Desirable properties of hydraulic fluids:

1. Oil should be incompressible i.e. it should resist high pressure so that greater
amount of force can be generated.
2. Oil should have sufficient lubricating properties to reduce wear and tear.
3. Oil should have high viscosity index to operate at temperature change situations.
4. Oil should be chemically stable.
5. The pour point of the oil should be as low as possible to avoid solidification at
low operating temperatures.
6. To prevent fire hazards, the flash point of the oil should be as high as possible.
7. The oil should have good oxidation resistance.
8. The oil should be non-toxic for operators’ safety.
9. The oil should have anti-foam properties so that bubbles and foam will not be
formed.
10. The oil should have good demulsivity to separate out water contained in it.

Hydraulic Fluids:
During the design of equipment that requires fluid power, many
factors are considered in selecting the type of system to be used—hydraulic,
pneumatic, or a combination of the two. Some of the factors are required
speed and accuracy of operation, surrounding atmospheric conditions,
economic conditions, availability of replacement fluid, required pressure
level, operating temperature range, contamination possibilities, and cost of
transmission lines, limitations of the equipment, lubricity, safety to the
operators, and expected service life of the equipment. After the type of
system has been selected, many of these same factors must be considered in
selecting the fluid for the system.

Fluid Properties:
If fluidity (the physical property of a substance that enables it to flow)
and incompressibility were the only properties required, any liquid not too
thick might be used in a hydraulic system. However, a satisfactory liquid for
a particular system must possess a number of other properties. The most
important properties and some characteristics are discussed below:

VISCOSITY
 Viscosity is one of the most important properties of hydraulic fluids. It
is a measure of a fluid’s resistance to flow. A liquid, such as gasoline, which
flows easily has a low viscosity; and a liquid, such as tar, which flows
slowly has a high viscosity. The viscosity of a liquid is affected by changes
in temperature and pressure. As the temperature of a liquid increases, its
viscosity decreases. That is, a liquid flows more easily when it is hot than
when it is cold. The viscosity of a liquid increases as the pressure on the
liquid increases.
A satisfactory liquid for a hydraulic system must be thick enough to
give a good seal at pumps, motors, valves, and so on. These components
depend on close fits for creating and maintaining pressure. Any internal
leakage through these clearances results in loss of pressure, instantaneous
control, and pump efficiency. Leakage losses are greater with thinner liquids
(low viscosity). A liquid that is too thin will also allow rapid wearing of
moving parts, or of parts that operate under heavy loads. On the other hand,
if the liquid is too thick (viscosity too high), the internal friction of the liquid
will cause an increase in the liquid’s flow resistance through clearances of
closely fitted parts, lines, and internal passages. This results in pressure
drops throughout the system, sluggish operation of the equipment, and an
increase in power consumption.
Viscosity Index
The viscosity index (V.I.) of an oil is a number that indicates the effect
of temperature changes on the viscosity of the oil. A low V.I. signifies a
relatively large change of viscosity with changes of temperature. In other
words, the oil becomes extremely thin at high temperatures and extremely
thick at low temperatures. On the other hand, a high V.I. signifies relatively
little change in viscosity over a wide temperature range. Ideal oil for most
purposes is one that maintains a constant viscosity throughout temperature
changes. The importance of the V.I. can be shown easily by considering
automotive lubricants. An oil having a high V.I. resists excessive thickening
when the engine is cold and, consequently, promotes rapid starting and
prompt circulation; it resists excessive thinning when the motor is hot and
thus provides full lubrication and prevents excessive oil consumption.
Another example of the importance of the V.I. is the need for a high
V.I. hydraulic oil for military aircraft, since hydraulic control systems may
be exposed to temperatures ranging from below –65°F at high altitudes to
over 100°F on the ground. For the proper operation of the hydraulic control
system, the hydraulic fluid must have a sufficiently high V.I. to perform its
functions at the extremes of the expected temperature range. Liquids with a
high viscosity have a greater resistance to heat than low viscosity liquids
which have been derived from the same source. The average hydraulic liquid
has a relatively low viscosity. Fortunately, there is a wide choice of liquids
available for use in the viscosity range required of hydraulic liquids. The V.I.
of an oil may be determined if its viscosity at any two temperatures is
known. Tables, based on a large number of tests, are issued by the American
Society for Testing and Materials (ASTM). These tables permit calculation
of the V.I. from known viscosities.
Pour point
The temperature at which a fluid can not flow. It should not be used as
a minimum temperature for operation. Actual minimum temperature should
be considerably higher. The pour point can be reduced with the use of
additives.
Flash point
The lowest temperature at which vapors rising to the surface form the
oil surface will ignite when exposed to an open flame.

Fire point
The oil temperature at which exiting vapors will ignite and become
self sustaining for a period of 5 seconds. This is usually about 26 0C (50 0F)
higher than the flash point.
Autogenious ignition temperature
The temperature at which droplets of oil will ignite when impinging
on a hot surface in the presence of air.
Lubrication
Hydraulic surfaces require that surfaces slide over each other (relative
motion) and have a low coefficient of friction.. To prevent wear, the fluid
must have excellent lubrication properties. Lubrication is a “boundary layer”
consideration. Oils should “stick”, “attach” or “bond” to surfaces (called
oiliness).
Poor lubricity will result in increased wear and thus over time,
increase clearances (increased leakage).
Thermal stability
The ability of a fluid to resist chemical reactions or decomposition at
higher temperatures is called thermal stability. If thermal stability is poor,
filters can easily clog.
Oxidation stability:
It is the ability of a fluid to resist a chemical reaction with oxygen.
Oxidation can be a problem at higher temperatures, and in places where
mixture rates with air or oxygen are high. If oxidation is severe, the fluid can
become acidic and sludge can easily form.
Hydrolytic Stability
It is the ability of a fluid to resist reaction with water. This can be a
consideration in water–in–oil emulsions. This can be alleviated somewhat
with the addition of rust inhibitors.
Foaming
Ability of a liquid to combine with gases (air , for example) and form
emulsions .This can reduce lubricity and the bulk modulus of the fluid.
Excessive foaming can readily be observed in the reservoir.
Toxicity
It is the ability of a fluid to produce toxic vapors. This can be a
problem with synthetic fluids at elevated temperatures.
Volatility
This is a measure of the ability of a fluid top produce vapour. We want
a very low vapour pressure in a fluid; that is we want to have vapors form
only if the pressure is very low.

Cavitation
This is not a fluid property but it is a consequence of fluid properties.
Cavitation refers to the formation and then collapse of a vapour cavity in a
fluid. This can occur when the pressure falls below the vapour pressure of
the fluid. The vapour cavities by themselves are not the main problem. When
the cavities are exposed to high pressures, the cavities are compressed very
rapidly and as a result, the internal pressure in the cavity becomes extremely
large. At some point, the cavity “collapses”. This means that the individual
molecules in the cavity are “shot” into the surrounding fluid at a molecular
level at very high velocities. The resulting pressure spikes and high velocity
vapour molecules can cause a lot of damage if they are close to any surfaces.
If the collapse occurs in the center of the fluid, the only consequence if
noise.
However, in most cases, the collapse occurs near surfaces so both
noise and surface damage can occur. (This is very much an
oversimplification of the process but the collapse is a very complex
phenomenon). The places where cavitation causes most damage are at any
venture sections, orifice and at pump inlets. The damage occurs at the
venturi and pump outlets because this is where the cavity collapses.
Types of Hydraulic Fluids:
Petroleum based fluids (mineral oil)
These fluids are most common in hydraulic circuits and are relatively
inexpensive. They have been around for a long time, have excellent
properties and can operate at a wide range of fluid temperatures and
pressures. The have one disadvantage that they are not fire resistant.
Synthetic fluids
- Can be very expensive
- Can have excellent fluid properties including fire resistance
- Can be used at a wide range of temperatures
- But can be hard to handle
Typical synthetic fluids are:
 Phosphate esters (excellent lubricity but thermal stability decreases at
high temperatures),
 Silicate esters (excellent thermal stability but poor hydrolytic
stability),
 Silicone base fluids: good (high) VI characteristics, high thermal
stability, low bulk modulus, which make them ideal for dampers, fluid
springs etc .However, they have poor lubrication (silicone is not a
good lubricant)
Water-based Fluids
These have been designed for fire resistance. Because they have water
in them, they have low vapour pressures, have low viscosity (approaching
that of water) and show generally poor lubrication properties.
 Water in oil (95% water- 5% oil) oil surrounded by water
 Water and oil can separate at times
 Lower viscosity because of water
 Poor lubricity
 Invert emulsions (40% oil and 60% water) water surrounded by oil
 Tend to be non-Newtonian in nature
 Tends to assume the properties of oil (good lubricity)
 Water glycols
 Excellent viscosity characteristics because if the glycols
 Medium pressure operation
 Can attack paints
 Must watch compatibility with seals (especially cork)