Micro vs. Nano: Effect of BN Additives on the Rheological and Tribological Properties of Lithium Grease

The influence of BN particle size on lithium grease performance was systematically compared among a base grease (Li), a micro-BN (3 µm, 0.1 wt%) modified grease (Li + 0.1% mBN), and a nano-BN (50 nm, 0.1 wt%) modified grease (Li + 0.1% nBN). SEM shows that addition nano-BN leads to a more compact soap fiber networks, whereas micro-BN tends to agglomerate and provides limited reinforcement, leaving the base grease with a loose, porous network. Consequently, Li + 0.1% nBN outperforms both Li and Li + 0.1% mBN in dropping point (199.5 °C vs. 194.9 °C and 198.6 °C), oil separation (0.39% vs. 0.64% and 0.44%), and flow point (49% vs. 45% and 47%). Its plateau modulus is significantly higher, reflecting stronger network entanglement. However, Li + 0.1% nBN shows lower structural recovery (61.0%) than Li (65.8%) and Li + 0.1% mBN (67.2%) due to rigid particle–fiber junctions. Notably, Li + 0.1% mBN exhibits a unique frequency-dependent viscoelasticity: higher tanδ at low frequencies but lower tanδ at high frequencies relative to Li. Tribologically, Li + 0.1% nBN reduces friction coefficient by 35% and wear scar diameter by 12.7% compared with Li, outperforming Li + 0.1% mBN. XPS confirms a protective hybrid tribofilm (BN + organic nitrogen species + iron oxides) on the nano-BN lubricated surface. Particle size critically governs BN–fiber interactions and the resulting rheological and tribological performance.