Comparison of Tribological Performance of Ashless Sulfur-Free Phosphite Ester Versus ZDDP Additives at Electrified Interfaces

In electric vehicle (EV) drivetrains, lubricant films must not only mitigate friction and wear but also manage stray currents to safely dissipate stray charge and avoid micro-arcing. This study directly compares how a conventional antiwear additive (ZDDP) and a long-chain, ashless, sulfur-free phosphite ester (Duraphos AP240L) manage this balance under current-carrying boundary lubrication conditions. Reciprocating steel-on-steel tests were conducted at fixed load and speed with applied current densities of 0, 0.02, and 42.4 A/cm2. Friction and four-probe electrical contact resistance (ECR) were measured in situ, and impedance of tribofilms was measured over a 1–105 Hz range after friction test. In the presence of ZDDP, ECR initially increased and then decreased to a value that was as low as the initial direct contact of two solid surfaces or even lower sometimes. During the initial stage with high ECR, a well-defined impedance semicircle was observed in the Nyquist plot; after forming the tribofilm with low ECR, frequency dependence of impedance could not be measured due to the very low resistance. The decrease in ECR suggested a structural evolution of the anti-wear film on the substrate. However, post-test wear analysis indicated that the formation of this film was accompanied by tribochemical polishing of the countersurface and sometimes pitting of the substrate, which may have been due to localized electrical discharge producing trenches deeper than ~0.5 µm; in additive-free base oil, wear was dominated by ploughing with micro-cutting of the substrate. In contrast, AP240L performed better in terms of friction and wear, showing a remarkable ~30% lower coefficient of friction, while the overall cycle dependence of ECR was similar to the ZDDP case. AP240L showed negligible boundary film controlled wear producing a shallow, smooth track (depth < 0.2 µm) during the friction test, and there was no sign of electrical arc damage. These findings support long-chain, ashless, sulfur-free phosphite esters as promising candidates for EV boundary lubrication where both mechanical and electrical protection are required.