Classifications

• • 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
  • 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
• • 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
  • C10M173/00—Lubricating compositions containing more than 10% water
  • C10M173/02—Lubricating compositions containing more than 10% water not containing mineral or fatty oils
• • 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
  • C10M2201/00—Inorganic compounds or elements as ingredients in lubricant compositions
  • C10M2201/06—Metal compounds
  • C10M2201/062—Oxides; Hydroxides; Carbonates or bicarbonates
  • C10M2201/0623—Oxides; Hydroxides; Carbonates or bicarbonates used as base material
• • 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
  • C10M2201/00—Inorganic compounds or elements as ingredients in lubricant compositions
  • C10M2201/085—Phosphorus oxides, acids or salts
• • 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
  • C10M2201/00—Inorganic compounds or elements as ingredients in lubricant compositions
  • C10M2201/085—Phosphorus oxides, acids or salts
  • C10M2201/0853—Phosphorus oxides, acids or salts used as base material
• • 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
  • C10M2207/00—Organic non-macromolecular hydrocarbon compounds containing hydrogen, carbon and oxygen as ingredients in lubricant compositions
  • C10M2207/10—Carboxylix acids; Neutral salts thereof
  • C10M2207/12—Carboxylix acids; Neutral salts thereof having carboxyl groups bound to acyclic or cycloaliphatic carbon atoms
• • 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
  • C10M2207/00—Organic non-macromolecular hydrocarbon compounds containing hydrogen, carbon and oxygen as ingredients in lubricant compositions
  • C10M2207/10—Carboxylix acids; Neutral salts thereof
  • C10M2207/12—Carboxylix acids; Neutral salts thereof having carboxyl groups bound to acyclic or cycloaliphatic carbon atoms
  • C10M2207/1203—Carboxylix acids; Neutral salts thereof having carboxyl groups bound to acyclic or cycloaliphatic carbon atoms used as base material
• • 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
  • C10M2207/00—Organic non-macromolecular hydrocarbon compounds containing hydrogen, carbon and oxygen as ingredients in lubricant compositions
  • C10M2207/10—Carboxylix acids; Neutral salts thereof
  • C10M2207/12—Carboxylix acids; Neutral salts thereof having carboxyl groups bound to acyclic or cycloaliphatic carbon atoms
  • C10M2207/125—Carboxylix acids; Neutral salts thereof having carboxyl groups bound to acyclic or cycloaliphatic carbon atoms having hydrocarbon chains of eight up to twenty-nine carbon atoms, i.e. fatty acids
  • C10M2207/1253—Carboxylix acids; Neutral salts thereof having carboxyl groups bound to acyclic or cycloaliphatic carbon atoms having hydrocarbon chains of eight up to twenty-nine carbon atoms, i.e. fatty acids used as base material
• • 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
  • C10M2207/00—Organic non-macromolecular hydrocarbon compounds containing hydrogen, carbon and oxygen as ingredients in lubricant compositions
  • C10M2207/10—Carboxylix acids; Neutral salts thereof
  • C10M2207/12—Carboxylix acids; Neutral salts thereof having carboxyl groups bound to acyclic or cycloaliphatic carbon atoms
  • C10M2207/125—Carboxylix acids; Neutral salts thereof having carboxyl groups bound to acyclic or cycloaliphatic carbon atoms having hydrocarbon chains of eight up to twenty-nine carbon atoms, i.e. fatty acids
  • C10M2207/126—Carboxylix acids; Neutral salts thereof having carboxyl groups bound to acyclic or cycloaliphatic carbon atoms having hydrocarbon chains of eight up to twenty-nine carbon atoms, i.e. fatty acids monocarboxylic
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
  • C10N2010/00—Metal present as such or in compounds
  • C10N2010/04—Groups 2 or 12
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
  • C10N2020/00—Specified physical or chemical properties or characteristics, i.e. function, of component of lubricating compositions
  • C10N2020/01—Physico-chemical properties
  • C10N2020/055—Particles related characteristics
  • C10N2020/061—Coated particles
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
  • C10N2030/00—Specified physical or chemical properties which is improved by the additive characterising the lubricating composition, e.g. multifunctional additives
  • C10N2030/06—Oiliness; Film-strength; Anti-wear; Resistance to extreme pressure
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
  • C10N2040/00—Specified use or application for which the lubricating composition is intended
  • C10N2040/20—Metal working
  • C10N2040/24—Metal working without essential removal of material, e.g. forming, gorging, drawing, pressing, stamping, rolling or extruding; Punching metal
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
  • C10N2040/00—Specified use or application for which the lubricating composition is intended
  • C10N2040/20—Metal working
  • C10N2040/243—Cold working
• • C—CHEMISTRY; METALLURGY
  • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
  • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
  • C10N2050/00—Form in which the lubricant is applied to the material being lubricated
  • C10N2050/08—Solids

Definitions

• This invention is roughly classified into two relevant inventions.
• One is an invention relating to particles of an inorganic polyvalent metal compound coated with a metallic soap as a fundamental invention, and their general utilization forms; and the other is an invention relating to a plastic working lubricant containing such coated particles as a more practical application form of such coated particles.
• the invention as a fundamental invention can be used in a wide range, and relates to metallic soap-coated particles excellent in seizure resistance and capable of preventing tools from wear and working oil from pollution at the time of plastic working; powder or suspension on such particles; a process for preparing the powder or suspension; and lubricating coating.
• the invention as a more practical applied invention relates to a lubricating coating forming agent, and, in more detail, relates to a lubricating coating forming agent giving excellent workability, namely excellent lubricity and excellent seizure resistance onto the surfaces of various metallic materials such as, for example, iron materials, steel materials, stainless steel materials, aluminum materials, magnesium materials, tin materials and titanium materials which need to be subjected to cold plastic working typically including forging, wire drawing, tube reducing and sheet forming; and lubricating coating.
• various metallic materials such as, for example, iron materials, steel materials, stainless steel materials, aluminum materials, magnesium materials, tin materials and titanium materials which need to be subjected to cold plastic working typically including forging, wire drawing, tube reducing and sheet forming; and lubricating coating.
• Metallic soap widely used as various lubricants, etc. plays an important role in the field of cold plastic working typically including forging, wire drawing, tube drawing of pipes, sheet forming, etc. of metallic materials.
• metallic soap has been used from long ago as a lubricating ingredient to lower the friction coefficient between materials to be wrought and tools at the time of plastic working and thereby reduce working energy drastically, and has greatly contributed to development of the cold plastic working field.
• metallic soap in the plastic working field, there can be mentioned its utilization in auxiliary lubricants used at wire drawing working.
• phosphating treatment plus soap treatment has generally been uses from long ago in this field.
• This technology is such that a phosphate salt coating layer is previously provided onto the surface of a material to be wrought, the coating layer firmly adhering to the surface as a reactive chemical conversion coating treatment layer, and then an aqueous solution of a water soluble fatty acid salt is contacted with the coating layer at an elevated temperature to form metallic soap coating containing a reactive soap layer.
• Lubricating coating comes in between the material to be wrought and the tool at the time of plastic working to avoid direct metal contact between the material to be wrought and the tool, and such lubricating coating may be liquid or solid.
• liquid lubricants represented by oil-type lubricants, etc. are often unfit for severe plastic working. The reason is that the lubricating coating preventing the material to be wrought and the tool from their direct contact undergoes shear to cause lubricating coating cutting, and thereby seizure occurs.
• JP 2000-63880 A discloses a lubricant composition for plastic working of metallic material which comprises (A) a synthetic resin, (B) a water soluble inorganic salt and water, (B)/(A) (ratio by weight in terms of solid matter) being 0.25/1 to 9/1, the synthetic resin dissolving or being dispersed.
• a lubricant ingredient at least one selected from the group consisting of a metallic soap, a wax, polytetrafluoroethylene and an oil in an amount of 1 to 20% by mass
• water soluble inorganic salt is preferred at least one selected from the group consisting of a sulfate, a borate, molybdate, a vanadate and a tungstate.
• this invention is characterized in that a lubricating ingredient such as a metallic soap or a wax is contained, in a dispersed state, in coating ingredients capable of becoming a carrier, and is an excellent technology capable of obtaining lubricating coating having high working performance simply and with labor saving only by applying the composition onto the surface of the material to be wrought.
• metallic soap is often used as the lubricating ingredient, it is mentioned that, since the metallic soap is immobilized in the coating by the inorganic salt and/or the resin ingredient, adhesion of the metallic soap is not influenced by adhesion between layers, as is the case in “carrier layer plus auxiliary lubricant layer”, the possibility of peeling of the metallic soap alone at the time of working is generally small.
• coating obtained from the above invention has an advantage that it is possible to adjust the surface area of the lubricant at will, e.g. by making lubricant ingredients fine particles, and thus lubricating coating exerting excellent performance even in strong working where enlargement of surface area is large is being developed, and the technology including the above invention is a prospective technology also in the aspect of lubricating performance.
• the carrier layer of a high friction coefficient exposed owing to the structure of the coating repeats contact with the tool to give the tool life bad influence.
• lubricating coating required in the cold plastic working field is considered to be lubricating coating which has such fine particle structure that the lubricant layer coats the carrier layer and strongly adheres to the carrier layer, and can be obtained by coating-type treatment without needing complicated treating steps.
• lubricating coating which has such fine particle structure that the lubricant layer coats the carrier layer and strongly adheres to the carrier layer, and can be obtained by coating-type treatment without needing complicated treating steps.
• lubricating coating is formed on the surface of the material to be wrought, for preventing seizure and galling formed by direct metal contact between the material to be wrought and the tool.
• lubricating coating formed on the surface of the material to be wrought there are two types, one being lubricating coating formed by making a lubricant physically adhere to the surface of the material to be wrought, the other being lubricating coating formed by forming a chemical conversion coating on the surface of the material to be wrought through chemical reaction and then applying a lubricant.
• Lubricants made to adhere onto the surface of the material to be wrought are inferior, in adhesion, to lubricants used after formation of a chemical conversion coating on the material to be wrought, and thus generally used in light working.
• a chemical conversion coating such as a phosphate coating or an oxalate coating playing a role as a carrier is formed on the material to be wrought, and then a lubricant having good slipping properties is applied thereon.
• This type of coating has two layer structure consisting of the conversion coating as a carrier coating and the lubricant coating and exerts very high seizure resistance, and thus has very widely been used in the field of plastic working such as wire drawing, tube reducing and forging. Particularly in a field of severe working among the plastic working field, a method of using phosphate coating or oxalate coating as undercoat and applying a lubricant thereon is being frequently adopted.
• Methods for forming a chemical conversion coating onto a material to be wrought and applying a lubricant thereon are classified broadly into two methods. One is a method of making a lubricant physically adhere onto the chemical conversion coating, and the other is a method of reacting a lubricant with the surface of the chemical conversion coating to form lubricating coating.
• the lubricant of the former made to physically adhere there can be mentioned one obtained by adding an extreme pressure additive into mineral oil, vegetable oil or synthetic oil as a base oil; one obtained by dissolving or dispersing a solid lubricant represented by graphite or molybdenum disulfide together with a binder ingredient in water; etc.
• a lubricant is applied onto the surface of a material to be wrought which was subjected in advance to chemical conversion coating treatment, and, in the application, the oil lubricant is used as such, and the aqueous lubricant is used, followed by a drying step.
• lubricants have advantages that there is no restriction about their application method and convenient spray coating or immersion coating can be used; and complicated liquid control as in chemical conversion coating treatment is almost unnecessary; etc., but these lubricants are often used in comparatively light working because of low lubricity.
• reactive soap As the lubricant of the latter to react it with the chemical conversion coating, there can generally be mentioned reactive soap.
• This method is a technology which has generally been used from long ago as “phosphating treatment plus soap treatment”, and according to the method, a chemical conversion coating is formed on the surface of material to be wrought, and then an aqueous solution of a water soluble fatty acid salt is contacted with the coating at elevated temperature to form, on the coating, metallic soap coating containing the reactive soap.
• the composite coating formed according to this method can be adapted to from light working to comparatively strong working, and is used in a very wide range of working including forging and tube reducing.
• phosphate treatment plus soap treatment a material to be wrought is first subjected to the cleaning step and the descaling step, and then to phosphating treatment and soap treatment. Since single or multi-stage water washing steps are necessary among these steps, space of about 7 to 12 vessels gets necessary as treating vessel space. Furthermore, control of the concentration and temperature of the treating liquid is necessary on each of the treating steps, and, in the phosphating step, free acid degree, total acid degree and accelerator concentration in the treating liquid are measured by manual operation according to a neutralization titration method and the like, and insufficient ingredients are supplemented appropriately. Furthermore, as to temperature, there are plural steps where the treatment is made at 60 to 80° C. and the heating is carried out with steam piping or the like, and thus a large amount of energy is used.
• washings as waste water are discharged after subjection to neutralization treatment, coagulating sedimentation treatment, etc., but coagulating sedimentation sludge containing phosphorus, etc. is dumped as industrial wastes as is the case with the above-mentioned sludge.
• a lubricating composition wherein a water soluble macromolecule or an aqueous emulsion thereof is used as a base material and a solid lubricant and a chemical conversion coating forming agent are compounded are disclosed in JP 52-20967 A, but coating equal to coating from chemical conversion coating treatment is not obtained.
• a lubricating composition wherein a water soluble macromolecule or an aqueous emulsion thereof is used as a base material and a solid lubricant and a chemical conversion coating forming agent are compounded
• the invention relates to an aqueous lubricant for cold forging working of metal which comprises (A) a water soluble inorganic salt, (B) a solid lubricant, (C) a at least one oil ingredient selected from mineral oil, vegetable or animal oil and synthetic oil, (D) a surfactant and (E) water, and wherein the solid lubricant and the oil are uniformly dispersed and emulsified.
• the invention relates to an aqueous non-reactive-type lubricant, and, therein, it is aimed to shorten the three steps of phosphating treatment-water washing-reactive-type soap treatment to one step of lubrication treatment alone.
• the aqueous non-reactive-type lubricant is contacted with a cleaned material to be wrought by immersion or the like to coat the surface of the material with the lubricant, and then dried (evaporation of water) to form lubricating coating on the surface of the material.
• Such type of lubricant is called one-step lubricant.
• the lubricant of the above invention is too unstable to be used industrially because it emulsifies an oil ingredient, and has not exerted stable lubricity in cold forging of large working degree or in tube drawing working where continuous heat load is imposed on the lubricating coating.
• a lubricant composition for plastic working of metallic material disclosed in JP 2000-63880 A and made by the present applicant.
• the invention relates to a lubricant composition for plastic working of metallic material which comprises (A) a synthetic resin, (B) a water soluble inorganic salt and water, and wherein the ratio by mass of (B)/(A) in terms of solid matter is 0.25/1 to 9/1 and the synthetic resin is dissolved or dispersed.
• stable lubricity has not been exerted in cold forging of large working degree or in tube drawing working where continuous heat load is imposed on the lubricating coating.
• the present invention is for solving problems which prior art (particularly prior art on the present invention as a fundamental invention) has, and aims to provide novel particles, as an ingredient used mainly in coating-type lubricating coating, which are excellent in seizure resistance, and can inhibit wear of tools at the time of plastic working due to a low friction coefficient of their surfaces, and are slow to cause pollution of working oil; such particles that, when the particles are incorporated into a lubricant layer, the lubricant layer can make itself firmly composite with the carrier layer so that the former layer may coat the latter layer; powder consisting of the particles; a suspension containing the particles; processes for preparing the powder or suspension; and lubricating coating containing the particles.
• the present inventors have intensely studied for solving the above problems (particularly Problem 1). As a result, they found that particles each of which consists of an inorganic polyvalent metal compound as a nucleus and a coating of a metallic soap of the polyvalent metal coating the nucleus, the inorganic polyvalent metal compound being water sparingly soluble or water insoluble and having reactivity with an alkali metal salt, ammonium salt or water soluble ester of a fatty acid; or particles each of which consists of each of the particles defined above and a coating of an alkali metal salt, ammonium salt or water soluble ester of a fatty acid coating the particle, when used mainly as an ingredient in coating-type lubricating coating, are very suitable as a material which is excellent in seizure resistance, can inhibit wear of tools at the time of plastic working due to a low friction coefficient of their surfaces, and is slow to cause pollution of working oil; and completed this invention.
• the invention relates to particles each of which consists of an inorganic polyvalent metal compound as a nucleus and a coating of a metallic soap of the polyvalent metal coating the surface of the nucleus, the inorganic polyvalent metal compound being water sparingly soluble or water insoluble and having reactivity with an alkali metal salt, ammonium salt or water soluble ester of a fatty acid (hereinafter, the above particles are sometimes referred to as two-layer particles); particles each of which consists of each of the particles defined above and a coating of an alkali metal salt, ammonium salt or water soluble ester of a fatty acid (hereinafter, the “alkali metal salt, ammonium salt or water soluble ester of a fatty acid” is sometimes referred to as “alkali soap or the like”) coating the surface of the particle (hereinafter, the above particles are sometimes referred to as three-layer particles); powder consisting of the particles; a suspension wherein the above particles are suspended in water or an aqueous
• the present invention is also for solving problems which prior art (particularly prior art on the present invention as a more practical applied invention) has. Namely, the invention aims to provide such a lubricating coating forming agent that protection of earthly environment is taken into consideration; convenient treatment by a spraying method or immersion method is possible; chemical conversion coating treatment is unnecessary; and resulting coating has excellent working performance and excellent seizure resistance equal to or more than those in chemical conversion coating treatment method, and, even when uniform application is difficult as mentioned above, exerts stable lubricating properties owing to self-repairing effect.
• the present invention have intensely studied for solving the above problems (particularly Problem 2), and as a result, they found that lubricating coating wherein cold forging working of large working degree is possible and which exerts good lubricity even in tube drawing working in which continuous heat load is imposed on the coating, can be obtained by a convenient treating method of applying, onto a material to be wrought, an aqueous solution containing particles each of which consists of a polyvalent metal salt of phosphoric acid as a nucleus and a coating of a metallic soap of the polyvalent metal coating the surface of the nucleus, and a water soluble inorganic salt and/or a water soluble organic acid salt, and drying the resulting wet coating; and further found that the above-mentioned particles have both seizure resistance and lubricity, and, therefore, even in a case as mentioned above where uniform coating is difficult, the particles are introduced into the tool by melted ingredients in the coating and exert self-repairing effect on the defect parts of the coating, and, finally, the coating exerts
• the invention relates to a lubricating coating forming agent wherein particles each of which consists of a water sparingly soluble or water insoluble polyvalent metal salt of phosphoric acid (hereinafter merely referred to as polyvalent metal salt of phosphoric acid) as a nucleus and a coating of a metallic soap of the polyvalent metal coating the surface of the nucleus (the particles being hereinafter referred to as particles of coated polyvalent metal salt of phosphoric acid) are suspended in an aqueous solution of a water soluble inorganic salt and/or a water soluble organic acid salt; each of the water soluble inorganic salt and organic acid salt having a property to form a firm coating when it is uniformly dissolved in water and the resulting solution is applied on a metallic material and dried.
• a lubricating coating forming agent wherein particles each of which consists of a water sparingly soluble or water insoluble polyvalent metal salt of phosphoric acid (hereinafter merely referred to as polyvalent metal salt of
• the above particles of coated polyvalent metal salt of phosphoric acid are included in the above-mentioned “two-layer particles” in the present invention as a fundamental invention.
• the inorganic polyvalent metal compound which is used for preparing the coated particles of the invention, and is water sparingly soluble or water insoluble and has reactivity with an alkali soap or the like is an important ingredient as a nucleus immobilizing the metallic soap layer in the coated particles of the invention.
• the inorganic polyvalent metal compound used in the invention is a granular substance usually supplied as powder or in a state dispersed in water.
• the inorganic polyvalent metal compound is not particularly limited, and includes oxides, hydroxides, carbonates, phosphates, oxalates, etc.
• Zn Zn, Fe, Mn, Ni, Co, Ca, Mg, Ba, Al and Sn are preferred also in the aspect of the industrial cost, and Zn is further preferred among them.
• the inorganic polyvalent metal compound there can be mentioned zinc phosphate, zinc oxide, iron zinc phosphate, iron phosphate (ferrous phosphate, ferric phosphate), iron oxalate, manganese phosphate, nickel phosphate, cobalt phosphate, calcium phosphate, calcium hydrogenphosphate, calcium oxide, calcium hydroxide, etc., and among them zinc phosphate and zinc oxide are particularly preferably used.
• the particle size of the inorganic polyvalent metal compound is preferably as small as possible for making the coated particles of lubricant use, and, specifically, is preferably 300 ⁇ m or less and more preferably 100 ⁇ m or less.
• the lower limit there is no particular limitation, but from a limitation on preparation, the order of 0.3 ⁇ m is usually a limit.
• the average particle size of the inorganic polyvalent metal compound is preferably 20 ⁇ m or less, and more preferably 10 ⁇ m or less. When the average particle size is more than 20 ⁇ m, it gets difficult to maintain stably the state dispersed in water.
• the metallic soap coating the inorganic polyvalent metal compound in the invention is a salt between the polyvalent metal and the fatty acid composing the alkali soap or the like, the salt being formed by reaction of the inorganic polyvalent metal compound with the alkali soap or the like.
• the metallic soap there can be mentioned salts between a polyvalent metal such as Zn, Fe, Mn, Ni, Co, Ca, Al or Sn and a saturated fatty acid or unsaturated fatty acid having preferably 8 to 22, more preferably 16 to 20 carbon atoms (for example, palmitic acid, stearic acid, eicosanoic acid, oleic acid, etc.), and zinc stearate is mentioned representatively.
• the proportion of the metallic soap coatings to all the coated particles is preferably 1 to 30% by mass, and more preferably 2 to 15% by mass.
• the coated particles of the invention also include particles each of which consists of a particle consisting of two layers of an inorganic polyvalent metal compound and a metallic soap of the polyvalent metal coating the metal compound, and a coating of an alkali soap or the like coating the particle.
• the particles consisting of these three layers the particles each of which consists of the inorganic polyvalent metal compound and the metallic soap of the polyvalent metal coating it may be the same as those mentioned above.
• the proportion of the coatings of the alkali soap or the like to all the particles is preferably 0.1 to 5% by mass, more preferably 0.1 to 3% by mass in view of minimizing the amount of water soluble ingredients for the purpose of heightening the heat resistance of the particles and maintaining stable lubricating properties.
• the alkali soap or the like is not only needed for preparing the two-layer particles, but itself forms the outmost layer of the three-layer particles.
• the alkali soap or the like used in the invention is an alkali metal salt, ammonium salt or water soluble ester of a fatty acid.
• fatty acid saturated fatty acids or unsaturated fatty acids having 8 to 22, particularly 16 to 20 carbon atoms are preferred, and there can specifically mentioned octanoic acid, decanoic acid, lauric acid, myristic acid, palmitic acid, stearic acid, eicosanoic acid, oleic acid, etc.
• As the alkali metal sodium, potassium and lithium are preferred.
• the water soluble ester there can be mentioned an ester obtained by ring-opening polymerizing ethylene oxide to the carboxyl group of the above fatty acid, etc.
• a sodium or potassium salt of palmitic acid, stearic acid or eicosanoic acid there can be mentioned a sodium or potassium salt of palmitic acid, stearic acid or eicosanoic acid, and most preferred among them is sodium stearate.
• Sodium stearate may include both pure one and one containing sodium salts of other fatty acids. As the latter sodium stearate, sodium stearate put on the market as C18 soap is mentioned, and its composition is 95% or more of sodium stearate, less than 3% of C 16 fatty acids and less than 1% of mixed C 15 and C 17 fatty acids.
• the present invention also relates to powder consisting of the above coated particles (namely, the above two-layer particles or three-layer particles).
• the present invention also relates to a suspension wherein the above two-layer particles are suspended in water or an aqueous solution of an alkali soap or the like, the average particle size of the particles of the inorganic polyvalent metal compound being 20 ⁇ m or less.
• the average particle size of the particles of the inorganic polyvalent metal compound in the two-layer particles is preferably 10 ⁇ m or less when the average particle size is more than 20 ⁇ m, it gets difficult to maintain the water suspension state stably.
• the proportion of metallic soap coatings to all the two-layer particles in the suspension is preferably 1 to 30% by mass, more preferably 2 to 15% by mass, as is the case of the above-mentioned two-layer particles.
• the proportion of the two-layer particles to the whole suspension is not particularly limited so long as stable suspension of the two-layer particles is maintained, but, usually, is preferably on the order of 1 to 50% by mass, more preferably on the order of 5 to 40% by mass.
• the powder of the invention can be obtained by suspending particles of the above inorganic polyvalent metal compound in an aqueous solution of an alkali soap or the like, stirring the resulting suspension under heating to form metallic soap coating on the surfaces of the particles of the inorganic polyvalent metal compound, and drying the suspension.
• the alkali soap or the like may be used so that the above-mentioned proportion of the metallic soap to the coated particles may be obtained, but, specifically, it is preferred that the mole ratio of the inorganic polyvalent metal compound:the alkali soap or the like is the range of 100:0.05 to 100:25.
• the amount of the alkali soap or the like is less than 100:0.05, the amount of the metallic soap layer gets extremely small, and expected effect tends not to be exerted sufficiently.
• the amount of the alkali soap or the like is more than 100:25, the efficiency of the coating reaction is extremely reduced to bring about economical disadvantage.
• the mole ratio of the inorganic polyvalent metal compound:the alkali soap or the like is preferably in the range of 100:0.25 to 100:15.
• the amount of the alkali soap or the like is less than 100:0.25, sufficient lubrication performance tends hard to obtain, and it is more than 100:15, such problems tend to occur that the foaming properties of the suspension gets high due to existence of a lot of unreacted alkali soap or the like, and so on.
• the temperature of the suspension is adjusted to 60° C. or more, particularly 70 to 100° C., and the pH to 9 or more, particularly 10 to 12.
• the mechanism of the reaction it is presumed that, on particles of the inorganic polyvalent metal compound, double decomposition reaction between the inorganic polyvalent metal compound and the alkali soap or the like takes place, and metallic soap layers coat the particles of the inorganic polyvalent metal compound as nuclei.
• hydroxides sodium hydroxide, potassium hydroxide, etc.
• carbonates sodium carbonate, potassium carbonate, etc.
• bicarbonates sodium bicarbonate, potassium bicarbonate, etc.
• alkali metal aqueous ammonia, etc.
• preferred among them is sodium hydroxide.
• the suspension is dried into powder, and the method of the drying may be a conventional one. For example, a method of filtering the suspension and drying the resulting solid, a method of spray drying the suspension, or the like can be adopted.
• Powder obtained by the above-mentioned process for preparing the powder of the invention is, usually, powder of three-layer particles consisting of the inorganic polyvalent metal compound, the metallic soap and the alkali soap or the like.
• Powder of two-layer particles consisting of the inorganic polyvalent metal compound and the metallic soap can be prepared by washing away the alkali soap or the like composing the outermost layer of the three-layer particles obtained in a way as mentioned above, with hot water, aqueous alcohol solution or the like.
• the suspension of the invention can be obtained by suspending particles of the inorganic polyvalent metal compound in an aqueous solution of an alkali soap or the like, and stirring the suspension under heating to form metallic soap coating on the surfaces of the particles of the inorganic polyvalent metal compound.
• the particle size of the particles of the inorganic polyvalent metal compound needs to be adjusted to 20 ⁇ m or less, and is preferably adjusted to 10 ⁇ m or less.
• the use amount of the alkali soap or the like to the inorganic polyvalent metal compound, the temperature and pH of the suspension for accelerating the reaction, and additives for making the pH the above-mentioned alkaline side may be the same as in the case of the preparation of the powder of the invention.
• the powder and suspension relating to the metallic soap of the invention exert excellent performance as lubricants used in the cold plastic working field, etc.
• coating formed by making the powder or suspension of the invention adhering to the surface of a material to be subjected to cold plastic working shows excellent performance as lubricating coating for cold plastic working.
• the powder of suspension when used for forming lubricating coating, the powder or suspension alone can be made into coating, but it can also be made into coating together with other general ingredients such as lubricating waxes, solid lubricants, extremely pressure additives, coating forming resins and/or viscosity adjusting agents.
• a lubricating oil containing a mineral oil or palm oil as a main ingredient or a olefin wax or high molecular wax which melts and is liquidized at the time of working, it is possible to give the latter (i.e., the lubricating oil, etc.) excellent seizure resistance.
• the compounding is preferably made so that the content of the powder or the solid matter in the suspension in the resulting coating may be 1% by mass or more, particularly 5% by mass or more.
• the compounding proportion of the powder or the solid matter in the suspension is less than 1% by mass, it is impossible to give the lubricating coating sufficient seizure resistance.
• the dry coating thickness of the lubricating coating is preferably made to be in the range of 0.5 to 50 ⁇ m, more preferably made to be in the range of 1.0 to 30 ⁇ m.
• the coating thickness is less than 0.5 ⁇ m, there is an anxiety that, especially in the strong working field, sufficient seizure resistance cannot be obtained to cause poor working. Further, the coating thickness of more than 50 ⁇ m is superfluous and only increases the amount of the coating peeling away at introduction into the tool, and, thus, tends to bring about economical disadvantage.
• a method for forming, on the surface of a material to be wrought, lubricating coating containing the powder or solid matter in the suspension of the invention is not particularly limited, and a conventional method can be adopted.
• lubricating coating can be obtained by making the aqueous suspension adhere onto the surface of the material by immersion treatment, spraying, roll coater treatment or the like, and then drying the resulting wet coating by natural seasoning, compulsory hot air drying or the like.
• the powder of the invention can be made to adhere by a powder box method, an electrostatic coating method or the like, and an electrostatic coating method is particularly preferred because control of adhesion properties and adhesion amount is easy and stable and uniform lubricating coating can be obtained. It is also possible to mix a resin ingredient or wax ingredient having a low melting point, when the powder is made to adhere, for preventing peeling of the powder from the surface of the material to be wrought, and then heat the material to be wrought to immobilize the powder. It is also possible to mix powder of soap, metallic soap, wax, resin or the like for supplement of lubricity.
• lubricating coating of a continuous coating state through working heat and pressure, by, after making the powder of the invention adhere, subjecting the material to be wrought to light plastic working of the order of skin pass; and the operation is preferred since the resulting coating is coating further excellent in lubrication performance and barrier performance such as corrosion resistance.
• lubricating coating obtained by a combination of electrostatic coating method and light plastic working of the order of skin pass is equal to “coating of phosphating treatment plus soap treatment” in all performance aspects.
• coating obtained after mixing the powder with a high molecular synthetic wax in a ratio by mass of preferably 1:9 to 9:1, more preferably 1:1 to 9:1 is excellent in lubricity, oil resistance, etc.
• the particles of the invention each of which consists of a polyvalent metal salt of phosphoric acid as a nucleus and a metallic soap of the polyvalent metal coating the nucleus, namely particles of coated polyvalent metal salt of phosphoric acid give the resulting coating heat resistance and lubricity. It is necessary for a polyvalent metal salt of phosphoric acid to be selected to be sparingly soluble or insoluble in water.
• a polyvalent metal salt of phosphoric acid there can be mentioned Zn, Fe, Mn, Ni, Co, Ca, Mg, Ba, Al and Sn, and further preferred among them are Zn, Fe and Ca.
• the polyvalent metal salt of phosphoric acid there can be mentioned zinc phosphate, iron zinc phosphate, iron phosphate (ferrous phosphate, ferric phosphate), manganese phosphate, nickel phosphate, cobalt phosphate, calcium phosphate, calcium hydrogenphosphate, magnesium phosphate, magnesium hydrogenphosphate, barium phosphate, barium hydrogenphosphate, aluminum phosphate, tin phosphate, etc., and preferred among them are zinc phosphate, iron zinc phosphate, iron phosphate (ferrous phosphate, ferric phosphate), calcium phosphate and calcium hydrogenphosphate. These can be used alone or in combination of two or more.
• the particles of the coated polyvalent metal salt of phosphoric acid exist in coating obtained by applying the lubricating coating forming agent of the invention onto a metallic material to be subjected to cold plastic working, and give the metallic material seizure resistance and lubricity; and, after being introduced into a die by melted coating ingredients at the time of working, exert an action to repair coating defects, namely a self-repairing action.
• the average particle size of the particles of the coated polyvalent metal salt of phosphoric acid is preferably 30 ⁇ m or less, more preferably 0.3 to 30 ⁇ m and still more preferably 0.5 to 20 ⁇ m.
• the average particle size of the polyvalent metal salt of phosphoric acid in the particles of the coated polyvalent metal salt of phosphoric acid is preferably 20 ⁇ m or less, more preferably 0.2 to 20 ⁇ m and still more preferably 0.4 to 10 ⁇ m. Furthermore, for giving sufficient lubricity, the proportion by mass of the metallic soap coatings to all the particles of the coated polyvalent metal salt of phosphoric acid is preferably 1 to 30%, more preferably 2 to 15%.
• the particles of the coated polyvalent metal salt of phosphoric acid are included in “two-layer particles” in the present invention particularly as a fundamental invention, and can be prepared in a similar way as in the two-layer particles.
• the water soluble inorganic salt needs to have not only a property to give the lubricating coating hardness but also a property to immobilize the particles of the coated polyvalent metal salt of phosphoric acid in the coating.
• a water soluble inorganic salt selected therefor needs to have a property to dissolve in water uniformly and, when the solution is applied onto a metallic material and dried, form firm coating. It is preferred to use, as the water soluble inorganic salt having such properties, at least one selected from the group consisting of alkali metal salts of sulfuric acid, alkali metal salts of silicic acid and alkali metal salts of boric acid.
• alkali metal salts of sulfuric acid alkali metal salts of silicic acid and alkali metal salts of boric acid.
• sodium sulfate, potassium sulfate, sodium silicate, potassium silicate, sodium borate, potassium borate, etc. there can be mentioned sodium sulfate, potassium sulfate, sodium silicate, potassium silicate
• the water soluble organic acid salt needs to have a property not only to give hardness to the lubricating coating, but to immobilize the particles of the coated polyvalent metal salt of phosphoric acid in the coating.
• a water soluble organic acid salt selected therefor needs to have a property to dissolve in water uniformly and, when the solution is applied onto a metallic material and dried, form firm coating. It is preferred to use, as the water soluble organic acid salt having such properties, at least one selected from the group consisting of alkali metal salts of malic acid, alkali metal salts of succinic acid, alkali metal salts of citric acid and alkali metal salts of tartaric acid. As more specific examples thereof, there can be mentioned sodium malate, potassium malate, sodium succinate, potassium succinate, sodium citrate, potassium citrate, sodium tartrate, potassium tartrate, etc.
• the compounding proportion between the particles of the coated polyvalent metal salt of phosphoric acid (A) and the total of the water soluble inorganic salt and the water soluble organic acid salt (B) as a ratio by mass in solid matter of (B)/(A) is preferably 0.01 to 20.0, more preferably 0.01 to 16.0 and still more preferably 0.01 to 7.5. At less than 0.01, the particles of the coated polyvalent metal salt of phosphoric acid are not immobilized in the coating, the water soluble inorganic salt of the lubricating coating is not drawn into the tool against shear onto the coating at the time of working, and seizure resistance gets insufficient.
• the lubricating coating forming agent of the invention may contain a smectite clay mineral according to necessity, and it is usually preferred to incorporate it.
• the smectite clay mineral used in the invention is a clay mineral having the following general formula. (“Clay Handbook 2nd edition” edited by Japan Clay Society and published by Gihodo Publishing CO., Ltd., pages 58-66, 1987 ): X m (Y 2+ , Y 3+ ) 2-3 Z 4 O 10 (OH) 2 .nH 2 O wherein X is at least one of K, Na, 1 ⁇ 2 Ca and 1 ⁇ 2 Mg, m is 0.25 to 0.6, Y 2+ is at least one of Mg 2+ , Fe 2+ , Mn 2+ , Ni 2+ , Zn 2+ and Li + , Y 3+ is at least one of Al 3+ , Fe 3+ , Mn 3+ and Cr 3+ , Z is at least one of Si and Al, and nH 2 O is water
• Y 2+ , Y 3+ in (Y 2+ , Y 3+ ) means Y 2+ and/or Y 3+ .
• X represents a cation among the layers
• Y is a cation of the octahedron
• Z is a cation of the tetrahedron.
• the smectite clay mineral used in the invention needs to have a property to give dispersion stability in liquid to the particles of the coated polyvalent metal salt of phosphoric acid and stabilize distribution of the particles in the coating. Therefor, formation of stable sol in an aqueous phase and increase of viscosity accompanying sharp increase of the concentrations of the contained ingredients get necessary.
• Smectite clay minerals generally show the above-mentioned properties when dispersed in an aqueous phase, and as smectite clay minerals having such properties, it is preferred to use at least one selected from the group consisting of hectorite, montmorillonite, beidellite, nontronite, saponite, iron saponite, stevensite and sauconite. Smectite clay minerals can be obtained not only as natural resources but as synthetic ones, and both can be used in the invention.
• the compounding proportion of the smectite clay mineral as s a ratio by mass in terms of solid matter of (C)/(A) wherein (A) are the particles of the coated polyvalent metal salt of phosphoric acid and (C) is the smectite clay mineral is preferably 0.005 to 0.5, more preferably 0.01 to 0.4. At less than 0.005, an effect to improve the dispersion stability of the particles of the coated polyvalent metal salt of phosphoric acid in the liquid and an effect to stabilize the distribution in the coating are not sufficient, and at more than 0.5, the lubricating coating forming agent gets a paste state to make its stable use difficult.
• the lubricating coating forming agent of the invention may contain an auxiliary lubricant according to necessity, and, usually, it is preferred to incorporate it in the agent.
• the auxiliary lubricant needs to have an action to lower the friction coefficient of lubricating coating formed by the lubricating coating forming agent of the invention, and, as a melt carrier introducing the particles of the coated polyvalent metal salt of phosphoric acid between the material to be wrought and the tool, help the self-repairing effect of the coating.
• the auxiliary lubricant as one which melts with heat generated at the time of plastic working to give the coating slipping properties and acts as a melt carrier, is preferably at least one selected from the group consisting of oil, soap, metallic soap, wax and polytetrafluoroethylene.
• the oil there can be used vegetable oils, synthetic oils, mineral oils, etc., and there can, for example, be mentioned palm oil, castor oil, rapeseed oil, machine oil, turbine oil, spindle oil, ester oil, silicone oil, etc.
• the soap is an alkali metal salt of a fatty acid, and there can, for example, be mentioned sodium salts, potassium salts, etc. of saturated or unsatureated fatty acids having 8 to 22 carbon atoms such as octanoic acid, decanoic acid, lauric acid, myristic acid, palmitic acid, stearic acid, eicosanoic acid and oleic acid.
• the metallic soap there can be mentioned salts of polyvalent metals such as calcium, zinc, magnesium and barium with the above-mentioned fatty acids.
• the wax there can be mentioned polyethylene wax, polypropylene wax, carnauba wax, paraffin wax, etc.
• polytetrafluoroethylene there can be mentioned polytetrafluoroethylene having a molecular weight of the order of 1,000,000 to 10,000,000. It is preferred that such an auxiliary lubricant is incorporated in the lubricating coating forming agent by mixing it in the form of aqueous emulsion or aqueous dispersion with other ingredients.
• the auxiliary lubricant is usually dispersed or emulsified in the lubricating coating forming agent of the invention.
• the compounding proportion of the auxiliary lubricant as s a ratio by mass in terms of solid matter of (D)/(A) wherein (A) are the particles of the coated polyvalent metal salt of phosphoric acid and (D) is the auxiliary lubricant is preferably 0.03 to 18.0, more preferably 0.05 to 15.0 and still more preferably 0.5 to 5.0.
• the friction coefficient of the lubricating coating is increased and the effect to act as a melt carrier is not sufficient, and at more than 18.0, the coating is softened, and the coating tends to be broken because it gets incapable of withstanding shearing force thereon at the time of working.
• the lubricating coating forming agent of the invention may contain an organic high molecular compound according to necessity. It is preferred that the organic high molecular compound is water soluble or water dispersible and has a weight average molecular weight of 1,000 to 1,000,000.
• the organic high molecular compound needs to have an action to give coating strength to lubricating coating formed using the lubricating coating forming agent.
• the organic high molecular compound is not particularly limited so long as it has coating formability, and there can, for example, be mentioned resin as a polymer of ethylenically unsaturated monomer(s) (particularly, acrylic resin), urethane resin, epoxy resin, phenol resin, hydroxymethylcellulose, carboxymethylcellulose, etc.
• such an organic high molecular compound is incorporated in the lubricating coating forming agent by mixing it in the form of aqueous emulsion or aqueous dispersion with other ingredients.
• the organic high molecular compound is added into the lubricating coating forming agent so that its content can be preferably 0.5 to 25% by mass, more preferably 1.0 to 15% by mass based on the whole solid matter including itself.
• a solid lubricant in the lubricating coating forming agent.
• the solid lubricant in such a case, one existing stably in the coating and capable of assisting lubrication at a high load is preferred.
• solid lubricants there can be mentioned graphite, molybdenum disulfide, boron nitride, fluorinated graphite, mica, etc.
• an extremely pressure additive in the lubricating coating forming agent.
• the extremely pressure additive in such a case, one existing stably in the coating and capable of exerting extreme-pressure effect at the contact surface between the tool and the metal is preferred.
• sulfur containing extremely pressure additives there can be mentioned sulfur containing extremely pressure additives, organomolybdenum extremely pressure additives, phosphorus containing extremely pressure additives and chlorine containing extremely pressure additives such as sulfurized olefins, sulfurized esters, sulfites, thiocarbonates, chlorinated fatty acids, phosphoric esters, phosphorous esters, molybdenum dithiocarbamate (MoDTC), molybdenum dithiophophate (MoDTP) and zinc dithiophosphate (ZnDTP).
• sulfurized olefins sulfurized esters, sulfites, thiocarbonates, chlorinated fatty acids, phosphoric esters, phosphorous esters
• MoDTC molybdenum dithiocarbamate
• MoDTP molybdenum dithiophophate
• ZnDTP zinc dithiophosphate
• a dispersant When a dispersant is necessary to disperse or emulsify the particles of the coated polyvalent metal salt of phosphoric acid, the auxiliary lubricant, and/or the solid lubricant and/or extremely pressure additives, as such a dispersant, there can be used a dispersant selected from nonionic surfactants, anionic surfactants, amphoteric surfactants, cationic surfactants, water soluble high molecular dispersants and so on.
• the agent can be obtained by adding particles of a coated polyvalent metal salt of phosphoric acid, and, as optional ingredients, a smectite clay mineral, an auxiliary lubricant, and/or a solid lubricant and/or an extremely pressure additive, if necessary after being made into a dispersion or emulsion using a dispersant and water, into an aqueous solution of a water soluble inorganic salt and/or a water soluble organic acid salt; and then stirring the resulting mixture.
• the solid matter concentration of the lubricating coating forming agent is not particularly limited so long as the lubricating coating forming agent prepared meets the above-mentioned conditions, but, in view of handling properties and stability of the lubricating coating forming agent, the solid matter concentration is preferably 1 to 80% by mass, more preferably 10 to 60% by mass.
• the lubricating coating forming agent of the invention can be used as a lubricant used when a metallic material such as iron or steel, stainless steel, plated steel (for example, steel subjected to plating treatment such as electrogalvanizing, molten zinc plating, aluminum zinc plating, aluminum plating or iron zinc plating), aluminum or aluminum alloy, magnesium alloy, tin or tin alloy, titanium or titanium alloy, or copper or copper alloy is subjected to cold plastic working such as forging, wire drawing, tube reducing or sheet forming.
• a metallic material such as iron or steel, stainless steel, plated steel (for example, steel subjected to plating treatment such as electrogalvanizing, molten zinc plating, aluminum zinc plating, aluminum plating or iron zinc plating), aluminum or aluminum alloy, magnesium alloy, tin or tin alloy, titanium or titanium alloy, or copper or copper alloy is subjected to cold plastic working such as forging, wire drawing, tube reducing or sheet forming.
• a metallic material such as iron or steel, stainless steel
• pretreat a metallic material to be worked in order of cleaning usually, an alkali cleaner is used
• water washing usually, descaling (shot blasting or acid washing with hydrochloric acid or the like)
• descaling shot blasting or acid washing with hydrochloric acid or the like
• water washing can be carried out by conventional ways.
• the lubricating coating forming agent of the invention is applied to the surface of a metallic material by a conventional method such as immersion, spraying or .
• the application is carried out until the metal surface is sufficiently coated with the lubricating coating forming agent, and there is no particular limitation on time of the application.
• the lubricating coating forming agent needs to be dried.
• the drying may be made by allowing the coating to stand at ordinary temperature, but, usually, is preferably made at 60 to 150° C. for 10 to 60 minutes.
• the coating mass of the lubricating coating forming agent is preferably 1 g/m 2 or more, more preferably 3 to 30 g/m 2 .
• Lubricating coating obtained from the lubricating coating forming agent of the invention shows stable cold plastic working performance because the particles of the coated polyvalent metal salt of phosphoric acid having good seizure resistance and slipping properties are uniformly held in the coating by immobilizing effect of the water soluble inorganic salt and/or the water soluble organic acid salt, and the smectite clay mineral.
• the lubricating coating shows stable lubricity, even in tube drawing working such as tube reducing or wire drawing wherein lubricating coating forming treatment is, usually, carried out in such a state such as a banded state or a coiled state that the resulting coating is liable to be ununiform.
• the present invention is further specifically described below together with its effects, by giving examples of the invention together with comparative examples.
• a suspension and powder of metallic soap-coated particles were prepared according to the processes shown below. For confirming that coated particles, wherein nuclei of the inorganic polyvalent metal compound are coated with coatings of the metallic soap, are prepared, soap ingredients in the powder prepared or soap ingredients in the powder obtained by drying the suspension prepared were separated into alkali soap or the like dissolving in an aqueous ethanol solution and metallic soap not dissolving therein, and the mass of each was measured, whereby formation of metallic soap was confirmed.
• the above method is explained in more detail below.
• One gram of a powder sample was stirred in aqueous 50% ethanol solution for 4 hours, and the mixture was filtered with filter paper.
• the filtrate and the residue were heated in 1N hydrochloric acid, respectively, to decompose the soap ingredients into fatty acid(s).
• the proportion of metallic soap formation is 50% or more, it was judged that the nuclei surfaces were coated with a sufficient amount of metallic soap layers.
• Evaluation criterion A: the suspended matter is completely precipitated, and the transparent layer occupies 95% or more of the whole volume.
• compositions of the lubricating coatings of Examples I-3 to I-9 obtained by using, as lubricating coating forming materials, the suspension of the metallic soap-coated particles of the invention prepared in the above or the powders of the metallic soap-coated particles of the invention prepared in the above, and the compositions of the lubricating coatings of Comparative examples I-3 to I-7 not using suspension of metallic soap-coated particles nor powder of metallic soap-coated particles of the present invention are shown in Table 2.
• Lubricating coating forming materials used in the present test are shown below.
• a test piece whose surface was cleaned was immersed in lubricating coating forming suspension of ordinary temperature to make the suspension adhere thereon, and was subjected to drying in a hot air drying furnace of 100° C. to form lubricating coating on the surface of the test piece.
• the amount of the dry coating adhering was about 15 g/m 2 .
• a test piece whose surface was cleaned was electrostatically coated with lubricating coating forming powder to form lubricating coating in a powder adhesion state on the surface of the test piece.
• GX300 made by Nihon Parkerizing Co., Ltd was used, and the lubricating coating forming powder was charged at a voltage of 60 kV.
• Adhesion of the charged lubricating coating forming powder on the surface of the test piece by an electrostatic coating method was carried out using an electrostatic coating gun GX116 made by Nihon Parkerizing Co., Ltd. Air pressures for supply of the powder in this operation were 98 kPa as the main air pressure and 196 kPa as the sub-air pressure.
• the coating time was 1 second, and the amount of the powder coating adhering was about 15 g/m 2 .
• Spike test working was made according to the method disclosed in JP 5-7969 A, and lubricity was evaluated by the spike height of the test piece after the working. The higher the spike height is, the better the lubricity is.
• Test piece A material used for the test was annealed S45C material which was made spherical and commercially available, and the shape of the test piece was 25 mm ⁇ in diameter and 30 mm in height.
• Test piece A material used for the test was SCr440 material on the market, and the shape of the test piece was 9.5 mm ⁇ in diameter and 1 m in length.
• the coated particles of the invention consisting of an inorganic polyvalent metal compound as a nucleus, and metallic soap coating or metallic soap coating plus coating of alkali soap or the like on it coating the nucleus, are mainly used as ingredients for coating type lubricating coating, and are suitable as materials which are excellent in seizure resistance, and, because of their low surface friction coefficient, can inhibit wear of tools at the time of plastic working, and do not easily cause pollution of working oil. Therefore, the industrial utility value of the present invention is extremely great.
• Lubricating coating forming agents of ingredients and their compositions shown in Table 4 were prepared.
• a lubricating coating forming agent was made so that the respective ingredients got to be the ratios of Table 4.
• the procedure of the preparation is as follows. First, the water soluble inorganic salt was dissolved in water, and then the smectite clay mineral was incorporated in the solution and uniformly dispersed. Thereafter, the above suspension of particles of coated polyvalent metal salt of phosphoric acid was incorporated in the suspension, and then the auxiliary lubricant was added, and the mixture was stirred to prepare the lubricating coating forming agent of Example II-1.
• the polyvalent metal salt of phosphoric acid is zinc phosphate (solid)
• the water soluble inorganic salt is aqueous 50% by mass sodium silicate dispersion
• the smectite clay mineral is montmorillonite (solid).
• the lubricating coating forming agents of Examples II-2 to II-12 and Comparative examples II-1 to II-7 were prepared in the similar manner as above.
• the lubricating coating forming agents of Comparative example II-8 is an existing coating-type lubricating coating forming agent, and the lubricating coating forming agent of Comparative example II-9 is a phosphate salt plus soap treating agent on the market.
• coating forming treatment was made according to the following steps.
• a friction coefficient measurement test was made, after the above coating forming treatment, according to a Bowden test which is the most standard friction coefficient measurement test. Since, in the Bowden test, there is a stable stage of friction coefficient after initial sliding, the friction coefficient at the stable stage was regarded as the friction coefficient of the lubricating coating. Measurement conditions in the test are as follows.
• a forging test was made by a backward piercing test.
• the backward piercing test is such a test that cylindrical test pieces are subjected to backward piercing working wherein punches are knocked into the test pieces, the heights of the test pieces are varied from 18 mm up to 40 mm by every 2 millimeters, and possible working degree is determined.
• seizure resistance is insufficient, flaws due to seizure are formed on the internal surfaces of the test pieces and on the punches. These flaws were checked by visual observation, and the highest height of the test pieces where no flaw is formed was evaluated as showing the lubricity of a lubricating coating forming agent.
• the treatment was carried out both by a method of treating test pieces separately one by one (one piece treatment) and by a method of treating plural pieces together in a rotary barrel (barrel treatment). Evaluation criterion is shown below. A and B are practical levels.
• a tube reducing test was made by carrying out tube reducing working under the following conditions and making evaluation by such limiting reduction in area that no seizure was formed.
• the limiting reduction in area was assumed to be such reduction in area that three pipes were subjected to the tube reducing working and all the three pipes could be worked.
• the treatment was carried out both by a method of treating pipes separately one by one (one pipe treatment) and by a method of treating three pipes in a bundled state (bundle treatment). Evaluation criterion is shown below. A and B are practical levels.
• a wire drawing test was made by carrying out wire drawing working under the following conditions and making evaluation by such limiting wire drawing velocity that stable wire drawing was possible.
• the coating treatment was carried out both by a method of extremely loosing the bundled state of the wire rod coil so that the wire rods could not contact mutually (a method of stretching the coil into a spring state; one rod treatment) and by a method of treating the wire rod coil in a bundled state so as to promote contact among the wire rods (bundled treatment). Evaluation criterion is shown below. A and B are practical levels.
• Comparative examples II-3 and II-4 where the surfaces of particles of the polyvalent metal salt of phosphoric acid were not coated with metallic soap, since the friction coefficients of the particles were high and the self-repairing effect of the resulting coatings was not exerted, lubricity was not stable in the barrel treatment and the bundled treatment.
• the lubricating coating forming agents of Comparative examples II-5 and II-6 where calcium hydroxide or iron oxalate poor in solubility in water was used in place of a water soluble inorganic salt or a water soluble organic acid salt could not form continuous coating, and the resulting coatings are low in lubricity.
• the lubricating coating forming agent of the invention because of containing particles of a coated polyvalent metal salt of phosphoric acid and a water soluble inorganic salt, can prevent lowering of lubricity owing to ununiform coating which was the most difficult problem of coating-type lubricating coating forming agent, and can realize stable lubricity.
• Ingredient B is sodium tetraborate
• Ingredient D is calcium stearate
• Ingredient E is urethane resin (made by Dai-ichi Kogyo Seiyaku Co., Ltd.; Superflex 110). *11
• Ingredient (E) a phenol resin (made by Gunei Kagaku Co., Ltd.; Resitop PL-6020) was used in Example 9, and an urethane resin (made by Dai-ichi Kogyo Seiyaku Co., Ltd.; Superflex 110) in Example 12.
• the # phenol resin and the urethane resin were used in amounts of 7.0% by mass and 8.5% by mass, respectively, based on the total of Ingredients (A) to (E), in terms of solid matter.
• Lubricating coatings obtained by applying the lubricating coating forming agent of the invention onto the surfaces of various metallic materials give the metallic materials excellent cold plastic working properties, namely excellent lubricity and excellent seizure resistance.
• the lubricating coating forming agent of the invention can give metallic materials excellent working performance even in barrel treatment and bundled treatment where it has been difficult for conventional coating-type lubricating coating forming agent to give stable working performance.

Landscapes

• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• General Chemical & Material Sciences (AREA)
• Oil, Petroleum & Natural Gas (AREA)
• Organic Chemistry (AREA)
• Lubricants (AREA)
• Metal Extraction Processes (AREA)

Priority Applications (1)

Applications Claiming Priority (3)

Related Child Applications (1)

Publications (1)

Family

ID=28449192

Family Applications (2)

Family Applications After (1)

Country Status (6)

Cited By (8)

Families Citing this family (13)

Citations (13)

Family Cites Families (13)

• 2003
  • 2003-03-24 JP JP2003578504A patent/JP3939700B2/ja not_active Expired - Lifetime
  • 2003-03-24 US US10/508,999 patent/US20050119133A1/en not_active Abandoned
  • 2003-03-24 EP EP03720889.9A patent/EP1491615B1/en not_active Expired - Lifetime
  • 2003-03-24 CN CNB038062658A patent/CN100510039C/zh not_active Expired - Lifetime
  • 2003-03-24 WO PCT/JP2003/003511 patent/WO2003080774A1/ja active Application Filing
  • 2003-03-24 AU AU2003236059A patent/AU2003236059A1/en not_active Abandoned
• 2009
  • 2009-03-11 US US12/382,215 patent/US7879772B2/en not_active Expired - Fee Related

Patent Citations (13)

Also Published As

Similar Documents

Legal Events