EP0553197A1 - Rheologically controlled glass lubricant for hot metal working. - Google Patents
Rheologically controlled glass lubricant for hot metal working.Info
- Publication number
- EP0553197A1 EP0553197A1 EP91918660A EP91918660A EP0553197A1 EP 0553197 A1 EP0553197 A1 EP 0553197A1 EP 91918660 A EP91918660 A EP 91918660A EP 91918660 A EP91918660 A EP 91918660A EP 0553197 A1 EP0553197 A1 EP 0553197A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- lubricant
- glass lubricant
- glass
- group
- carrier
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Classifications
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
- C10M111/00—Lubrication compositions characterised by the base-material being a mixture of two or more compounds covered by more than one of the main groups C10M101/00 - C10M109/00, each of these compounds being essential
- C10M111/04—Lubrication compositions characterised by the base-material being a mixture of two or more compounds covered by more than one of the main groups C10M101/00 - C10M109/00, each of these compounds being essential at least one of them being a macromolecular organic compound
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- C10M103/00—Lubricating compositions characterised by the base-material being an inorganic material
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- C10M103/00—Lubricating compositions characterised by the base-material being an inorganic material
- C10M103/04—Metals; Alloys
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- C10M107/00—Lubricating compositions characterised by the base-material being a macromolecular compound
- C10M107/02—Hydrocarbon polymers; Hydrocarbon polymers modified by oxidation
- C10M107/14—Hydrocarbon polymers; Hydrocarbon polymers modified by oxidation containing conjugated diens
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- C10M107/20—Lubricating compositions characterised by the base-material being a macromolecular compound containing oxygen
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- C10M107/32—Condensation polymers of aldehydes or ketones; Polyesters; Polyethers
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- C10M107/50—Lubricating compositions characterised by the base-material being a macromolecular compound containing silicon
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- C10M169/00—Lubricating compositions characterised by containing as components a mixture of at least two types of ingredient selected from base-materials, thickeners or additives, covered by the preceding groups, each of these compounds being essential
- C10M169/04—Mixtures of base-materials and additives
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- C10M2201/003—Inorganic compounds or elements as ingredients in lubricant compositions used as base material
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Definitions
- the present invention relates to a lubricant for hot metal working.
- it relates to a lubricant for the precision forging of superalloys for turbine engines.
- the manufacture of precision engineered machines such as jet engines requires that various metal component parts be hot worked by forging, extruding, rolling, or by similar processes. These processes entail rapidly applying high pressure by means of a metal die or other tool to the part being worked to induce a high strain rate.
- the tools are often made of various steels such as H13 type tool steel.
- the parts are typically fabricated from materials such as titanium alloys, nickel alloys, or stainless steels. To facilitate these processes, the part and the tool are coated with a lubricant which minimizes friction between the part and tool and prevents metal to metal contact.
- glass lubricants One class of hot metal working lubricants which is widely used is glass lubricants. These lubricants comprise ground glass particles which are suspended in a carrier.
- Such lubricants are applied to the part to be worked to reduce friction and minimize metal to metal contact which results in damage to the tool and part.
- Examples of commercially available lubricants include GP-803 available from Graphite Products (Brookfield, OH) and
- Acheson Colloids Port Huron, MI
- Titanium alloys in particular have proven troublesome. Due to their high strength, these alloys require extremely high pressures in order to be worked, resulting in high friction conditions which commercially available lubricants cannot obviate entirely.
- forge loads of 454 metric tons (500 short tons) to 1814 metric tons (2000 short tons) which can result in surface pressures in excess of 1.4 GPa (100 tons per square inch) or more, are typical.
- lubricants are subjected to high shear stresses and temperatures which cause them to lose their lubricating properties.
- the loss of lubricating properties is related to changes in viscosity, surface tension, density, and chemistry.
- metal tools wear rapidly and friction between the tool and part often ruptures the surface of the part.
- metal to metal contact occurring under these conditions can result in localized welding of the part to the tool, further damaging the part and tool. As a result, dies must be repaired or replaced frequently and parts can require extensive reworking.
- the present invention is directed towards providing a lubricant which can reduce friction between a tool and part in hot working operations which are carried out at extremely high pressures.
- One aspect of the invention includes a
- Theologically controlled glass lubricant for hot metal working comprising a mixture of a glass powder, a binder, a rheological agent, and a wetting and viscosity modifier.
- Another aspect of the invention includes a forged metal part with a smooth, rupture-free surface comprising a metal body formed into a desired shape by coating the metal body with a rheologically controlled glass lubricant.
- the lubricant comprises a mixture of a glass powder, a binder, a rheological agent, and a wetting and viscosity modifier.
- the coated metal body is heated, placed in a forge and sufficient pressure to deform the coated metal body into a desired shape is rapidly applied.
- Figure 1 shows a titanium alloy forging for which a prior art glass lubricant was used.
- Figure 2 shows a titanium alloy forging for which the present invention was used as a lubricant.
- the present invention is an improved lubricant for hot metal working under extremely high pressures. It comprises a mixture of a glass powder, a binder, a rheological agent, and a wetting and viscosity modifier. These components may be either a dry mixture or dispersed in a carrier. This combination of materials provides a lubricant which does not lose its lubricating properties when subjected to high pressures, temperatures, and shear stresses.
- the lubricant may be used with a wide variety of metals and metal working operations.
- the glass powder provides the basic lubricating activity of the present invention, especially when the part being hot worked is subjected to mild pressures, by fusing to form a continuous lubricating coating on the part when it is heated prior to the metal working operation.
- This continuous lubricating coating will be referred to as the glass base lubricant or base lubricant.
- the glass powder may be any of a number of glass powders or frits which have been used in the manufacture or formation of existing hot metal working lubricants.
- any glass powder with a viscosity of between about 10 2 poi.ses to about 104 poises at a working temperature of about 899 ⁇ C (1650 ⁇ F) to about 1149"C (2100 ⁇ F) would be suitable.
- such a glass powder will have a softening point of about 649 ⁇ C (1200 ⁇ F) and an as received particle size of about 150 microns to about 0.5 millimeters.
- Glass powder suitable for use at temperatures up to about 954 "C (1750*F) is available from Specialty Glass (Oldsmar, FL) and can have the following composition: 1 % by weight (%wt) to 3 %wt A1 2 0 3 ; 25 %wt to 35 %wt PbO; ⁇ 0.1 %wt MgO; ⁇ 0.5 %wt CaO; 5 %wt to 8.5%wt Na 2 0; balance SiO_.
- the glass powder should make up about 48 %wt to about 55 %wt of the lubricant.
- the binder improves the adhesion of the lubricant to the surface to which it is applied by forming a mechanical bond with the surface.
- Suitable binders include alkyd and silicone resins; water based emulsions such as vinyl acetate and vinyl alcohol; and thermoplastic resins such as polyacrylates, polyvinyl benzene, and styrene butadienes.
- the preferred binder is a styrene butadiene.
- the binder should make up between about 5 %wt to about 20 %wt of the lubricant. Preferably, the binder will make up about 15 %wt of the lubricant.
- the binders may be dissolved in a compatible carrier such as xylene; trichloroethylene; glycol ether; alcohols, such as methyl alcohol and isopropyl alcohol; ketones, such as methylethyl ketone; or water.
- a compatible carrier such as xylene; trichloroethylene; glycol ether; alcohols, such as methyl alcohol and isopropyl alcohol; ketones, such as methylethyl ketone; or water.
- Xylene is the preferred organic carrier, while water is the preferred inorganic carrier.
- Suitable products which comprise a suitable glass powder and binder dispersed in a carrier may be used to supply the glass powder and binder.
- Suitable products include GP-803, available from Graphite Products (Brookfield, OH) , and DeltaglazeTM and 17, available from Acheson Colloids (Port Huron, MI) .
- the preferred commercial product for use with this invention is Deltaglaze 17 because it uses xylene as a carrier. If a commercial product is used, sufficient product should be used to provide the above specified amounts of glass powder and binder in the final lubricant.
- the rheological agent serves to control the flow of the liquid glass base lubricant, hence the use of term rheological agent.
- the rheological agent supports the load on the part and prevents metal to metal contact between the part and tool when the hydrodynamic glass base lubricant film suffers catastrophic breakdown at high pressure.
- the rheological agent should be able to function as a lubricant under pressures above about 40 tons/in .
- materials such as BN, Ni, NiO, and Cr-0- will meet this requirement. They are incorporated into the invention as particles which may be suspended in the carrier.
- BN is the preferred rheological agent because it has a laminar structure.
- the particles should be about 5 microns to about 40 microns in diameter.
- the particles will be about 6 microns to about 15 microns in diameter. They make up between about 3 %wt and about 6 %wt of the lubricant.
- they will make up about 5 %wt to about 6 %wt of the lubricant.
- the wetting and viscosity modifier alters and controls the flow properties or rheology of the glass base lubricant to extend the range of pressures over which it will provide good lubricating properties by preventing the viscosity of the glass base lubricant from breaking down at high pressures.
- Compounds which are silica lattice modifiers make suitable wetting and viscosity modifiers.
- Preferred compounds include sodium tetraborate, potassium tetraborate, boric acid, lead monosilicate, and lead bisilicate.
- Potassium tetraborate is the most preferred viscosity modifier because of its effect on viscosity adjustment.
- the viscosity modifier should make up about 4 %wt to about 8 %wt of the lubricant.
- the lubricant will comprise 5 %wt to about 7 %wt viscosity modifier.
- the glass powder, binder, rheological agent, and wetting and viscosity modifier may be a dry mixture or may be dispersed in a carrier.
- the materials will be dispersed in a carrier to make the lubricant more convenient to apply.
- any additional carrier must be compatible with the carrier in which the glass powder and binder are dispersed.
- any additional carrier will be the same material used as a carrier for the glass powder and binder.
- the carrier may be any of a number of organic or inorganic materials including xylene; trichloroethylene; glycol ether; alcohols, such as methyl alcohol and isopropyl alcohol; ketones, such as methylethyl ketone; or water.
- Xylene is a preferred carrier.
- the carrier should make up between 35 %wt to about 45 %wt of the lubricant.
- the invention is made by mixing the glass powder, binder, rheological agent, viscosity modifier, and carrier, if any, and milling them in a reduction mill, such as a ball mill, until the mixture is homogeneous and the particles are of a suitable size.
- the majority of the glass particles should be between 1 micron and 30 microns in diameter after milling. Preferably, the majority of the particles should be 5 microns to 12 microns in diameter.
- the milling operation may take up to 8 hours. If the lubricant contains a carrier, the milling operation produces a complex suspension whose viscosity will tend to fluctuate during the first several hours after it is prepared, making its properties somewhat unpredictable.
- the lubricant should be stabilized before use to ensure adequate results.
- One way to stabilize the lubricant is to store it in sealed containers for at least 24 hours and preferably for at least 48 hours to permit it to age.
- Another way to stabilize the lubricant is to put it into a dynamic storage device, such as a constantly rotating container. Dynamic storage prevents viscosity fluctuation by constantly mixing the lubricant. If the lubricant is stored in a dynamic storage device, it may be used at any time after preparation. If the lubricant is a dry mixture, it needs no stabilization and can be used immediately after preparation.
- the finished lubricant may be applied to a part to be worked by any appropriate method.
- the lubricant is a mixture dispersed in a carrier, it can be applied by painting, dipping, electrostatic spraying, or conventional spraying.
- the lubricant is a dry mixture, it can be applied by conventional spraying, electrostatic spraying, electrophoretic application, or by placing a heated part in a fluidized bed of the lubricant.
- it should form a dry film of about 0.004 g/cm 2 to about 0.015 g/cm2 when applied to the part to be worked.
- This loading corresponds to a coating of about 0.025 mm (0.001 inch) to about 0.13 mm (0.005 inch) thick. If the film is too thin, it will not provide adequate lubrication. If the film is too thick, poor metal flow will result when operating pressures are applied. Preferably, the lubricant will form a dry film of about
- additional carrier may be added to dilute the lubricant.
- carrier may be allowed to evaporate from the lubricant or a thixotrope may be added.
- Thixotropes are inorganic or organic rheological additives which can thicken the lubricant. They must be compatible with the carrier used in the lubricant.
- Preferred organic thixotropes include bentones, micronized hydrogenated castor oil, castor oil, ethane diol, or methyl cellulose.
- Preferred inorganic thixotropes include fumed silica, bentonite, or water.
- the lubricant has a carrier, it must be dried after being applied to the part. This can be accomplished by heating the lubricant to a temperature above the solvent's boiling point or by allowing the lubricant to air dry. If the lubricant is a dry mixture, it needs no drying. After the lubricant has been dried, the part must be heated to fuse the glass powder into the base lubricant. The part must be heated to at least the softening point of the glass. Once the glass powder has fused, the part is ready to be hot worked.
- the lubricant may be used with a wide range of metals in a number of different hot working operations.
- the lubricant has been found to be suitable for use with titanium alloys, particularly Ti8-1-1, Ti6-4, and Ti6-2-4-2 over the temperature range of about 946 ⁇ C (1735 ⁇ F) to about 1004 ⁇ C (1840 ⁇ F) .
- titanium alloys particularly Ti8-1-1, Ti6-4, and Ti6-2-4-2 over the temperature range of about 946 ⁇ C (1735 ⁇ F) to about 1004 ⁇ C (1840 ⁇ F) .
- nickel alloys and stainless steels used in aerospace engines and commonly called superalloys.
- the lubricant is useful in reducing friction in forging operations in general, and particularly in conventional precision or net forging operations in which pressure is rapidly applied to the part to be worked, inducing a high strain rate. It can also be used to reduce friction in extrusion, blocking, heading, and rolling operations.
- the lubricant can be used at temperatures ranging from about 849'C (1560 * F) up to the temperature at which the rheological agent decomposes. If the working temperature is much below about 840 ⁇ C (1560'F), the lubricant will be too stiff to function properly. Preferably, the minimum working temperature will be about 899 ⁇ C (1650 ⁇ F) .
- U.S. Stoneware (Mahwah, NJ) was prepared for mixing the lubricant. 12 kg of pebbles were milled in a ball mill jar in the presence of 1 kg of abrasive material and an ample amount of clean water for 48 hours in order to condition the media. The abrasive material was then removed and the water and any very small or split pebbles were discarded. The jar and its pebble charge were thoroughly dried.
- TM kg of Deltaglaze 17 (available from Acheson Colloids, Port Huron, MI) and 915.4 g of xylene were added to the jar.
- the ball mill jar was place on the mill and the mill was started. After 7 hours, the mill was stopped and the jar was removed.
- the lubricant was strained into a clean metal can through a muslin cloth and a straining plate. The can was closed and the lubricant was permitted to age for 48 hours.
- the can was opened and the lubricant was gently stirred with a wooden paint stirrer to ensure that all sediment was blended into the body of the lubricant. While stirring, care was taken to avoid entrapping air in the lubricant.
- a clean, chemically milled metal extrusion was dipped into the lubricant and hung up to dry for 1 hour at ambient temperature. When dry, the coating thickness was measured with a micrometer and found to be 0.064 mm (0.0025 inch) thick. As this thickness was within the preferred range of 0.051 mm (0.002 inch) to 0.076 mm (0.003 inch), which corresponds to a loading of about 0.01 g/cm2 ⁇ no additional carrier was needed.
- Figs. 1 is a photomicrograph of the surface of a Ti6-2-4-2 part which was coated with a prior art lubricant before forging. Areas of shearing and surface rupture which result from metal to metal contact with the die are evident.
- Fig. 2 is a photomicrograph of the surface of a similar Ti6-2-4-2 part which was coated with a lubricant of a composition similar to that disclosed in the example before forging. The surface is uniform and displays no evidence of shearing or rupture. This is evidence of little or no metal to metal contact between the part and die. A part with a surface like this is acceptable as a finished piece and needs no reworking.
- the improved die life and decreased part damage result from improved lubrication and less metal to metal contact at forging conditions.
- the viscosity modifier in the invention enhances the glass base lubricant so it can provide lubrication at the extremely high pressures encountered when forging titanium alloy and nickel and stainless steel superalloy parts.
- the rheological agent controls glass base lubricant flow and provides additional lubrication under these pressures and helps to prevent metal to metal contact.
- the invention also improves the movement or deformation of the metal being forged by decreasing the friction between the tool and the part. As a result, when the invention is used as the lubricant, lower forge pressures are needed to achieve the desired deformation than if a prior art lubricant is used.
- the lower forging pressures further improve die life and decrease part damage.
- Decreased die wear means that dies need to be replaced less frequently and require less hand dressing to repair damage.
- the improvement to the part surface reduces or eliminates the need for hand repair.
- Another benefit of reduced part damage is improved dimensional reproducibility of the parts.
- each part is more uniform. This can also be expressed as an improvement in process control because the results obtained during the forging operation are more uniform and predictable.
Abstract
Lubrifiant à base de verre régulé par un agent rhéologique, destiné au façonnage de la fonte liquéfiée comprenant du verre pulvérisé, un liant, un agent rhéologique et un agent modifiant la mouillabilité et la viscosité. Ces matériaux peuvent être dispersés dans un support. On prépare le lubrifiant en mélangeant les éléments constituants, en moulant le mélange et en stabilisant le mélange précédemment moulu. On peut utiliser le lubrifiant pour une opération de forgeage en appliquant une couche de lubrifiant sur une partie de métal, en chauffant cette partie qu'on place ensuite dans une forge et en appliquant rapidement une pression suffisante pour déformer la partie de métal enduite, afin qu'elle adopte la forme désirée.Lubricant based on glass regulated by a rheological agent, intended for the shaping of liquefied cast iron comprising sprayed glass, a binder, a rheological agent and an agent modifying the wettability and the viscosity. These materials can be dispersed in a support. The lubricant is prepared by mixing the constituent elements, molding the mixture and stabilizing the previously ground mixture. The lubricant can be used for a forging operation by applying a layer of lubricant to a part of metal, heating this part which is then placed in a forge and quickly applying sufficient pressure to deform the coated metal part, in order to that it adopts the desired form.
Description
Claims
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US60063790A | 1990-10-19 | 1990-10-19 | |
US600637 | 1990-10-19 | ||
PCT/US1991/004647 WO1992007050A1 (en) | 1990-10-19 | 1991-06-28 | Rheologically controlled glass lubricant for hot metal working |
Publications (2)
Publication Number | Publication Date |
---|---|
EP0553197A1 true EP0553197A1 (en) | 1993-08-04 |
EP0553197B1 EP0553197B1 (en) | 1994-07-27 |
Family
ID=24404433
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP91918660A Expired - Lifetime EP0553197B1 (en) | 1990-10-19 | 1991-06-28 | Rheologically controlled glass lubricant for hot metal working |
Country Status (5)
Country | Link |
---|---|
EP (1) | EP0553197B1 (en) |
JP (1) | JP2918689B2 (en) |
AU (1) | AU8753091A (en) |
DE (1) | DE69103160T2 (en) |
WO (1) | WO1992007050A1 (en) |
Families Citing this family (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2007122972A1 (en) * | 2006-04-24 | 2007-11-01 | Sumitomo Metal Industries, Ltd. | Lubricant composition for hot plastic working and method of hot plastic working with the same |
DE102009038179B4 (en) | 2008-08-22 | 2015-04-23 | KLüBER LUBRICATION MüNCHEN KG | Method for producing a protective layer having a lubricating effect to prevent metal oxidation and steel scaling of dies and workpieces to be formed during hot and warm forging |
US9267184B2 (en) | 2010-02-05 | 2016-02-23 | Ati Properties, Inc. | Systems and methods for processing alloy ingots |
US10207312B2 (en) | 2010-06-14 | 2019-02-19 | Ati Properties Llc | Lubrication processes for enhanced forgeability |
JP5482533B2 (en) * | 2010-07-16 | 2014-05-07 | 新日鐵住金株式会社 | Antioxidant, method for producing antioxidant, and method for producing metal material |
JP5408104B2 (en) * | 2010-10-26 | 2014-02-05 | 新日鐵住金株式会社 | Antioxidant and method for producing metal material |
US8789254B2 (en) * | 2011-01-17 | 2014-07-29 | Ati Properties, Inc. | Modifying hot workability of metal alloys via surface coating |
JP6045434B2 (en) * | 2013-04-26 | 2016-12-14 | 株式会社神戸製鋼所 | Hot forging method |
CN106660106B (en) * | 2014-09-29 | 2019-05-07 | 日立金属株式会社 | The manufacturing method of Ni base superalloy |
WO2018117226A1 (en) | 2016-12-21 | 2018-06-28 | 日立金属株式会社 | Method for producing hot-forged material |
JP6749669B1 (en) * | 2019-12-02 | 2020-09-02 | 株式会社青木科学研究所 | Mold release agent containing hollow glass for mold, coating method using the same, and molding method |
Family Cites Families (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4096076A (en) * | 1976-01-29 | 1978-06-20 | Trw Inc. | Forging compound |
US4281528A (en) * | 1978-07-27 | 1981-08-04 | Trw Inc. | Process for isothermally shaping a titanium-containing metal workpiece |
US4409111A (en) * | 1982-04-12 | 1983-10-11 | Loctite Corporation | Anti-galling lubricative composition |
CH660023A5 (en) * | 1984-05-30 | 1987-03-13 | Lonza Ag | HIGH-TEMPERATURE LUBRICANT FOR CHIP-FREE HOT FORMING OF METALS. |
-
1991
- 1991-06-28 JP JP3517786A patent/JP2918689B2/en not_active Expired - Fee Related
- 1991-06-28 AU AU87530/91A patent/AU8753091A/en not_active Abandoned
- 1991-06-28 WO PCT/US1991/004647 patent/WO1992007050A1/en active IP Right Grant
- 1991-06-28 DE DE69103160T patent/DE69103160T2/en not_active Expired - Fee Related
- 1991-06-28 EP EP91918660A patent/EP0553197B1/en not_active Expired - Lifetime
Non-Patent Citations (1)
Title |
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See references of WO9207050A1 * |
Also Published As
Publication number | Publication date |
---|---|
DE69103160D1 (en) | 1994-09-01 |
JPH06504302A (en) | 1994-05-19 |
WO1992007050A1 (en) | 1992-04-30 |
AU8753091A (en) | 1992-05-20 |
JP2918689B2 (en) | 1999-07-12 |
DE69103160T2 (en) | 1994-11-03 |
EP0553197B1 (en) | 1994-07-27 |
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