Different industries and machinery have unique demands, and grease formulations must be tailored accordingly. An experienced grease maker knows how to adjust the chemical composition to suit specific operating conditions, temperatures, load-bearing capacities and environmental factors. This ability to customize greases to meet precise requirements reflects the artistry in the field.

The consistency of grease, characterized by its viscosity and texture, is crucial for its effectiveness. Getting the right balance between fluidity and the ability to adhere to surfaces is a delicate task that involves both scientific calculations and intuitive judgment.

Grease’s behavior can change under different conditions, such as temperature variations and mechanical stress. The artistry lies in comprehending these complex interactions and formulating greases that maintain their functionality and stability in diverse operating environments.

Like any art form, grease production requires a spirit of continuous improvement and innovation. Grease makers must stay abreast of the latest research, advancements and industry trends to refine their formulations and develop new, more efficient products.

Producing high-quality grease consistently is an art in itself. A skilled grease maker can maintain the same level of excellence across different batches, ensuring customers receive reliable and effective products.

In conclusion, making grease is considered an art because it involves a harmonious blend of science, technical expertise, experience and creativity. The ability to create custom formulations, optimize performance and deliver consistent results requires the touch of a skilled artisan, making grease production a true art in the world of manufacturing.

TLT: What measures can be taken to make grease manufacturing more efficient and sustainable?
Kumar: Improving the efficiency and sustainability of grease manufacturing is crucial for reducing environmental impact and optimizing resource utilization. Some measures that can be taken to achieve these goals may be based on research and development, raw material selection, waste reduction and recycling, energy efficiency, water management, lifecycle analysis, packaging, supply chain optimization, green certifications, continuous improvement, collaboration and knowledge sharing, etc. 
Invest in research and development to explore innovative and ecofriendly formulations, base oils and additives. Emphasize the development of high-performance, long-lasting greases that require less frequent reapplication, reducing overall grease consumption.

Choose raw materials that are environmentally friendly and renewable whenever possible. Opt for biodegradable base oils and sustainable thickening agents to reduce the ecological footprint of the grease manufacturing process.

Implement waste reduction strategies throughout the manufacturing process. Minimize material waste by optimizing mixing and blending processes. Where feasible, establish recycling programs to reuse certain waste materials, reducing overall waste generation.

Implement energy-efficient practices in the manufacturing facilities. Use energy-efficient equipment, optimize production schedules to reduce idle time, and consider investing in renewable energy sources to power the manufacturing process.

Optimize water usage in the manufacturing process and explore ways to recycle or treat wastewater. Reducing water consumption helps conserve this valuable resource and minimizes the impact on local water sources.

Conduct a comprehensive lifecycle analysis of the grease products to identify areas for improvement in terms of energy consumption, waste generation and environmental impact. Use this data to drive sustainability initiatives.

Evaluate packaging materials for environmental impact and use ecofriendly alternatives where possible. Lightweight and recyclable packaging options can help reduce the environmental footprint of the grease products.

Work closely with suppliers to ensure that raw materials are sourced responsibly and sustainably. Collaborate with suppliers who prioritize environmental and social responsibility.

Pursue relevant ecolabels and certifications, such as EcoLogo or Blue Angel, for grease products that meet strict environmental standards. These certifications can demonstrate a commitment to sustainability to customers and stakeholders.

Foster a culture of continuous improvement within the organization. Encourage employees to suggest and implement sustainable practices and regularly assess and update manufacturing processes to incorporate new advancements in sustainability.
Participate in industry associations and collaborate with other grease manufacturers to share best practices and collectively work toward a more sustainable industry.

By implementing these measures, grease manufacturing may become more efficient and sustainable, promoting responsible environmental stewardship while meeting the needs of customers and industries.

You can reach Abhishek Kumar at seth.abhishek02@gmail.com.