Application Bulletin: ZDDP alternative for GL-5 Gear Oil (80W-90)

Ultrium™ Polyester - Zero-SAPS, Ashless Anti-Wear Technology as a replacement in lubricant formulations

The drive to minimize sulphated ash, phosphorus and sulfur (SAPS) content in gear oil formulations has increased primarily to address debits of yellow-metal corrosion, fluid degradation, potential for excessive wear and non-metallic compatibility resulting from sulfur and phosphorus-based aggressive chemistry.

Traditional anti-wear additives such as ZDDP, while highly effective in boundary lubrication regimes, present challenges due to their thermal instability, volatility, and contribution to SAPS levels. This necessitates the development of alternate additive chemistries that maintain wear protection under highly loaded conditions without compromising hardware corrosion, additive degradation and ensuring smooth gear engagement.

Ultrium Technology in Action Aurorium Ultrium Polyester represents a next-generation multifunctional polyester additive engineered to meet the increasingly stringent demands of high-performance gear lubrication systems. Its molecular architecture—characterized by a sulfur- and phosphorus-free ashless design—delivers exceptional oxidative stability and thermal robustness while maintaining full compatibility with conventional ZDDP and other anti-wear chemistries. This unique synergy enables formulators to push the boundaries of gear oil durability, load-carrying capacity, and cleanliness without compromising on regulatory or environmental constraints.

Key Features of Ultrium Polyester Additive Solution in Gear Oil:

1. Minimize Environmental Impact
   Free of sulfur, phosphorus, and metals
2. Multi-functional Performance
   Delivers anti-wear and corrosion protection in one package
3. Formulation Flexibility 
   Compatible across diverse base oils and reduces formulation complexity
4. Enhanced Thermal Stability
   Outperforms ZDDP in oxidation resistance
5. Simplified Supply Chain 
   Supports global companies streamlining their ingredients

Why Choose Ultrium Polyester for your Gear Oil Formulations?

Ultrium Polyester functions by developing a robust boundary film on the metal surface thereby providing asperity level protection to highly loaded components. Ultrium Polyester also contributes to corrosion mitigation, further enhancing the reliability of the finished lubricant under demanding gear operating conditions. When formulating for advanced gear oil, Ultrium Polyester can be used as a multi-functional top-treat additive, showing improvements in wear results. For new gear oil products with ZDDP as primary anti-wear chemistry, demonstration of synergistic effects with Ultrium Polyester have been shown.

Performance Comparison: Ultrium Polyester as a top-treat in GL-5 Gear Oil (SAE 80W-90)

Getting Started with Ultrium Polyester

To learn more about how Ultrium Polyester can improve your gear oil formulations, visit Aurorium.com for technical datasheets, performance insights, and contact us directly for customized recommendations.