US20240166968A1

US20240166968A1 - One-step pretreatment method of metallic substrates at non-neutral ph values for metal cold forming

Info

Publication number: US20240166968A1
Application number: US18/549,258
Authority: US
Inventors: Yinfeng Shi; Martin Orben
Original assignee: Chemetall Asia Pte Ltd; Chemetall GmbH
Current assignee: Chemetall GmbH
Priority date: 2021-04-01
Filing date: 2022-04-01
Publication date: 2024-05-23
Also published as: WO2022207901A1; CN117178077A; BR112023019649A2; MX2023011416A; CA3213974A1; EP4314385A1

Abstract

Disclosed herein is a method of pretreatment of a metallic substrate for a subsequent metal cold forming process. The method includes at least steps (1) and (2), namely providing at least one substrate having at least one surface at least partially made of at least one metal (step (1)), contacting the at least one surface of the substrate provided in step (1) with an aqueous lubricant composition (B) (step (2)), where the aqueous lubricant composition (B) includes besides water at least constituents (b1) to (b4) and optionally (b5).

Further disclosed herein are a pretreated metallic substrate obtained by the method, a method of cold forming of a metallic substrate, and an aqueous lubricant composition (B).

Description

The present invention relates to a method of pretreatment of a metallic substrate for a subsequent metal cold forming process, said method comprising at least steps (1) and (2), namely providing at least one substrate having at least one surface at least partially made of at least one metal (step (1)), contacting the at least one surface of the substrate provided in step (1) with an aqueous lubricant composition (B) (step (2)), wherein the aqueous lubricant composition (B) comprises besides water at least constituents (b1) to (b4) and optionally (b5), namely as (b1) at least one homopolymer and/or copolymer being prepared by polymerization of at least vinyl pyrrolidone as at least one monomer, wherein (b1) has a polydispersity index (PDI) in a range of from 1.5 to 8.0, as (b2) at least one wax, as (b3) at least one defoamer, and as (b4) (i) oxalate anions and/or phosphate anions or (ii) calcium cations, chloride anions and hydroxide anions, as well as optionally Fe(III) ions as (b5), wherein (b5) is present in case at least oxalate anions are present as (b4), a pretreated metallic substrate obtainable by the inventive method, a method of cold forming of a metallic substrate, and an aqueous lubricant composition (B) as defined above.

BACKGROUND OF THE INVENTION

Cold forming of metallic workpieces is conventionally achieved by rolling such as thread rolling, drawing, in particular sliding drawing or deep-drawing, pressing, stretch forming and/or cold upsetting of the workpieces in order to transform them into articles having a desired shape. Cold forming usually takes place at temperatures below the recrystallization temperature of the metallic material of the workpiece subjected to cold forming, such as at temperatures below and up to 450° C. No external heating source is used in the method of cold forming. Instead, any heat development or temperature increase in general is caused solely by frictional forces between the metallic workpiece and the work tools used during forming and due to internal friction forces generated by material flow in the workpiece. Cold forming usually results in an increased pressure, e.g. for steel, for example in the range of from 200 MPa to 1 GPa and sometimes even up to 2 GPa. The temperature of the workpieces to be cold formed is initially at ambient temperature, i.e., at approximately 10 to 32° C. In case the workpieces are pre-heated prior to forming, for example to a temperature in the range from 650 to 1250° C., the forming process is no longer a “cold forming” process, but rather a “semi-hot” forming, a hot forming or a forging process.
If the metallic workpieces are cold formed to shaped articles with a comparably only low degree of deformation rather low forces for the cold forming process to take place are needed. For this purpose, conventionally non-reactive forming oils are applied to the workpieces. At higher degrees of deformation, however, usually first a conversion coating layer is applied onto the surfaces of the workpieces and then a further lubricant layer is applied on top prior to the cold forming process in order to prevent a cold welding during the cold forming. Such two-steps-processes are e.g. disclosed in EP 0 232 929 A1, WO 94/16119 A1, WO 2009/095373 A1, WO 2009/095375 A1, WO 2009/095374 A1 and JP S56 72090 A.
EP 0 232 929 A1 relates to a two-step pretreatment method for facilitating a subsequent cold forming of stainless steel substrates. In a first step an oxalate coating is applied onto the substrate by making use of a solution containing inter alia oxalic acid as well as a water-soluble polymer. Afterwards, in a second step a lubricant is applied onto the oxalate coating. Metal soaps are named as suitable lubricants in EP 0 232 929 A1. WO 94/16119 A1 discloses a liquid aqueous composition for forming a conversion coating on metal surfaces in a first step for a subsequent cold forming process. The composition comprises an organic cationic polymer and may further comprise oxalate anions. In a second step a lubricating film can be applied onto the conversion film by making use of inter alia oil-based lubricants and/or soaps. WO 2009/095373 A1 discloses a two-step pretreatment method for facilitating a subsequent cold forming of metal substrates. In a first step a phosphate layer on the surface of the workpiece is formed by using an aqueous acidic phosphatizing solution containing Ca, Mg and/or K cations. In a second step, an aqueous alkaline lubricant composition containing organic polymers is applied. WO 2009/095375 A1 and WO 2009/095374 A1 both disclose a method for the preparation of metallic workpieces for cold forming. A lubricant coating layer is applied onto the metallic surface of the workpieces optionally bearing a conversion coating layer as separating layer by contacting the surface with an aqueous lubricant composition comprising at least one water-soluble, water-containing or water-binding oxide and/or silicate and an organic polymer in case of WO 2009/095375 A1 or by contacting the surface with an aqueous lubricant composition comprising at least two waxes and an organic polymer in case of WO 2009/095374 A1. Finally, JP S56 72090 A relates to a two-step pretreatment method for facilitating a subsequent cold forming of steel substrates. An oxalate coating is applied for this purpose onto the substrates in a first step. The oxalate coating is obtained by making use of a solution containing inter alia oxalic acid and a water-soluble organic titanium compound as well as a polyvinyl pyrrolidone. In a second step, a lubricant is applied onto the oxalate coating. Metal soaps and solid lubricants are named as suitable lubricants in JP S56 72090 A.
There are, however, several drawbacks as far as these processes known in the prior art are concerned. First of all, both for ecologic reasons and in order to avoid the formation of undesired phosphorous-induced delta ferrite on the substrate, it is desired to not use phosphate coating films as conversion coating films such as the conversion coating films applied in the process disclosed in WO 2009/095373 A1, but to rather only use phosphate-free systems. As far as the lubricant compositions known from the prior art are concerned, oil-based lubricant compositions in general lead to a higher VOC-content, since considerable amounts of oil can evaporate during their use. In addition, oil-based lubricant systems may cause safety issues, as they are flammable and must be stored at flash points >150° C. as hazardous materials. For these reasons, the use of oil-based lubricant formulations is undesired. Solid lubricants such as lubricants based on MoS₂and/or graphite are only feasible for heavy cold forming with extensive degrees of deformation and thus, such lubricants are of limited use only. Furthermore, sulfide present in such lubricant films often has a detrimental effect in particular on stainless steel. The use of aqueous lubricant compositions is thus more desirable both for ecologic and economic reasons than using solid and/or oil-based lubricants.
Conventional aqueous lubricant compositions of the prior art are, however, usually alkaline compositions such as the (metal) soaps and soap solutions disclosed in EP 0 232 929 A1, WO 2009/095373 A1, WO 2009/095375 A1, WO 2009/095374 A1 and JP S56 72090 A, which are for example based on alkali or earth alkali stearate. These are only stable under alkaline conditions and are, e.g., not stable in an acidic medium. Further, the alkaline lubricant compositions of the prior art often have only comparably short lifetimes and thus have to be renewed rather frequently. This, of course, is disadvantageous both from an ecological view (higher amounts of water and of the constituents present in the compositions have to be used) and an economic view (higher energy costs and changeover time). In contrast to these aqueous alkaline lubricant compositions used for providing a lubricant layer on the prior to be applied conversion coating layer, the compositions used for generating said aforementioned conversion coating layer are acidic compositions as already mentioned hereinbefore. For performing such a two-steps pretreatment process usually two different open treatment baths are employed, into which the metallic workpieces are dipped, namely a first bath containing the aqueous acidic conversion coating composition and a second bath containing the aqueous alkaline lubricant composition. It is essential, however, to include a rinsing and/or neutralization step between these two dipping steps in order to remove any excessive acid present onto the workpiece after having it removed from the first acidic bath and before having dipped it into the second alkaline bath in order to preserve the life of the two baths and in particular of the second bath as long as possible. It is, however, disadvantageous for economic and ecological reasons to have to necessarily carry out such a rinsing and/or neutralization step. Simple mixing or combining the conventional aqueous acidic compositions such as phosphate and/or oxalate compositions for providing the conversion coating layer with the conventional aqueous alkaline compositions for providing the lubricant layer is not possible as these compositions are not miscible with each other and consequently an undesired phase separation would be observed. Moreover, most of the known organic polymer dispersions used for preparing conventional aqueous alkaline lubricant compositions are unstable in an acidic environment. Therefore, it is not always possible to simply use acidic versions of the known aqueous alkaline lubricant compositions.
EP 3 290 544 A1 relates to an acidic water-based lubricating coating agent having a pH value of 2.0 to 6.5, which inter alia contains a chemical conversion component such as oxalic acid and a lubricating component such as a lipophilic lubricating component including an oil or a soap. The coating agent may further comprise a water-based resin as a binder component. EP 3 290 544 A1 further discloses a one-step pretreatment method of metal substrates for a subsequent cold forming.
JP S54 5847 A relates to a lubricant composition for facilitating the cold forming of metals. The lubricant contains oxalic acid and at least one constituent selected from water-soluble organic titanium compounds, vinyl pyrrolidone homopolymers and vinyl pyrrolidone copolymers. The lubricant composition may further contain a lubricating aid.
WO 2020/165035 A1 discloses a one-step pretreatment method for preparation of steel and/or steel alloy workpieces for cold forming. An oxalate and lubricant layer on a metallic surface is formed by using an aqueous acidic oxalating solution containing a film-forming polymer. A wide range of polymers may be used for preparing the solution. However, this lubricant is not necessarily stable in other acidic solutions such as phosphating solutions and is also generally not stable in alkaline solutions. In addition, it may contain a lubricating oil. The use of such oils is, however, in general disadvantageous for the reasons outlined hereinbefore.
In addition, the conventional pretreatment processes for cold forming known in the prior art not always result in a sufficiently high coating weight of the lubricant layer formed on the workpiece or—if a separating layer such as a conversion coating layer is also present underneath the lubricant layer—in a sufficiently high coating weight of the lubricant layer and said separating layer combined. This may result in only insufficient adhesion properties of the layer(s) to the metallic substrate. Further, this can result in an ineffective separation of the tool from the workpiece after and during cold forming and in an only ineffective reduction of the coefficient of friction or even in an undesired cold welding, as an only insufficiently high amount of the coating layer(s) as measured by their coating weight remains present on the workpieces during the cold forming process.
Thus, there is a need for simplifying the conventional surface pretreatment processes for metal cold forming that make use of aqueous lubricant compositions both for economic reasons and for ecological reasons, in particular to provide an improved technology for the water-based pretreatment of metallic substrates for the cold forming process that requires fewer treatment steps and makes use of aqueous lubricant compositions, which contain suitable constituents that are stable both in an acidic and in an alkaline medium. At the same time such a simplified pretreatment must still lead to sufficiently high coating weights of the coating layer(s) formed on the metallic substrates in order to both ensure a good adhesion to the substrate and an effective reduction of the coefficient of friction during cold forming and to prevent cold welding.

Problem

It has been therefore an object underlying the present invention to provide a simplified surface pretreatment method for metal cold forming that makes use of an aqueous lubricant composition both for economic reasons and for ecological reasons, in particular to provide an improved technology for the water-based pretreatment of metallic substrates for the cold forming process that requires fewer treatment steps and makes use of aqueous acidic lubricant compositions, which are stable both in an acidic and in an alkaline medium. At the same time, however, it is required that such a simplified pretreatment must still lead to sufficiently high coating weights of the coating layer(s) formed on the metallic substrates in order to both ensure a good adhesion to the substrate and an effective reduction of the coefficient of friction during cold forming and to prevent any cold welding.

Solution

This object has been solved by the subject-matter of the claims of the present application as well as by the preferred embodiments thereof disclosed in this specification, i.e., by the subject matter described herein.
A first subject-matter of the present invention is a method of pretreatment of a metallic substrate for a subsequent metal cold forming process, said method comprising at least steps (1) and (2) and optionally step (3), namely

- (1) providing at least one substrate having at least one surface at least partially made of at least one metal and/or alloy thereof, wherein said metal and/or alloy thereof is at least one of steel, aluminum and alloys of aluminum and/or steel,
- (2) contacting the at least one surface of the substrate provided in step (1) with an aqueous lubricant composition (B) having a pH value, which is in the non-neutral pH range, wherein the neutral pH range is a pH range of from >6.0 to <8.0,
  - wherein the aqueous lubricant composition (B) comprises besides water at least constituents (b1) to (b4) and optionally (b5), which are different from one another, namely
    - (b1) at least one film-forming polymer, which is a homopolymer and/or copolymer being prepared by polymerization of at least vinyl pyrrolidone as at least one monomer, wherein said homopolymer and/or copolymer has a polydispersity index (PDI) in a range of from 1.5 to 8.0,
    - (b2) at least one wax,
    - (b3) at least one defoamer, and
    - (b4) (i) oxalate anions and/or phosphate anions or (ii) calcium cations, chloride anions and hydroxide anions, as well as
    - (b5) optionally Fe(III) ions, wherein constituent (b5) is present in case at least oxalate anions are present as constituent (b4),
- and
- (3) optionally drying the coating film obtained after having performed step (2).

A further subject-matter of the present invention is a pretreated metallic substrate obtainable by the inventive method.
A further subject-matter of the present invention is a method of cold forming a metallic substrate, characterized in that it comprises a step of subjecting the inventive pretreated metallic substrate to a cold forming process.
A further subject-matter of the present invention is an aqueous lubricant composition (B) as defined hereinbefore in connection with the inventive pretreatment method.
A further subject-matter of the present invention is a master batch to produce the inventive aqueous composition (B) by diluting the master batch with water and if applicable by adjusting the pH value.
It has been surprisingly found that aqueous lubricant composition (B), in particular its constituents (b1) and (b2), is compatible to organic and/or inorganic acids, in particular to oxalic acid and phosphoric acid, and thus represents an acid stable composition. At the same time, it has been unexpectedly found that aqueous lubricant composition (B), in particular its constituents (b1) and (b2), is also compatible to organic and/or inorganic bases, and thus represents also a composition, which is stable in alkaline medium. Thus, advantageously basically the same composition can be used both as acidic aqueous lubricant composition and as alkaline aqueous lubricant composition depending on the mere selection of constituent (b4). This offers a greater flexibility to the end user.
It has been in particular surprisingly found that it is thus possible to include (i) oxalate and/or phosphate anions into composition (B) as (b4), in particular when the pH value of composition (B) is in the non-neutral acidic range up to pH 6.0, or to include (ii) calcium cations, chloride anions and hydroxide anions into composition (B) as (b4), in particular when the pH value of composition (B) is in the non-neutral alkaline range of 8.0 or higher. This has the advantage that composition (B) can be used in the inventive method both as an aqueous acidic or alkaline composition in a single step. In particular, aqueous acidic or alkaline composition (B) can be used both as an lubricant composition and as a conversion coating composition in a single step only and, consequently, it is not necessary to apply any conversion coating in an additional step prior to applying the lubricant, which, of course, has both economic and ecologic advantages. Similarly, it is not necessary to apply any lubricating aids subsequently.
In particular, it has been surprisingly found that all constituents present in aqueous lubricant composition (B) can be formulated as and into an acidic composition at a pH value in the range of from 0.1 to 6.0 or into an alkaline composition at a pH value in the range of from 8.0 to 14.0. It has been in particular surprisingly found that composition (B) is stable both under such acidic conditions and under such alkaline conditions and that in particular the at least one film-forming polymer (b1) as well as the at least one wax (b2) present in composition (B) are stable in both of these environments in the additional presence of (i) oxalate and/or phosphate anions (b4) in case of acidic conditions or in the additional presence of (ii) calcium cations, chloride anions and hydroxide anions (b4) in case of alkaline conditions, even when these ions are present in comparably high concentrations in composition (B). As mentioned above, this offers a greater flexibility to the end user.
It has been further surprisingly found that—as composition (B) can be used in the inventive method both as lubricant composition and as a conversion coating composition in a single step only—no rinsing and/or neutralization steps have to be performed at all in contrast to conventional multi-step methods, wherein such a rinsing and/or neutralization step has to be performed at least after applying the conversion coating composition and before applying the lubricant composition.
In addition, it has been further found that the coating film obtained after step (2) is a combined conversion and lubricant film. Thus, the coating film obtained combines the properties of a conversion layer and a lubricant layer. The lubricant coating film can be present on top of the conversion coating film. The combined layers can be separated and adjusted in part. When a substrate having a surface at least partially made of aluminum and/or an alloy thereof is used, it has been found that when using a composition (B) comprising calcium cations, chloride anions and hydroxide anions as constituent (b4), a calcium aluminate coating film is formed as conversion coating film as aluminate anions are formed in situ after application of composition (B) onto the surface.
In addition, it has been surprisingly found that the coating layer obtained from applying composition (B) adheres firmly on the substrate and shows good lubricant properties. Thus, the substrate pretreated by the inventive method can be subsequently subjected to a metal cold forming process including cold extrusion and wire drawing with high speed drawing. In the cold forming of substrates, it has been found that a coating layer obtained from application of composition (B) to the substrate can be efficiently subjected to a drawing step for the purpose of metal cold forming. In the cold forming of substrates such as steel wire in a wire-drawing machine, it has been found that a lubricant layer obtained from application of composition (B) to the substrate can be efficiently used even with a drawing up to 35% cross-area, decreasing in each drawing step.
Furthermore, it has been surprisingly found that the coated metallic substrates obtained by the inventive method bear a sufficiently high coating weight of the coating layer(s) formed on the metallic substrates obtained from applying composition (B). The resulting coating layer(s) is/are homogenous, thick and adhered firmly on the surface of the substrate. It has been found that such a high coating weight not only ensures a good adhesion to the substrate, but also an effective reduction of the coefficient of friction during cold forming and to prevent any cold welding. It has been surprisingly found that higher coating weights are obtained when performing the inventive method comprising one contacting step (step (2)) only compared to performing conventional multi-step methods, wherein conversion coating and lubricant layers are applied in separate steps. In case oxalate anions are present as (b4) it has been surprisingly found that the additional use of Fe(III) ions as accelerator positively influences the coating weight compared to the use of nitroguanidine.
Moreover, it has been found that coated metal workpieces obtained from the inventive method have a good corrosion resistance. It has been surprisingly found in this regard that the presence of the optional corrosion inhibitor (b6) in composition (B) does not negatively influence the formation of an oxalate and/or phosphate and/or aluminate conversion coating layer in any manner when performing the inventive method as the conversion coating layer formed has an excellent coating quality, in particular when a mixture of an alkyl amide and an alkanolamine is used as optional constituent (b6). Further, it has been found that no stable foams have been formed during the inventive surface treatment process.
In addition, it has been surprisingly found that the lubricant properties of the lubricant film obtained after step (2) or after optional step (3) of the inventive method are in particular improved compared to making use of conventional lubricant compositions due to the use of the specific film-forming polymer (b1) in combination with the at least one wax (b2).
It has been further surprisingly found that baths containing the acidic aqueous lubricant composition (B) have comparably long lifetimes, in particular longer lifetimes that bath containing conventional alkaline aqueous lubricant compositions. This, of course, has economic and ecologic advantages.

DETAILED DESCRIPTION OF THE INVENTION

The term “comprising” in the sense of the present invention, in particular in connection with the inventive method, the inventive composition (B) and the master batch used to prepare the composition (B), preferably has the meaning “consisting of”. In this case, for example, with regard to the inventive composition (B), in addition to the mandatory constituents therein (constituents (b1) to (b4), optionally (b5), and water) one or more of the further optional components mentioned hereinafter may be contained in the composition. The same principle applies with respect to the composition (B) used in the inventive method and the master batch. All components/constituents can be present in each case in their preferred embodiments mentioned hereinafter. The same applies to the further subject-matters of the present invention.
The proportions and amounts in wt.-% (% by weight) of any of the constituents given hereinafter, which are present in each of the compositions such as composition (B) add up to 100 wt.-%, based in each case on the total weight of the respective composition such as composition (B).
Inventive Pretreatment Method
The inventive method is a method of pretreatment of a metallic substrate for a subsequent metal cold forming process. The inventive method comprises at least steps (1) and (2) and optionally additionally step (3). The inventive method may comprise one or more further additional optional steps.
Preferably, the inventive method does not comprise any oxalating and/or phosphatizing steps besides step (2), and, further, does not comprise any lubricating steps besides step (2).
Step (1)
In step (1) of the inventive method at least one substrate having at least one surface at least partially made of at least one metal and/or alloy thereof is provided. Said metal and/or alloy thereof is at least one of steel, aluminum and alloys of aluminum and/or steel.
The surface of the substrate used is at least partially made of at least one metal and/or alloy thereof, i.e., at least one region of said surface is made of at least one metal and/or alloy thereof. The surface can consist of different regions comprising different metals. Preferably, the overall surface of the substrate is made of at least one metal and/or alloy thereof. More preferably, the substrate consists of at least one metal and/or alloy thereof.
Preferably, the at least one metal is selected from the group consisting of aluminum, aluminum alloys, zinc, steel including cold rolled steel, hot rolled steel, galvanized steel (zinc plated steel) including hot-dip galvanized steel (hot zinc dipped steel) or electrolytically galvanized steel, steel alloys, aluminum and/or aluminum alloys.
Preferably, the at least one surface of the substrate is made of steel, aluminum and/or of a steel and/or aluminum alloy, more preferably the substrate as such is made of steel, aluminum and/or of a steel and/or aluminum alloy.
As substrates, e.g., strips, sheets, slugs, wires, wire coils, more complicated shaped parts, sleeves, profiles such as hollow or solid profiles, tubes, discs, discs, rods, bars or cylinders can be used.
Optional Steps (1a) and (1b) and (1c)
The surfaces to be substrates provided in step (1) may be cleaned by means of an acidic, alkaline or pH-neutral cleaning composition and/or etched before treatment with the composition (B) in step (2) as it will be outlined hereinafter: Prior to step (2) of the inventive method one or more of the following optional steps can be performed, preferably in this order:

- Step (1a): cleaning, preferably by making use of an alkaline aqueous cleaning composition for surfaces made at least partially of steel and/or an alloy thereof and/or by making use of a pH-neutral aqueous cleaning composition for surfaces made at least partially of aluminum and/or an alloy thereof, and optionally subsequently rinsing the surface of the substrate provided in step (1), and/or
- Step (1b): subjecting the surface of the substrate to acidic pickling, i.e., etching, and subsequently rinsing the surface of the substrate, and/or
- Step (1c): optionally activating the surface of the substrate by using an aqueous activating composition (A) being different from composition (B).

Alternatively, optional steps (1a) and (1b) may be performed in one step. Preferably, both steps (1a) and (1b) are performed. Rinsing included in step (1a) is preferably performed with deionized water or tap water. Preferably, the acidic pickling is performed by making use of hydrochloric acid, hydrofluoric acid, sulfuric acid, nitric acid and/or phosphoric acid. In the case phosphate anions are present as constituent (b4) in composition (B), the surface of the substrate can optionally be activated by using an aqueous activating composition (A) according to optional step (1c), e.g., by using commercially available activating product Gardolene® V 6522 from Chemetall GmbH.
Step (2)
In step (2) of the inventive method the at least one surface of the substrate provided in step (1) is contacted with, preferably dipped into, an aqueous lubricant composition (B).
The treatment procedure according to step (2), i.e., the “contacting”, can, for example, include a spray coating and/or a dip coating procedure. The composition (B) can also be applied by flooding the surface or by roll coating or even manually by wiping or brushing. However, dipping is preferred. In this case, the substrate used is dipped into a bath containing the composition (B).
Preferably, contacting step (2) is performed by at least partially dipping the substrate into a bath containing the aqueous lubricant composition (B) having a bath temperature in the range of from 20 to 95° C., preferably of from 45 to 90° C., in particular of from 50 to 85° C.
The treatment time, i.e., the period of time the surface is contacted with the aqueous composition (B) used in step (2) is preferably from 15 seconds to 20 minutes, more preferably from 30 seconds to 15 minutes, and most preferably 45 seconds to 10 minutes.
Preferably, no rinsing step is performed after having carried out step (2).
Composition (B)
The term “aqueous” with respect to composition (B) in the sense of the present invention preferably means that the composition (B) is a composition containing at least 40 or at least 50 wt.-%, preferably at least 60 wt.-%, more preferably at least 70 wt.-% in particular at least 80 wt.-%, most preferably at least 90 wt.-% or 95 wt.-% or 98 wt.-% or 99 wt.-% or even 100 wt.-% of water, based on its total content of organic and inorganic solvents including water. Thus, the composition (B) may contain at least one organic solvent besides water—however, in an amount significantly lower than the amount of water present. Preferably, composition (B) is free of organic solvents. Thus, preferably water is the only solvent/diluent present.
Preferably, composition (B) contains water in an amount of at least 40 wt.-%. More preferably, composition (B) contains water in an amount of at least 45 wt.-% or at least 50 wt.-%, more preferably of at least 60 wt.-%, even more preferably of at least 70 wt.-% and still more preferably of at least 80 wt.-%, in each case based on the total weight of composition (B).
Aqueous lubricant composition (B) has a pH value, which is in the non-neutral pH range, wherein the neutral pH range is a pH range of from >6.0 to <8.0. In other words, aqueous lubricant composition (B) has a pH value of either pH 7.0+1.0 or higher, i.e., a pH value in a range of from 8.0 to 14.0, or a pH value of pH 7.0−1.0 or lower, i.e., a pH value in a range of from 0 to 6.0 such as of from 0.1 to 6.0. If composition (B) has a pH value in a range of from 8.0 to 14.0 it represents an alkaline composition. If composition (B) has a pH value in a range of from 0 to 6.0 such as of from 0.1 to 6.0 it represents an acidic composition. The pH value can be in particular adjusted by selecting constituent (b4) and its amount.
Preferably, aqueous lubricant composition (B) has a

- pH value in a range of from 0.1 to 6.0, preferably of from 0.2 to 5.8, more preferably of from 0.5 to 5.5, preferably (i) when at least one of oxalate anions and phosphate anions are present as constituent (b4), in particular when the surface of the substrate is at least partially made of steel and/or an alloy thereof,
- or has a
- pH value in a range of from 8.0 to 14.0, preferably of from 9.0 to 14.0, more preferably of from 10.0 to 13.5, even more preferably of from 11.0 to 13.0, preferably when (ii) calcium cations, chloride anions and hydroxide anions are present as constituent (b4), in particular when the surface of the substrate is at least partially made of aluminum and/or an alloy thereof.

More preferably, the aqueous lubricant composition (B) has a

- pH value in a range of from 0.1 to <2.0, even more preferably of from 0.2 to 1.9, still more preferably of from 0.5 to 1.8, preferably when (i) at least oxalate anions are present as constituent (b4), more preferably when oxalate anions are present as constituent (b4) and no phosphate anions are present or—if present—are present in an amount in g/l lower than the amount of oxalate anions in g/l, in particular when the surface of the substrate is at least partially made of steel and/or an alloy thereof,
- or has a
- pH value in a range of from 2.0 to 6.0, even more preferably of from 2.2 to 5.8, still more preferably of from 2.4 to 5.5, preferably (i) when at least phosphate anions are present as constituent (b4), more preferably when phosphate anions are present as constituent (b4) and no oxalate anions are present or—if present—are present in an amount in g/l lower than the amount of phosphate anions in g/l, in particular when the surface of the substrate is at least partially made of steel and/or an alloy thereof, or has a
- pH value in a range of from 8.0 to 14.0, even more preferably of from 9.0 to 14.0, still more preferably of from 10.0 to 13.5, yet more preferably of from 11.0 to 13.0, preferably (ii) when calcium cations, chloride anions and hydroxide anions are present as constituent (b4), more preferably when calcium cations, chloride anions and hydroxide anions are present as constituent (b4) and none of oxalate anions and phosphate anions are present or—if present—are each present in an amount in g/l lower than the amount of each of calcium cations, chloride anions and hydroxide anions in g/l, in particular when the surface of the substrate is at least partially made of aluminum and/or an alloy thereof.

Preferably, composition (B) is present in the form of a solution or dispersion, in particular in the form of a solution, preferably at a temperature of at least 40° C., in particular at least 50° C.
Preferably, composition (B) has a solid content in the range of from 0.1 to 30 wt.-%, more preferably in the range of from 0.2 to 25 wt.-%, even more preferably in the range of from 0.3 to 20 wt.-%, still more preferably in the range of from 0.4 to 15 wt.-%, in each case based on the total weight of composition (B).
Since composition (B) comprises at least one of (i) oxalate and/or phosphate anions or (ii) calcium cations, chloride anions and hydroxide anions as constituent (b4), it represents an oxalating composition, phosphating composition or aluminate forming composition, which is suitable of forming a conversion coating on the surface of a substrate. Since composition (B) further comprises (b2) at least one wax and at least one film-forming polymer (b1) it anyhow also represents a lubricant composition at the same time, which is suitable of forming a lubricating coating on the surface of a substrate.
Preferably, composition (B) does not comprise any oils such as lubricating oils. In particular, composition (B) does not comprise any further lubricating aids besides constituents (b1) and (b2).
Composition (B) comprises besides water at least constituents (b1) to (b4) and optionally (b5), which are different from one another.
Constituent (b1)
Composition (B) comprises at least one film-forming polymer, which is a homopolymer and/or copolymer being prepared by polymerization of at least vinyl pyrrolidone as at least one monomer, wherein said homopolymer and/or copolymer has a polydispersity index (PDI) in a range of from 1.5 to 8.0. PDI as well as the weight average molecular weight (M_w) are determined according to the method disclosed hereinafter in the ‘methods’ section.
Preferably, film-forming polymer (b1) has a polydispersity index (PDI) in a range of from 1.8 to 7.5, more preferably of from 2.0 to 7.0, still more preferably of from 2.5 to 6.5, even more preferably of from 3.0 to 6.0, in particular of from 3.5 to 5.5.
Preferably, film-forming polymer constituent (b1) has a weight average molecular weight in the range of from 1 000 to 500 000 g/mol, more preferably of from 2 500 to 400 000 g/mol, even more preferably of from 4 000 to 300 000 g/mol, still more preferably of from 5 500 to 200 000 g/mol, yet more preferably of from 7 000 to 100 000 g/mol, still more preferably of from 8 500 to 75 000 g/mol.
Preferably, film-forming polymer (b1) has at least one glass transition temperature (T_g) in a range of from 40 to 200° C., more preferably of from 50 to 190° C., yet more preferably of from 60 to 170° C., still more preferably of from 70 to 150° C., even more preferably of from 80 to 130° C., in particular of from 90 to 120° C. T_gis determined according to the method disclosed hereinafter in the ‘methods’ section.
Preferably, the at least one film-forming polymer is water-soluble or water-dispersible, more preferably water-soluble. Preferably, the at least one film-forming polymer is soluble or dispersible, more preferably soluble, in composition (B).
In case the at least one film-forming polymer (b1) is a copolymer at least one further monomer bearing at least one ethylenically unsaturated group, preferably at least one vinyl group, and being different from vinyl pyrrolidone can be used for preparing constituent (b1). Preferably, at least one further vinyl monomer different from vinyl pyrrolidone is used. However, such further monomers may also or alternatively bear at least one (meth)acrylate group. This includes (meth)acrylic acid groups. Preferably, however, no monomers with acid groups are used. The further monomer can be an ionomer. The further monomer can also be ethylene, propylene, butylene, styrene etc. The term “(meth)acryl” means “acryl” and/or “methacryl”. Similarly, “(meth)acrylate” means acrylate and/or methacrylate.
Preferably, film-forming polymer (b1) is a homopolymer being prepared from vinyl pyrrolidone or a copolymer being prepared from vinyl pyrrolidone and at least from at least one monomer selected from the group consisting of (meth)acrylate monomers, vinyl amine, vinyl alcohol, vinyl formamide, vinyl caprolactam, vinyl acetate and vinyl imidazole. Preferably, the amount of structural units derived from the at least one further monomer different from vinyl pyrrolidone in the copolymer is 50 mol-% at most. Preferably, the amount of structural units derived from vinyl pyrrolidone in the copolymer is 50 mol-% at least and more preferably is at least 60 mol-% or at least 70 mol-% or at least 75 mol-%.
Most preferred are polyvinyl pyrrolidone homopolymers and copolymers of vinyl pyrrolidone and vinyl acetate. An exemplary polymer is Sokalan® K 17P, from BASF SE, Germany.
Preferably, the at least one film-forming polymer (b1) is present in the composition (B) in an amount in the range of from 0.05 to 20 wt.-%, more preferably in the range of from 0.10 to 15 wt.-%, even more preferably in the range of from 0.15 to 10 wt.-%, still more preferably in the range of from 0.20 to 7.5 wt.-%, in particular of from 0.25 to 5.0 wt.-%, in each case based on the total weight of the composition (B).
Constituent (b2)
Composition (B) comprises at least one wax as constituent (b2), which is different from constituent (b1).
As the term “wax” already implies, the at least one wax is a solid substance at room temperature (23° C.). A person skilled in the art is familiar with the term “wax”. Said term is, e.g., defined in by the German Society for Fat Science (DGF) within DGF standard method M-I 1 (75) (2015). Preferably, the at least one wax used as constituent (b2) satisfies this definition of a wax. Waxes according to this definition can be kneaded at 20° C., have a firm (solid) to brittle hardness, have a coarse to fine crystalline structure, are translucent to opaque in color but not glassy or glass-like, melt without decomposition at temperatures above 40° C., are slightly liquid above their melting point and have a low viscosity above their melting point, have a highly temperature-dependent consistency and solubility, and can be polished under light pressure. Preferably and according to the definition of the DGF (DGF standard method M-I 1 (75)), a substance is not a wax if it does not meet more than one of the above properties.
Preferably, the at least one wax (b2) is water-soluble or water-dispersible, more preferably water-dispersible. Preferably, the at least one wax (b2) is soluble or dispersible in composition (B).
Preferably, composition (B) is obtainable by using an aqueous dispersion or solution of the at least one wax (b2) for its preparation.
Preferably, the at least one wax (b2) has a melting point in the range of from 30° C. to 170° C., more preferably in the range of from 40° C. to 165° C., especially preferred in the range of from 60° C. to 160° C.
Composition (B) preferably comprises more than one wax as constituent (b2). Preferably, composition (B) comprises at least two, more preferably at least three different waxes as constituents (b2). Preferably, the at least two or at least three different waxes differ from each other at least in their melting temperature (melting point). Preferably, the difference between melting points of at least two of the waxes is at least 20° C.
Preferably, the at least one wax (b2) is present in the composition (B) in an amount in the range of from 0.1 to 20 wt.-%, more preferably in the range of from 0.5 to 15 wt.-%, even more preferably in the range of from 0.75 to 12.5 wt.-%, still more preferably in the range of from 1.0 to 10.0 wt.-%, in particular of from 1.5 to 9.0 wt.-%, most preferably in the range of from 2.0 to 7.5 wt.-%, in each case based on the total weight of the composition (B).
Preferably, the at least one wax (b2) is selected from the group consisting of cationic waxes, cationically stabilized waxes and non-ionic waxes. A “cationically stabilized wax” is preferably a wax that is stabilized by cationic groups in acidic medium such as in the composition (B) or is stabilized by at least one cationic surfactant.
Preferably, the at least one wax (b2) is stabilized by at least one emulsifier. For example, the at least one wax (b2) can be stabilized by a cationic emulsifier (cationically stabilized) or can be stabilized by a non-ionic emulsifier (non-ionically stabilized). Examples of cationic emulsifiers are alkoxylated such as ethoxylated stearyl amine and/or polyalkoxylated such as polyethoxylated tallow amine. Examples of non-ionic emulsifiers are alcohols including for example diethylaminoethanol.
Preferably, the at least one wax (b2) is selected from the group consisting of polyolefin waxes (including polyethylene waxes, in particular HDPE (high density polyethylene) and/or polypropylene waxes, natural waxes including plant and animal waxes such as montan waxes, bees waxes and/or carnauba waxes, paraffin waxes (petroleum derived waxes) and mixtures thereof.
In this context, the term “olefin” mainly refers to alkenes typical of polyolefins, preferably alkenes with 2 to 8, especially alkenes with 2 to 6 and especially alkenes with 2 to 4 carbon atoms, especially those with a terminal double bond. In the context of this invention, preferred representatives are ethylene, propylene, 1-butene and isobutene. Ethylene and propylene are particularly preferred olefin monomers in the context of this invention. The term “polyolefin” is generally understood to mean homopolymers of a single type of olefin monomer (e.g., ethylene homopolymers) or copolymers of at least two olefin monomers (e.g. polymers of mixtures comprising or consisting of ethylene, propylene, 1-butene and/or isobutene). Polyolefins thus contain one or more types of olefin monomers and are therefore homopolymers or copolymers. However, they may also additionally contain one or more ethylenically unsaturated monomers other than olefin monomers, in particular ethylenically unsaturated monomers bearing carboxylic acid groups, polymerized or grafted. If different ethylenically unsaturated monomers with carboxyl groups or carboxylic acid anhydride groups are used for the purpose of polymerization or grafting of the olefin monomers, this is done in an amount such that the polyolefin wax as constituent (a5) containing carboxyl groups has an acid number in the range from 3 to 50, preferably from 5 to 40, particularly preferably from 8 to 35, very particularly preferably from 10 to 25 and particularly preferably from 13 to 20 mg KOH/g. Polyolefin waxes are preferably selected from the group consisting of oxidized polyethylene waxes, oxidized polypropylene waxes, oxidized poly(ethylene-co-propylene) waxes and oxidized ethylene-olefin copolymers, ethylene-(meth)acrylic acid copolymers and polymers of ethylene and/or propylene other than the abovementioned copolymers, which have been grafted, for example, with maleic anhydride (converted into the hydrolyzed form, and carrying free COOH groups). Of course, other ethylenically unsaturated acids such as acrylic acid can also be used for grafting.
The paraffin waxes used are preferably microcrystalline.
Exemplary waxes that are commercially available and that can be used are, e.g. Aquacer® 1041 from BYK Chemie, Germany, Aquacer® 561 from BYK Chemie, Aquacer® 517 from BYK Chemie, Wukonil® O-33a from Münzing Chemie and Licowax® KST from Clariant, Germany,
Constituent (b3)
Composition (B) comprises at least one defoamer as constituent (b3). Preferably, the defoamer is free of silicone. Thus, no siloxane and/or polysiloxane units are preferably present in (b3).
Preferably, (b3) is present in composition (B) in an amount of from 0.01 to 5.0 wt.-%, more preferably of from 0.01 to 4.0 wt.-%, even more preferably of from 0.01 to 3 wt.-%, in particular of from 0.05 to 1.5 wt.-%, in each case based on the total weight of composition (B).
Constituent (b4)
Composition (B) comprises (i) at least one of oxalate anions and phosphate anions or comprises (ii) calcium cations, chloride anions and hydroxide anions as constituent(s) (b4). Preferably, composition (B) comprises precisely one of oxalate anions and phosphate anions, i.e., either oxalate or phosphate ions, or comprises calcium cations, chloride anions and hydroxide anions.
Oxalate and/or phosphate anions are preferably present in composition (B) as (b4), when the pH value of composition (B) is in the non-neutral acidic range up to pH 6.0. Calcium cations, chloride anions and hydroxide anions are preferably present in composition (B) as (b4), when the pH value of composition (B) is in the non-neutral alkaline range having a pH value of 8.0 or higher.
Preferably, oxalate anions (b4) are present in the composition (B) in an amount in the range of from 2 to 500 g/l, more preferably of from 5 to 100 g/l, in particular of from to 50 g/l of oxalic acid, calculated in each case as oxalic acid dihydrate. In this case, preferably no additional phosphate anions are present.
As outlined hereinbefore in case oxalate anions (b4) are present in the composition (B), composition (B) preferably has a pH value in a range of from 0.1 to <2.0, even more preferably of from 0.2 to 1.9, still more preferably of from 0.5 to 1.8. This in particular applies when oxalate anions are present as sole constituent (b4) and no phosphate anions are present or—if phosphate anions present—if these are present in an amount in g/l lower than the amount of oxalate anions in g/l, in particular when the surface of the substrate is at least partially made of steel and/or an alloy thereof.
In the sense of the present invention, “oxalic acid” also means the single and double deprotonated form of oxalic acid. Likewise, in the sense of the present invention, “oxalate” also means the single and double protonated form thereof, the double protonated from being oxalic acid. Preferably, oxalic acid dihydrate is used, as is it cheap and less hygroscopic.
Preferably, phosphate anions (b4) are present in the composition (B) in an amount in the range of from 2 to 500 g/l, particularly preferably in the range from 4 to 320 g/l, most particularly preferably in the range from 8 to 200 g/l, in particular in the range from 12 to 120 g/l, calculated in each case as PO₄. In this case, preferably no additional oxalate anions are present.
As outlined hereinbefore in case phosphate anions (b4) are present in the composition (B), composition (B) preferably has a pH value in a range of from 2.0 to 6.0, even more preferably of from 2.2 to 5.8, still more preferably of from 2.4 to 5. This in particular applies when phosphate anions are present as sole constituent (b4) and no oxalate anions are present or—if oxalate anions present—if these are present in an amount in g/l lower than the amount of phosphate anions in g/l, in particular when the surface of the substrate is at least partially made of steel and/or an alloy thereof.
If, in connection with weight concentrations (e.g., g/l), the term “calculated as X” is used, where X is a specific, specified chemical compound, this is to be understood as follows: If an alternative chemical compound (not X) it should be used in such a molar concentration as calculated for X, taking into account its molar mass, from the specific weight concentration (e.g., g/l) indicated in each case.
Preferably, calcium cations are present in the composition (B) as part of (b4) in an amount in the range of from 0.05 to 15.0 g/l, more preferably of from 0.07 to 10.0 g/l, even more preferably of from 0.10 to 7.5 g/l, in particular of from 0.20 to 5.0 g/l, yet more preferably of from 0.30 to 2.5 g/l, in particular of from 0.40 to 2.0 g/l or of from 0.50 to 1.5 g/l, calculated in each case as metal. Preferably, chloride anions are present in the composition (B) as part of (b4) in an amount in the range of from 0.10 to 15.0 g/l, more preferably of from 0.50 to 10.0 g/l, even more preferably of from 0.70 to 7.0 g/l, in particular of from 0.80 to 5.0 g/l, yet more preferably of from 0.9 to 4.0 g/l, in particular of from 1.0 to 3.0 g/l, calculated in each case as sodium chloride. Preferably, hydroxide anions are present in the composition (B) as part of (b4) in an amount in the range of from 0.01 to 6.0 g/l, more preferably of from 0.02 to 5.0 g/l, even more preferably of from 0.03 to 3.0 g/l, in particular of from 0.04 to 1.5 g/l, yet more preferably of from 0.05 to 0.8 g/l, in particular of from 0.10 to 0.6 g/l, calculated in each case as sodium hydroxide.
As outlined hereinbefore in case calcium cations, chloride anions and hydroxide anions (b4) are present in the composition (B), composition (B) preferably has a pH value in a range of from 8.0 to 14.0, even more preferably of from 9.0 to 14.0, still more preferably of from 10.0 to 13.5, yet more preferably of from 11.0 to 13.0. This in particular applies when calcium cations, chloride anions and hydroxide anions are present as sole constituent (b4) and none of oxalate anions and phosphate anions are present or—if oxalate anions and/or phosphate anions present—if these are each present in an amount in g/l lower than the amount of each of calcium cations, chloride anions and hydroxide anions in g/l, in particular when the surface of the substrate is at least partially made of aluminum and/or an alloy thereof.
Optional Constituent (b5)
Composition (B) may optionally comprise Fe(III) ions (i.e. iron(III) cations) as constituent (b5). In case oxalate anions are present as constituent (b4), constituent (b5) is necessarily present in composition (B).
Fe(III) ions as constituent (b5) are used as oxalating accelerator. A source of iron(III) cations in the sense of the present invention is preferably a water soluble iron(III) salt such as iron(III) nitrate. Also, a water soluble iron(II) salt in combination with an oxidizing agent suitable for the production of iron(III) cations can be used as a source of iron(III) cations.
Preferably, the content of iron(III) is in the range of from 0.0004 to 2 g/l, more preferably of from 0.04 to 2 g/l and especially preferred from 0.4 to 2 g/l, calculated as iron(III) nitrate.
Preferably, composition (B) does not comprise nitroguanidine when oxalate anions are present therein.
Optional Constituent (b6)
Composition (B) may further comprise at least one corrosion inhibitor as optional constituent (b6), which is preferably different from each of constituents (b1) to (b4) and optional constituent (b5).
The term “corrosion inhibitor” is a term known to a person skilled in the art. Said term is for instance defined in Römpp Lexikon, Lacke und Druckfarben 1998, Georg Thieme Verag, 10. Auflage”.
Preferably, corrosion inhibitors for use as constituent (b6) are alkyl amides, amines and alkanol amines. Examples of suitable constituents (b6) are morpholine, benzylamine, butindiol, diisopropylamine nitrite, morpholine nitrite, 2-(2-heptadec-8-enyl-2-imidazolin-1-yl)ethanol, dicyclohexylamine nitrite, cyclohexylamine benzoate, dicyclohexylamine caprylate, guanadine chromate, hexamethyleneimine benzoate, dicyclohexylamine benzoate, ethylaniline, mercaptobenzotriazole, pyridine, rosin amine, phenylacridine, hexamethylentetramin, nonylphenoxyacetic acid, succinic acid semi-ester and alkindiols such as butindiol.
Preferably, the at least one corrosion inhibitor is present in composition (B) is preferably in an amount of from 0.01 to 5.0 wt.-%, more preferably of from 0.05 to 4.0 wt.-%, even more preferably of from 0.1 to 3 wt.-%, in particular of from 0.1 to 1.5 wt.-%, in each case based on the total weight of composition (B).
Optional Constituent (b7)
Composition (B) may further comprise at least one optional constituent (b7), which is at least one phosphatizing accelerator when (B) comprises phosphate anions as constituent (b4), and which is preferably different from each of constituents (b1) to (b4) and optional constituents (b5) and (b6). Preferably, nitrate used as (b7) and is present in an amount in the range from 1 to 600 g/l, particularly as nitrate anions, particularly preferably in the range from 4 to 450 g/l, most particularly preferably in the range from 8 to 300 g/l, in particular in the range from 16 to 200 g/l.
In particular when (B) comprises phosphate anions as constituent (b4), additional or alternative accelerators are selected from the group consisting of chlorate, guanidine, hydroxylamine, nitrite, nitrobenzene, sulfonate, perborate, peroxide, peroxysulfuric acid and other accelerators containing nitro groups. A low or moderate content of nitrate can have an accelerating effect on electrolytic phosphating and can therefore be advantageous.
In particular when (B) comprises phosphate anions as constituent (b4), composition (B) may further comprise at least one constituent selected from the group consisting of organic acids and phosphonic acids and the salts and esters thereof in the range from 0.1 to 200 g/l, particularly preferably in the range from 1 to 150 g/l, most particularly preferably in the range from 3 to 100 g/l, in particular in the range from 6 to 70 g/l. These constituents may act in particular as complexing agents.
In particular when (B) comprises phosphate anions as constituent (b4), composition (B) may further comprise at least one cation selected from the group consisting of Zn, Mg, Ca, Ni, Cu and/or Mn, preferably in the range from 4 to 100 g/L, particularly preferable in the range from 5 to 60 g/L, most particularly preferably in the range from 8 to 50 g/L.
The content of cations and anions mentioned herein with respect to composition (B) can be monitored and determined by the means of ICP-OES (optical emission spectroscopy with inductively coupled plasma). Said method is described hereinafter in detail. The content of free fluoride anions is, however, determined by means of a fluoride electrode.
Optional Constituent (b8)
Optionally, composition (B) may comprise at least one further constituent (b8). Said at least one further constituent (b8) is preferably selected from the group consisting of thickeners, pigments, fillers, surfactants and mixtures thereof. Constituent(s) (b8) may be present in amount of from 0.01 to 10 wt.-% in composition (B), based on the total weight of composition (B). Preferably, optional constituent (b8) is different from each of constituents (b1) to (b4) and optional constituents (b5), (b6) and (b7).
Examples of thickeners are polysaccharide, polysiloxane, polyvinlyamide, polyacrylamide and polyglycol.
Examples of pigments and fillers are boron nitride, graphite and molybdenum sulfide. However, as in particular graphite and molybdenum sulfide are solid lubricants and their use is related to disadvantages as outlined in the introductory part, preferably no such pigments, in particular neither graphite nor molybdenum sulfide, is present in composition (B).
Examples of surfactants are fatty alcohol alkoxylates and especially fatty alcohol ethoxylates.
Optional Step (3)
Optional step (3) of the inventive method is a step, wherein the coating film obtained after step (2) is optionally dried.
The drying step (3) may be preferably performed, e.g. at a temperature in the range of 15° C. to 100° C., more preferably at a temperature in the range of 18° C. to 95° C., in particular at a temperature in the range of 20° C. to 90° C.
Inventive Pretreated Substrate
A further subject-matter of the present invention is a pretreated metallic substrate obtainable by the inventive method.
All preferred embodiments described above herein in connection with the inventive method of pretreatment are also preferred embodiments of pretreated substrate. The same applies, of course, to the embodiments of the substrate as such as outlined hereinbefore in connection with step (1) of the inventive method.
The coating film obtained after step (2) or optionally after step (3) is a combined conversion and lubricant coating film. Thus, the coating film obtained combines the properties of a conversion layer and a lubricant layer.
Preferably, the pretreated metallic substrate obtainable by the inventive method contains a conversion coating film obtained by performing step (2) and further contains a lubricant coating film on top of said conversion coating film also obtained by performing step (2). However, it is also possible that the coating film obtained after step (2) or optionally after step (3) is chemically heterogeneous.
Preferably, the coating film present on the surface of the substrate after having performed step (2) and optionally step (3) has a coating weight in a range of from 1.0 to 40.0 g/m², preferably in a range of from 5.0 to 35.0 g/m², more preferably in a range of from 10.0 to 30.0 g/m². The method for determining the coating weight is disclosed in the example section.
Inventive Cold Forming Method
A further subject-matter of the present invention is a method of cold forming a metallic substrate, characterized in that it comprises a step of subjecting the inventive pretreated metallic substrate according to a cold forming process, preferably by drawing.
All possible cold forming processes known in the prior art can be carried out, in particular rolling such as thread rolling or beating, e.g. for nut or bolt blanks, drawing, in particular sliding drawing (tensile compression forming), e.g. of welded or seamless tubes, hollow sections, solid sections, wires or rods, e.g. during wire drawing or tube drawing, or deep-drawing, e.g. of strips or sheet metal, pressing such as cold extrusion (pressure forming), e.g. of hollow or solid bodies, stretch forming (forming to gauge block/final size) and/or cold upsetting, e.g. from wire sections to fasteners such as nuts.
The most common shaped bodies to be formed from the inventive pretreated metallic substrates are strips, sheets, slugs, wires, wire coils, more complicated shaped parts, sleeves, profiles such as hollow or solid profiles, tubes, discs, discs, rods, bars or cylinders.
Preferably, the cold-formed substrate obtained after the cold forming process still bears at least part of the coating film obtained after having performed step (2) and optionally step (3): Due to the amount of the coating weight of the coating film obtained after step (2) or optionally step (3) present on the pretreated substrate, said coating film “survives” conventional cold forming processes. For example, this leaves at least 10%, preferably at least 15%, particularly preferred at least 20% of the coating weight on a pretreated and cold formed substrate after cold forming, in particular if the substrate has undergone a drawing.
However, the coating film may be removed from the cold formed substrate, e.g., by using an aqueous cleaning composition. Thus, after the cold forming process, the obtained substrate is preferably cleaned, in order to remove the conversion and lubricant coating film from the substrate, e.g. by means of alkaline cleaners, acids or pickling agents.
Inventive Composition (B)
A further subject-matter of the present invention is an aqueous lubricant composition (B) as defined hereinbefore in connection with the inventive pretreatment method.
All preferred embodiments described above herein in connection with the inventive method and the composition (B) used in step (2) thereof and the constituents contained therein are also preferred embodiments of the inventive composition (B).
Inventive Master Batch
A further subject-matter of the present invention is a master batch to produce the inventive aqueous composition (B) by diluting the master batch with water and if applicable by adjusting the pH value.
All preferred embodiments described above herein in connection with the inventive methods and the inventive composition (B) and the constituents contained therein are also preferred embodiments of inventive master batch.
If a master batch is used to produce the aqueous composition (B) according to the present invention, the master batch typically contains the constituents of the aqueous composition (B) to be produced in the desired proportions, but at a higher concentration. Such master batch is preferably diluted with water to the concentrations of constituents as disclosed above to form the aqueous composition (B). If necessary, the pH value of the aqueous composition (B) may be adjusted after dilution of the master batch.
Of course, it is also possible to further add any of the optional components to the water, wherein the master batch is diluted or to add any of the optional components after diluting the master batch with water. It is however preferred that the master batch already contains all necessary components.
Preferably, the master batch is diluted with water and/or an aqueous solution in the ratio of 1:5,000 to 1:10, more preferred 1:1,000 to 1:10, most preferred in the ratio of 1:300 to 1:10 and even more preferred 1:150 to 1:50 to produce composition (B).
Methods
1. Total Acid (TA)
The total acid (TA) is the sum of the divalent cations present as well as free and bound oxalic acids and/or phosphoric acid. It is determined by the consumption of 0.1 M NaOH using a pH meter and an electrode. For this, 10 ml of the composition are pipetted into a suitable vessel, for example a 300 ml Erlenmeyer flask and diluted with 25 ml of deionized water. It is then titrated with 0.1 M NaOH to a pH of 9. The consumption in ml per 10 ml of the diluted composition corresponds to the total acid score (TA).
2. Free Acid (FA) and Fischer Total Acid (TAF)
The free acid (FA) is determined by the consumption of 0.1 M NaOH using a pH meter and an electrode. For this, 5 ml of the composition are pipetted into a suitable vessel, for example a 300 ml Erlenmeyer flask and diluted with 50 ml of deionized water. It is then titrated with 0.1 M NaOH to a pH of 4. The consumption in ml per 10 ml of the diluted composition corresponds to the free acid score (FA). After FA titration, 40 mL of 30% potassium oxalate solution is added into the solution. It is then titrated with 0.1 M NaOH to a pH of 9. The consumption in ml per 10 ml of the diluted composition corresponds to the Fischer total acid score (TAF)
3. Solid Content
The non-volatile fraction (solids or solid content) is determined in accordance with DIN EN ISO 3251 (date: June 2019). This involves weighing out 1 g of sample into an aluminum dish which has been dried beforehand and drying the dish with sample in a drying cabinet at 130° C. for 60 minutes, cooling it in a desiccator, and then reweighing. The residue, relative to the total amount of sample employed, corresponds to the nonvolatile fraction.
4. ICP-OES
The amount of certain elements in a sample under analysis is determined using inductively coupled plasma atomic emission spectrometry (ICP-OES) according to DIN EN ISO 11885 (date: Sep. 1, 2009).
4. Alkaline Points
The alkaline points are determined by consumption of 0.05 M sulphuric acid using a pH meter and an electrode. For this, 5 ml of the composition are pipetted into a suitable vessel, for example a 300 ml Erlenmeyer flask and diluted with 50 ml of deionized water. It is then titrated with 0.05 M sulphuric acid to a pH of 4.5.
5. Calcium Points
The calcium points are determined by titration of 0.1 M EDTA solution.
6. Glass Transition Temperature (Ta)
Glass transition temperature (T_g) is determined through differential scanning calorimetry (DSC). 10 mg of a polymer sample is analyzed by DSC. The temperature-program is set from −50° C. to 210° C. and the heating/cooling rate is selected to be 10° C./Min.
7. Polydispersity Index (PDI) and Weight Average Molecular Weight (M_w)
Determination of M_w(weight average molecular weight) and PDI as well as of Mn (number average molecular weight) is performed by gel permeation chromatography (GPC), equipped with a RI and UV detector. Polymer samples are dissolved in the mobile phase and the resulting solutions are filtrated with a Millipore filter 0.45 μm. Eluting conditions are the following ones. Mobile phase: DMF 100% vol. 0.01% LiBr; flow rate: 1 mL/min; columns: Varian Aquagel OH mixed H, 8 μm, 3*30 cm; detection: RI (concentration detector Agilent)+UV at 290 nm; samples concentration: around 0.5 wt % in the mobile phase; injection loop: 100 μL.

EXAMPLES

The following examples further illustrate the invention but are not to be construed as limiting its scope.

1. Inventive and Comparative Lubricant Compositions

1.1 Example H1 (Inventive)

An acid stable phosphate anions containing aqueous polymeric lubricant composition 11 for steel and/or steel alloy pretreatment was prepared in a high-speed mixer with stirring. The composition of this lubricant is given in Table 1. It has a pH value of about 2.5.

TABLE 1

Composition of phosphate
containing lubricant example I1

		Amount
	Constituent	[wt.-%]

	Polymer 1	0.3
	Aqueous polymer solution 2	0.1
	(30 wt.-% solids)
	Aqueous wax dispersion 1	2.7
	(40 wt.-% solids)
	Aqueous wax dispersion 2	3.6
	(45 wt.-% solids)
	Aqueous wax dispersion 3	2.1
	(40 wt.-% solids)
	Wax 4	0.5
	Polyglycol	0.1
	Silicone-free defoamer	0.2
	Corrosion inhibitor	0.1
	Gardobond ® Z 3100	9.4
	Deionized water	80.9
		Σ 100.0

Polymer 1 is a polyvinyl pyrrolidone homopolymer, which is commercially available from BASF SE. Polymer 1 has a polydispersity index (PDI) of about 4.5 and a glass transition temperature (T_g) of about 100 to 110° C. Aqueous polymer solution 2 contains a polyvinyl pyrrolidone copolymer, which is commercially available from BASF SE. Aqueous wax dispersion 1 contains a polypropylene wax, which is commercially available from BYK Chemie. Aqueous wax dispersion 2 contains a polyethylene wax, which is commercially available from Münzing Chemie. Aqueous wax dispersion 3 contains a microcrystalline wax, which is commercially available from Michelman. Wax 4 is a montane wax, which is dispersible in aqueous medium. A mixture of an alkyl amide and an alkanolamine is used as corrosion inhibitor. Gardobond® Z 3100 is a commercially available phosphate anions containing product from Chemetall GmbH, which is used for zinc phosphating. The phosphating point (free acid (FA) plus Fischer total acid (TFA) of 11 is 20.

1.2 Example I2 (Inventive)

An acid stable oxalate anions containing aqueous polymeric lubricant composition 12 was prepared was prepared for steel and/or steel alloy pretreatment in a high-speed mixer with stirring. The composition of this lubricant is given in Table 2. It has a pH value of about 1.0.

TABLE 2

Composition of oxalate
containing lubricant example I2

		Amount
	Constituent	[wt.-%]

	Polymer 1	0.3
	Aqueous polymer solution 2	0.1
	(30 wt.-% solids)
	Aqueous wax dispersion 1	2.8
	(40 wt.-% solids)
	Aqueous wax dispersion 2	3.8
	(45 wt.-% solids)
	Aqueous wax dispersion 3	2.2
	(40 wt.-% solids)
	Wax 4	0.6
	Polyglycol	0.1
	Silicone-free defoamer	0.2
	Corrosion inhibitor	0.1
	Gardo ® Hybrid 4100	3.1
	Gardobond ® Additive H 7104	2.2
	Deionized water	84.5
		Σ 100.0

Polymer 1, aqueous polymer solution 2, aqueous wax dispersions 1, 2 and 3, and wax 4 as well as the corrosion inhibitor have been described above in connection with lubricant example nt. Gardo® Hybrid Z 4100 is a commercially available oxalic acid containing product (Chemetall GmbH), which is free from phosphates. Gardobond® Additive H 7104 is a Fe(NO₃)₃containing commercially available product from Chemetall GmbH and is used as an oxalating accelerator in combination with Gardo® Hybrid Z 4100.
The concentration of Gardo® Hybrid Z 4100 in 12 is 33 g/L and the concentration of Gardobond® Additive H 7104 in 12 is 23.6 g/L. The total acid (TA) value of 12 is 55.

1.3 Example I3 (Inventive)

An acid stable phosphate anions containing aqueous polymeric lubricant composition 13 was prepared was prepared for steel and/or steel alloy pretreatment in a high-speed mixer with stirring. The composition of this lubricant is given in Table 3. It has a pH value of about 5.5.

TABLE 3

Composition of phosphate
containing lubricant example I3

		Amount
	Constituent	[wt.-%]

	Polymer 1	0.3
	Aqueous polymer solution 2	0.1
	(30 wt.-% solids)
	Aqueous wax dispersion 1	2.7
	(40 wt.-% solids)
	Aqueous wax dispersion 2	3.6
	(45 wt.-% solids)
	Aqueous wax dispersion 3	2.1
	(40 wt.-% solids)
	Wax 4	0.5
	Polyglycol	0.1
	Silicone-free defoamer	0.2
	Corrosion inhibitor	0.1
	Gardobond ® Z 3911	5.1
	Gardobond ® Additive H 7201	0.3
	Deionized water	85.0
		Σ 100.0

Polymer 1, aqueous polymer solution 2, aqueous wax dispersions 1, 2 and 3, and wax 4 as well as the corrosion inhibitor have been described above in connection with lubricant example 11. Gardobond® Z 3911 is a commercially available phosphate containing product from Chemetall GmbH, which is used for iron phosphating. Gardobond® Additive H 7201 is a commercially available additive for iron phosphating. The total acid (TA) of 13 is 15 and alkaline point is 0.7.

1.4 Example 14 (Inventive)

An alkaline stable aqueous polymeric lubricant composition 14 was prepared for aluminum and/or aluminum alloy pretreatment in a high-speed mixer with stirring. The composition of this lubricant is given in Table 4. It has a pH value of about 12.0.

TABLE 4

Composition of lubricant example I4

		Amount
	Constituent	[wt.-%]

	Polymer 1	0.3
	Aqueous polymer solution 2	0.1
	(30 wt.-% solids)
	Aqueous wax dispersion 1	2.7
	(40 wt.-% solids)
	Aqueous wax dispersion 2	3.6
	(45 wt.-% solids)
	Aqueous wax dispersion 3	2.1
	(40 wt.-% solids)
	Wax 4	0.5
	Polyglycol	0.1
	Silicone-free defoamer	0.2
	Corrosion inhibitor	0.1
	Gardobond ® Z 3900	3.0
	Deionized water	87.3
		Σ 100.0

Polymer 1, aqueous polymer solution 2, aqueous wax dispersions 1, 2 and 3, and wax 4 as well as the corrosion inhibitor have been described above in connection with lubricant example 11. Gardobond® Z 3900 is a commercially available product from Chemetall GmbH comprising calcium chloride, sodium chloride and calcium hydroxide. The calcium point of 14 is in a range of from 15 to 20.

1.5 Example 15 (Comparative)

The commercially available product Gardomer® L 6332 from Chemetall GmbH has been used as comparative composition 15, which is an aqueous alkaline and wax containing polymeric lubricant. Gardomer® L 6332 has a pH value of 9.5 and is not stable in acid solution. In Gardomer® L 6332 an acid-functional copolymer not containing any monomeric unit derived from vinyl pyrrolidone is used as film-forming polymer.

1.5 Example 16 (Comparative)

An acid stable oxalate anions containing aqueous polymeric lubricant composition 16 was prepared for steel and/or steel alloy pretreatment in a high-speed mixer with stirring. The composition of this lubricant and its pH value is identical to the composition and pH value of the lubricant of example 12 except that not Gardobond® Additive H 7104 has been used but instead a commercially available oxalating accelerator comprising nitroguanidine.

2. Inventive and Comparative Method

2.1 Zinc-Phosphating Treatment and Treatment with Acid Stable Aqueous Polymeric Lubricant I1 for Steel and/or Steel Alloy in a Single Step (Inventive)

As metal workpieces the following substrates were used:

- a) Sheet made of 2.0 mm hot-rolled steel (HRS) (DC11 (no. 1.0332); substrate S1),
- b) Slugs with 27 mm diameter and 13 mm height made of tempered steel (C15 (no. 1.0401); substrate S2) and,
- c) Wire sections with 11.0 mm diameter made of steel (C15 (no. 1.0401); substrate S3).

Each of the workpieces was dipped in a cleaning bath with a 50 g/L aqueous cleaning solution of Gardoclean® 351 available from Chemetall GmbH at 90° C. for 10 min. and then rinsed by cold tap water for 1 min. Afterwards, the surface purified workpieces were then pickled by using a 15 wt.-% HCl solution for 1 min. and subsequently rinsed by cold tap water for 1 min. The workpieces were then optimally activated by Gardolene® V 6522 available from Chemetall GmbH at room temperature for 1 min.
Then, in a single step, the workpieces were dipped into a bath containing lubricant example 11 at 60° C. for 10 min.
Finally, the coated workpieces obtained were dried with air at 85° C.
No solid foams were formed during this process. The resulting sludge in the reaction bath of 11 was powdery and could be easily removed from the reaction bath.

2.2 Oxalating Treatment and Treatment with Acid Stable Aqueous Polymeric Lubricant 12 (Inventive) or 16 (Comparative) for Steel and/or Steel Alloy in a Single Step

As metal workpieces the following substrates were used:

- a) Sheet made of 0.8 mm cold-rolled steel (CRS) (DC05 (no. 1.0332); substrate S4),
- b) Sheet made of 2.0 mm hot-rolled steel (HRS) (DC11 (no. 1.0332); substrate S1), c) Slugs with 27 mm diameter and 13 mm height made of tempered steel (C15 (no. 1.0401); substrate S2 and,
- d) Wire sections with 11.0 mm diameter made of steel (C15 (no. 1.0401); substrate S3).

Each of the workpieces was dipped in a cleaning bath with a 50 g/L aqueous cleaning solution of Gardoclean® 351 available from Chemetall GmbH at 85° C. for 10 min. and then rinsed by cold tap water for 1 min. Afterwards, the surface purified workpieces were then pickled by using a 15 wt.-% HCl solution for 1 min. and subsequently rinsed by cold tap water for 1 min.
Then, in a single step, the workpieces were dipped into a bath containing lubricant example I2 or I6 at 85° C. for 8 min.
Finally, the coated workpieces obtained were dried with air at 85° C.
No solid foams were formed during this process. The resulting sludge in the reaction baths of 12 and 16 was powdery and could be easily removed from the reaction bath.

2.3 Iron-Phosphating Treatment and Treatment with Acid Stable Aqueous Polymeric Lubricant I3 for Steel and/or Steel Alloy in a Single Step (Inventive)

As metal workpieces the following substrates were used:

- a) Sheet made of 2.0 mm hot-rolled steel (HRS) (DC11 (no. 1.0332); substrate S1),
- b) Seamless tube made of steel (no. 1.0050, substrate S5)

Each of the workpieces was dipped in a cleaning bath with a 50 g/L aqueous cleaning solution of Gardoclean® 351 available from Chemetall GmbH at 85° C. for 10 min. and then rinsed by cold tap water for 1 min. Afterwards, the surface purified workpieces were then pickled by using a 15 wt.-% HCl solution for 1 min. and subsequently rinsed by cold tap water for 1 min.
Then, in a single step, the workpieces were dipped into a bath containing lubricant example 13 at 70° C. for 10 min.
Finally, the coated workpieces obtained were dried with air at 85° C.
No solid foams were formed during this process. The resulting sludge in the reaction bath of 13 was powdery and could be easily removed from the reaction bath.

2.4 Treatment with Alkaline Stable Aqueous Polymeric Lubricant I4 for Aluminum and/or Aluminum Alloy in a Single Step (Inventive)

As metal workpieces the following substrates were used:
Slugs with 27 mm diameter and 13 mm height made of tempered aluminum (1050A, substrate S6).
Each of the workpieces was dipped in a cleaning bath with a 20 g/L aqueous cleaning solution of Gardoclean® T 5550 available from Chemetall GmbH at 55° C. for 10 min. and then rinsed by cold tap water for 1 min. Afterwards, the surface purified workpieces were then pickled by using a 35 g/L acid solution of Gardoacid® P 4304 for 1 min. and subsequently rinsed by cold tap water for 1 min.
Then, in a single step, the workpieces were dipped into a bath containing lubricant example 14 at 75° C. for 10 min.
Finally, the coated workpieces obtained were dried with air at 85° C.
No solid foams were formed during this process. The resulting sludge in the reaction bath of 14 was powdery and could be easily removed from the reaction bath.

2.5 Treatment of Steel and/or Steel Alloy with a Conventional Alkaline Polymeric Lubricant I5 after Performance of (i) a Zinc Phosphating Treatment Followed by (ii) Rinsing in Two Steps (Plus Rinsing) (Comparative)

As metal workpieces the following substrates were used:

- a) Sheet made of 2.0 mm hot-rolled steel (HRS) (DC11 (no. 1.0332); substrate S3),
- b) Wire sections with 11.0 mm diameter made of steel (C15 (no. 1.0401); substrate S1).

Each of the workpieces was dipped in a cleaning bath with a 50 g/L aqueous cleaning solution of Gardoclean® 351 available from Chemetall GmbH at 85° C. for 10 min. and then rinsed by cold tap water for 1 min. Afterwards, the surface purified workpieces were then pickled by using a 15 wt.-% HCl solution for 1 min. and subsequently rinsed by cold tap water for 1 min. The workpieces were then optimally activated by Gardolene® V 6522 available from Chemetall GmbH at room temperature for 1 min.
The workpieces were dipped into a zinc-phosphating bath containing commercial product Gardobond® Z 3100 from Chemetall GmbH at 60° C. for 10 min. The phosphate point of this zinc-phosphating bath is 20, same as in case of lubricant I1. Then the zinc-phosphated workpieces were rinsed with tap water for neutralization of the surface. After rinsing, the workpieces were dipped into a bath containing a conventional comparative aqueous alkaline lubricant I5 at 60° C. for 2 min.
Finally, the coated workpieces obtained were then dried with air at 85° C.

2.6 Treatment of Steel and/or Steel Alloy with a Conventional Alkaline Polymeric Lubricant I5 after Performance of (i) an Oxalating Treatment Followed by (ii) Rinsing in Two Steps (Plus Rinsing) (Comparative)

- a) Sheet made of 0.8 mm cold-rolled steel (CRS) (DC05 (no. 1.0332); substrate S2),
- b) Wire sections with 11.0 mm diameter made of steel (C15 (no. 1.0401); substrate S1).

Each of the workpieces was dipped in a cleaning bath with a 50 g/L aqueous cleaning solution of Gardoclean® 351 available from Chemetall GmbH at 85° C. for 10 min. and then rinsed by cold tap water for 1 min. Afterwards, the surface purified workpieces were then pickled by using a 15 wt.-% HCl solution for 1 min. and subsequently rinsed by cold tap water for 1 min.
The workpieces were dipped into an oxalating bath containing commercial product Gardo® Hybrid Z 4100 and Gardobond® Additive H 7104 from Chemetall GmbH at 85° C. for 10 min. The total acid (TA) of this oxalating bath is 55, same as 12. Then the oxalated workpieces were rinsed with tap water for neutralization of the surface. After rinsing, the workpieces were dipped into a bath containing a conventional comparative aqueous alkaline lubricant I5 at 60° C. for 2 min.
Finally, the coated workpieces obtained were then dried with air at 85° C.

3. Properties of the Coated Substrates

3.1 Coated Substrates Obtained from the 1-Step-Process as Outlined in Item 2.1 (Inventive)—Use of Lubricant I1

The resulting coating layer on each of the coated workpieces is homogenous, thick and adhered firmly on the treated surface of each workpiece. The coating layers showed a very good stability against corrosion, and no brown discoloration existed on any of the steel surfaces. The top coating layer formed by the method is a polymer lubricant layer and the bottom coating layer formed is a zinc phosphate conversion coating layer.
The lubricated workpiece was weighted. Then, the polymer lubricant coating layer was washed with xylene in order to detach it and subsequently with water. The workpiece was then dried and weighted. The phosphate coating layer was washed with an alkaline solution containing NaOH, triethyl amine and EDTA (PL 83 from Chemetall GmbH) in order to detach it. Finally, the workpiece was rinsed with water, dried and weighted once again. The coating weights on different substrate surfaces are listed in Table 5. These data relate to the use of lubricant I1.

TABLE 5

Coating weights on different substrate
surfaces (S1, S2 and S3) in g/m²

	Polymer	Zinc-phosphate
	lubricant coating	coating weight	Total
Substrate	weight [g/m²]	[g/m²)]	[g/m²]

S1	2.7	8.0	10.7
S2	5.0	8.7	13.7
S3	2.9	8.1	11.0

Drawing-tests of the coated substrate S3 were carried out to prove the cold forming performance with different drawing-speeds (three parallel runs I and II and III). The results are displayed in Table 6. The drawing test of run I was with 30 m/Min drawing-speed and 20% cross-sectional area reduction in each step. Run II was performed with 60 m/Min drawing-speed and 20% cross-sectional area reduction in each step. These data also relate to the use of lubricant I1.

TABLE 6

Test parameters of drawing-performance of coated substrates S3

	Run I (30 m/Min)	Run II (60 m/Min)

1. Draw	Ø(11 mm) to Ø(9.8 mm)	Ø(11 mm) to Ø(9.8 mm)
2. Draw	Ø(9.8 mm) to Ø(8.8 mm)	Ø(9.8 mm) to Ø(8.8 mm)
3. Draw	Ø(8.8 mm) to Ø(7.8 mm)	Ø(8.8 mm) to Ø(7.8 mm)

Both parallel runs showed good drawing performance. The coating layer on substrate S3 showed very good lubricating properties. In addition, the coating layers showed a very good stability against corrosion. After drawing a homogenous coating layer still existed on the wire surface and the steel wire substrate S3 showed no scratches or other visible imperfections on its steel surface. The remaining polymer lubricant coating weight and zinc phosphate coating weight are listed in Table 7. The polymer lubricant coating has a good lubricating performance and is thus suitable for metal cold forming with high speed drawing.

TABLE 7

Remaining coating weights of
coated substrate S3 after drawing

Polymer	Zinc phosphate
lubricant coating	coating weight	Total
weight [g/m²]	[g/m²]	[g/m²]

Run I	1.0	3.9	4.9
Run II	0.7	2.8	3.5

Coated substrate S2 was cold extruded. The cold extrusion was successful. No scratches or other visible imperfection existed on the cold extruded substrates.
The coatings have proven to have a high quality and to be very suitable for cold forming with high drawing speeds and for cold extrusion. The remaining coating layers adhered still firmly on the metal surface of the substrates.
After the cold forming process, the remaining coating layer can be washed using alkaline cleaner, e.g. Gardoclean® S 5171 with Gardobond® Additive H 7375 from Chemetall GmbH, or with acidic cleaner, e.g. Gardobond® Additive H 7132 with Gardobond® Additive H 7390 from Chemetall GmbH, without impairing any of the desired properties.

3.2 Coated Substrates Obtained from the 1-Step-Process as Outlined in Item 2.2 (Inventive)—Use of Lubricant I2

The resulting coating layer on each of the coated workpieces is homogenous, thick and adhered firmly on the treated surface of each workpiece. The coating layers showed a very good stability against corrosion, and no brown discoloration existed on any of the steel surfaces. The top coating layer formed by the method is a polymer lubricant layer and the bottom coating layer formed is an oxalate conversion coating layer.
The coating weights on the different substrates were determined by the method described hereinbefore in item 3.1 and are listed in Table 8. These data relate to the use of lubricant I2.

TABLE 8

Coating weights on different substrate
surfaces (S1, S2 and S3) in g/m²

	Polymer	Oxalate
	lubricant coating	coating weight	Total
Substrate	weight [g/m²]	[g/m²)]	[g/m²]

S1	6.9	7.7	14.6
S3	6.3	7.8	14.1
S2	9.0	12.5	21.5

Drawing-tests of the coated substrate S1 were carried out to prove the cold forming performance with different drawing-speeds (three parallel runs I and II and III). The results are displayed in Table 9. The drawing test of run I was with 30 m/Min drawing-speed and 20% cross-sectional area reduction in each step. Run II was performed with 60 m/Min drawing-speed and 20% cross-sectional area reduction in each step. Run III was performed with 40 m/Min drawing-speed and 35% cross-sectional area reduction in each step. These data also relate to the use of lubricant I2.

TABLE 9

Test parameters of drawing-performance of coated substrate S3

	Run I (30 m/Min)	Run II (60 m/Min)	Run III (40 m/Min)

1. Draw	Ø(11 mm) to Ø(9.8 mm)	Ø(11 mm) to Ø(9.8 mm)	Ø(11 mm) to Ø(8.5 mm)
2. Draw	Ø(9.8 mm) to Ø(8.8 mm)	Ø(9.8 mm) to Ø(8.8 mm)	Ø(8.5 mm) to Ø(7.4 mm)
3. Draw	Ø(8.8 mm) to Ø(7.8 mm)	Ø(8.8 mm) to Ø(7.8 mm)	nd
4. Draw	Ø(7.8 mm) to Ø(6.7 mm)	Ø(7.8 mm) to Ø(6.7 mm)	nd

nd = not determined

All three parallel runs showed good drawing performance. The coating layer on steel wire showed very good lubricating properties. After drawing a homogenous coating layer still existed on the wire surface and the steel wire showed no scratches or other visible imperfections on steel surface. The remaining coating weights after having performed the drawing test are listed in Table 10. After drawing, the total remaining coating weights are all still higher than 6 g/m². The steel wires could even still be drawn to reduce the diameter. These data also relate to the use of lubricant I2.

TABLE 10

Remaining coating weights of
coated substrate S3 after drawing

	Polymer	Oxalate	Total
	lubricant coating	coating	coating
	weight [g/m²]	weight [g/m²]	weight [g/m²]

Run I	3.2	3.8	7.0
Run II	3.4	5.2	8.6
Run III	2.7	3.6	6.3

3.3 Coated Substrates Obtained from the 1-Step-Process as Outlined in Item 2.3 (Inventive)—Use of Lubricant I3

The resulting coating layer on each of the coated workpieces is homogenous, thin and adhered firmly on the treated surface of each workpiece, which is especially suitable for tube industry. The coating layers showed a good stability against corrosion, and no brown discoloration existed on any of the steel surfaces. The top coating layer formed by the method is a polymer lubricant layer and the bottom coating layer formed is an iron phosphate coating layer.
The coating weights on the different substrates were determined by the method described hereinbefore in item 3.1 and are listed in Table 11. These data relate to the use of lubricant I3.

TABLE 11

Coating weights on different substrate
surfaces (S1 and S5) in g/m²

	Polymer lubricant	Iron
	coating weight	phosphate coating	Total
Substrate	[g/m²]	weight [g/m²)]	[g/m²]

S1	2.1	1.1	3.2
S5	2.1	0.9	3.0

3.4 Coated Substrates Obtained from the 1-Step-Process as Outlined in Item 2.4 (Inventive)—Use of Lubricant I4

The resulting coating layer on each of the coated workpieces is homogenous, thick and adhered firmly on the treated surface of each workpiece. The coating layers showed a very good stability against corrosion, and no brown discoloration existed on any of the aluminum surfaces. The top coating layer formed by the method is a polymer lubricant layer and the bottom coating layer formed is a calcium aluminate conversion coating layer.
The polymer coating weights on the different substrates were determined by the method described hereinbefore in item 3.1. The calcium aluminate coating layer was washed with an acid solution containing 10% HNO₃in order to detach it. Finally, the workpiece was rinsed with water, dried and weighted once again.
The coating weights on aluminum slug (S6) are given in Table 12. These data relate to the use of lubricant I4.

TABLE 12

Coating weights on aluminum slug surfaces (S6) in g/m²

	Polymer lubricant	Calcium
	coating weight	aluminate coating	Total
Substrate	[g/m²]	weight [g/m²)]	[g/m²]

S6	8.2	5.3	13.5

3.5 Comparing Coated Substrates Obtained from Inventive 1-Step Process as Outlined in Item 2.1 with Coated Substrates Obtained from a Conventional Multi-Step Process as Outlined in Item 2.5, which Make Use of Conventional Lubricant I5 for Steel Treatment

The coating properties obtained from 1-step process as outlined in item 2.1 are comparable or slightly better than coating obtained from conventional multi-step process at outlined in item 2.5. However, only one process step has to be performed in case of the inventive method and thus no rinsing step is necessary as in case of the comparative method and the total coating weights obtained in case of the inventive 1-step method are higher than in case of the comparative multi-steps method.

3.6 Comparing Coated Substrates Obtained from Inventive 1-Step Process as Outlined in Item 2.2 with Coated Substrates Obtained from a Conventional Multi-Step Process as Outlined in Item 2.6, which Make Use of Conventional Lubricant I5 for Steel Treatment

The coating properties obtained from 1-step process as outlined in item 2.2 are comparable or slightly better than coating obtained from conventional multi-step process at outlined in item 2.6. However, only one process step has to be performed in case of the inventive method and thus no rinsing step is necessary as in case of the comparative method and the total coating weights obtained in case of the inventive 1-step method are higher than in case of the comparative multi-steps method.

3.7 Coated Substrates Obtained from the 1-Step-Process as Outlined in Item 2.2 (Inventive)—Use of Lubricant I6

Wherein the oxalate coating weights on substrates S1 to S3 in case of using lubricant I2 were found to be in a range of 7.7 to 12.5 g/m²as it is evident from Table 8, the observed oxalate coating weights in case of using lubricant I6 in the same manner as described in item 2.2 were unexpectedly found to be substantially lower, namely in a range of from only 4.0 to 6.0 g/m². This effect is thus associated with the use of Fe(III) ions as accelerator in 12 vs. the use of nitroguanidine in 16, which is unexpected.

Claims

1. A method of pretreatment of a metallic substrate for a subsequent metal cold forming process, said method comprising at least steps (1) and (2) and optionally step (3), namely

(1) providing at least one substrate having at least one surface at least partially made of at least one metal and/or alloy thereof, wherein said metal and/or alloy thereof is at least one of steel, aluminum and alloys of aluminum and/or steel,

(2) contacting the at least one surface of the substrate provided in step (1) with an aqueous lubricant composition (B) having a pH value, which is in the non-neutral pH range, wherein the neutral pH range is a pH range of from >6.0 to <8.0,

wherein the aqueous lubricant composition (B) comprises besides water at least constituents (b1) to (b4) and optionally (b5), which are different from one another, namely

(b1) at least one film-forming polymer, which is a homopolymer and/or copolymer prepared by polymerization of at least vinyl pyrrolidone as at least one monomer, wherein said homopolymer and/or copolymer has a polydispersity index (PDI) in a range of from 1.5 to 8.0,

(b2) at least one wax,

(b3) at least one defoamer,

(b4) (i) oxalate anions and/or phosphate anions or (ii) calcium cations, chloride anions and hydroxide anions, and

(b5) optionally Fe(III) ions, wherein constituent (b5) is present in case at least oxalate anions are present as constituent (b4),

and

(3) optionally drying the coating film obtained after having performed step (2).

2. The method according to claim 1, wherein the film-forming polymer (b1) has a polydispersity index (PDI) in a range of from 1.8 to 7.5.

3. The method according to claim 1, wherein the film-forming polymer (b1) has at least one glass transition temperature (T_g) in a range of from 40 to 200° C.

4. The method according to claim 1, wherein the film-forming polymer (b1) is a homopolymer being prepared from vinyl pyrrolidone or a copolymer prepared from vinyl pyrrolidone and at least one monomer selected from the group consisting of (meth)acrylate monomers, vinyl amine, vinyl alcohol, vinyl formamide, vinyl caprolactam, vinyl acetate and vinyl imidazole.

5. The method according to claim 1, wherein the film-forming polymer (b1) is present in the composition (B) in an amount in a range of from 0.05 to 20 wt.-%, based on the total weight of the composition (B).

6. The method according to claim 1, wherein the aqueous lubricant composition (B) has a

pH value in a range of from 0.1 to 6.0, or has a

pH value in a range of from 8.0 to 14.0.

7. The method according to claim 1, wherein the aqueous lubricant composition (B) has a

pH value in a range of from 0.1 to <2.0, or has a

pH value in a range of from ≥2.0 to 6.0, or has a

pH value in a range of from 8.0 to 14.0,

8. The method according to claim 1, wherein the at least one wax (b2) is selected from the group consisting of polyolefin waxes.

9. The method according to claim 1, wherein the composition (B) further comprises at least one corrosion inhibitor as constituent (b6), which is different from each of constituents (b1) to (b4) and optional constituent (b5).

10. The method according to claim 1, wherein the defoamer constituent (b3) is a defoamer, which is free of silicone.

11. The method according to claim 1, wherein the contacting step (2) is performed by at least partially dipping the substrate into a bath containing the aqueous lubricant composition (B) having a bath temperature in a range of from 20 to 95° C.

12. A pretreated metallic substrate obtained by the method according to claim 1.

13. The pretreated metallic substrate according to claim 12, wherein the coating film present on the surface of the substrate after having performed step (3) has a coating weight in a range of from 1.0 to 40.0 g/m².

14. A method of cold forming a metallic substrate, comprising a step of subjecting the pretreated metallic substrate according to claim 12 to a cold forming process.

15. An aqueous lubricant composition (B), comprising:

water; and

at least constituents (b1) to (b4) and optionally (b5), which are different from one another, namely

(b2) at least one wax,

(b3) at least one defoamer,

(b5) optionally Fe(III) ions, wherein constituent (b5) is present in case at least oxalate anions are present as constituent (b4).

16. The method according to claim 1, wherein the film-forming polymer (b1) has a polydispersity index (PDI) in a range of from 2.0 to 7.0.

17. The method according to claim 1, wherein the film-forming polymer (b1) has at least one glass transition temperature (T_g) in a range of from 50 to 190° C.

18. The method according to claim 1, wherein the film-forming polymer (b1) is present in the composition (B) in an amount in a range of from 0.10 to 15 wt.-% based on the total weight of the composition (B).

19. The method according to claim 1, wherein the at least one wax (b2) is selected from the group consisting of polyethylene waxes and polypropylene waxes, montan waxes, bees waxes and carnauba waxes, and mixtures thereof.

20. The method according to claim 1, wherein the at least one wax (b2) is present in the composition (B) in an amount in the range of from 0.1 to 20 wt.-% based on the total weight of the composition (B).