The combustion by-products formed by burning diesel fuel, sulfur oxides and water, readily combine to form sulfur-based acids. The bulk of these corrosive acids is removed as part of the engine’s exhaust, but some remain and escape into the engine cavity in blow-by gas where they are neutralized by additives in the oil, or proceed to attack the thin oil films providing lubrication for piston rings and cylinder liners.
The sulfate index from infrared analysis is a measurement of the amount of sulfur-based acids that have reacted with the oil and reflect the amount of sulfation that has occurred. If fuel sulfur levels remain constant, the sulfate index would be expected to increase continuously with use until the oil reaches the end of its useful service life, for which the sulfation level or sulfate index can be an important determinant.
At normal operating temperatures, acids remain in a gaseous state in the blow-by gas with minimal contact with reactive surfaces. However, when an engine experiences lower-than-normal operating temperatures (such as just after start-up, at shutdown, or when a faulty cooling system results in continuous overcooling) the acids condense and come in contact with the oil in the sump, causing the oil to film on exposed metal surfaces. This places an extra burden on the lubricant because it must neutralize more acid than would be expected during normal operation. Thus, high sulfation early in the oil’s life often indicates abnormally low operating temperatures.
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