US3269943A - Multi-layer lubrication utilizing encapsulating coating - Google Patents

Multi-layer lubrication utilizing encapsulating coating Download PDF

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Publication number
US3269943A
US3269943A US464849A US46484965A US3269943A US 3269943 A US3269943 A US 3269943A US 464849 A US464849 A US 464849A US 46484965 A US46484965 A US 46484965A US 3269943 A US3269943 A US 3269943A
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Prior art keywords
lubricant
film
metal
encapsulating
coating
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US464849A
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English (en)
Inventor
David E Armstrong
Gerald P Roeser
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HORACE T POTTS
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HORACE T POTTS
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Priority to BE618785D priority Critical patent/BE618785A/xx
Priority claimed from US116527A external-priority patent/US3191286A/en
Priority to DE19621444776 priority patent/DE1444776A1/de
Priority to GB22555/62A priority patent/GB1035981A/en
Application filed by HORACE T POTTS filed Critical HORACE T POTTS
Priority to US464849A priority patent/US3269943A/en
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    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
    • C10M177/00—Special methods of preparation of lubricating compositions; Chemical modification by after-treatment of components or of the whole of a lubricating composition, not covered by other classes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES, PROFILES OR LIKE SEMI-MANUFACTURED PRODUCTS OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C37/00—Manufacture of metal sheets, rods, wire, tubes, profiles or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
    • B21C37/06—Manufacture of metal sheets, rods, wire, tubes, profiles or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
    • B21C37/15—Making tubes of special shape; Making tube fittings
    • B21C37/28—Making tube fittings for connecting pipes, e.g. U-pieces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES, PROFILES OR LIKE SEMI-MANUFACTURED PRODUCTS OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C37/00—Manufacture of metal sheets, rods, wire, tubes, profiles or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
    • B21C37/06—Manufacture of metal sheets, rods, wire, tubes, profiles or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
    • B21C37/15—Making tubes of special shape; Making tube fittings
    • B21C37/28—Making tube fittings for connecting pipes, e.g. U-pieces
    • B21C37/29—Making branched pieces, e.g. T-pieces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D37/00—Tools as parts of machines covered by this subclass
    • B21D37/18—Lubricating, e.g. lubricating tool and workpiece simultaneously
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
    • B29C63/26—Lining or sheathing of internal surfaces
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    • C08L27/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Compositions of derivatives of such polymers
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    • C10M7/00—Solid or semi-solid compositions essentially based on lubricating components other than mineral lubricating oils or fatty oils and their use as lubricants; Use as lubricants of single solid or semi-solid substances
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    • C10M2215/02—Amines, e.g. polyalkylene polyamines; Quaternary amines
    • C10M2215/04—Amines, e.g. polyalkylene polyamines; Quaternary amines having amino groups bound to acyclic or cycloaliphatic carbon atoms
    • C10M2215/042—Amines, e.g. polyalkylene polyamines; Quaternary amines having amino groups bound to acyclic or cycloaliphatic carbon atoms containing hydroxy groups; Alkoxylated derivatives thereof
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    • C10M2215/08—Amides [having hydrocarbon substituents containing less than thirty carbon atoms]
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    • C10M2215/082—Amides [having hydrocarbon substituents containing less than thirty carbon atoms] containing hydroxyl groups; Alkoxylated derivatives
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    • C10M2215/16—Nitriles
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    • C10M2215/24—Organic non-macromolecular compounds containing nitrogen as ingredients in lubricant Compositions having hydrocarbon substituents containing thirty or more carbon atoms, e.g. nitrogen derivatives of substituted succinic acid
    • C10M2215/26—Amines
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    • C10M2215/24—Organic non-macromolecular compounds containing nitrogen as ingredients in lubricant Compositions having hydrocarbon substituents containing thirty or more carbon atoms, e.g. nitrogen derivatives of substituted succinic acid
    • C10M2215/28—Amides; Imides
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    • C10M2217/04—Macromolecular compounds from nitrogen-containing monomers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C10M2217/042—Macromolecular compounds from nitrogen-containing monomers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds between the nitrogen-containing monomer and an aldehyde or ketone
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    • C10M2217/04—Macromolecular compounds from nitrogen-containing monomers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C10M2217/043—Mannich bases
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    • C10M2217/04—Macromolecular compounds from nitrogen-containing monomers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C10M2217/046—Polyamines, i.e. macromoleculars obtained by condensation of more than eleven amine monomers
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    • C10M2217/06—Macromolecular compounds obtained by functionalisation op polymers with a nitrogen containing compound
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    • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
    • C10N2020/00—Specified physical or chemical properties or characteristics, i.e. function, of component of lubricating compositions
    • C10N2020/01—Physico-chemical properties
    • C—CHEMISTRY; METALLURGY
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    • C10N2040/00—Specified use or application for which the lubricating composition is intended
    • C10N2040/20—Metal working
    • C10N2040/24—Metal working without essential removal of material, e.g. forming, gorging, drawing, pressing, stamping, rolling or extruding; Punching metal
    • C—CHEMISTRY; METALLURGY
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    • C10N2040/00—Specified use or application for which the lubricating composition is intended
    • C10N2040/20—Metal working
    • C10N2040/241—Manufacturing joint-less pipes
    • C—CHEMISTRY; METALLURGY
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    • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
    • C10N2040/00—Specified use or application for which the lubricating composition is intended
    • C10N2040/20—Metal working
    • C10N2040/242—Hot working
    • C—CHEMISTRY; METALLURGY
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    • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
    • C10N2040/00—Specified use or application for which the lubricating composition is intended
    • C10N2040/20—Metal working
    • C10N2040/243—Cold working
    • C—CHEMISTRY; METALLURGY
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    • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
    • C10N2040/00—Specified use or application for which the lubricating composition is intended
    • C10N2040/20—Metal working
    • C10N2040/244—Metal working of specific metals
    • C—CHEMISTRY; METALLURGY
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    • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
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    • C10N2040/20—Metal working
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    • C10N2040/245—Soft metals, e.g. aluminum
    • C—CHEMISTRY; METALLURGY
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    • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
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    • C10N2040/20—Metal working
    • C10N2040/244—Metal working of specific metals
    • C10N2040/246—Iron or steel
    • C—CHEMISTRY; METALLURGY
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    • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
    • C10N2040/00—Specified use or application for which the lubricating composition is intended
    • C10N2040/20—Metal working
    • C10N2040/244—Metal working of specific metals
    • C10N2040/247—Stainless steel
    • C—CHEMISTRY; METALLURGY
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    • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
    • C10N2050/00—Form in which the lubricant is applied to the material being lubricated
    • C10N2050/015—Dispersions of solid lubricants
    • C10N2050/02—Dispersions of solid lubricants dissolved or suspended in a carrier which subsequently evaporates to leave a lubricant coating
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
    • C10N2050/00—Form in which the lubricant is applied to the material being lubricated
    • C10N2050/08—Solids
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
    • C10N2050/00—Form in which the lubricant is applied to the material being lubricated
    • C10N2050/10—Form in which the lubricant is applied to the material being lubricated semi-solid; greasy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23—Sheet including cover or casing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
    • Y10T428/263—Coating layer not in excess of 5 mils thick or equivalent
    • Y10T428/264—Up to 3 mils

Definitions

  • This invention relates to a novel lubricating composition used for metal which is to be subjected to forming operations.
  • a removable, substantially non-destructible solid synthetic plastic film-hereinafter known as the encapsulating film is applied to said metal and a novel lubricant coating is applied to said resin film to facilitate forming the encapsulated metal against a hard metal die.
  • liquid lubricants of the mineral oil type known synthetic lubricants, such as the stable non-volatile esters of organic and inorganic acids, the metal soaps and the silicone oils, the fluorocarbons, and the naturally occurring fats, oil, waxes and rosin oils, have each been found to be unsatisfactory for deforming of metal against metal in the cold, by reason of metal scoring and seizing.
  • Solid film lubricants such as graphite, copper phthalocyanine, molybdenum disulfide, alkaline earth oxides and other polyvalent metal sulfides, and certain polymers, such as trifluorethylene polymers and tetrafluorethylene polymers have also been proposed for lubrication of metal-tometal parts under extreme pressure conditions, but have also been found to be unsatisfactory for deforming of metal.
  • the lubricating system of the present invention has some superficial similarity to the solid film lubricants which are well-known in the art, there are essential differences in the specific materials which are used underlying the novelty of the present compositons.
  • the new concept of the present invention and its inherent simplicity are better understood by comparing the encapsulating principle of the present invention with conventional (unmodified) solid film lubricants.
  • the invention employs as a critical feature thereof the new principle of reduced coefficeint of friction between metal-to-metal through interposition of a physically permanent plastic barrier between one metal surface being deformed and the other metal surface of the die or forming structure.
  • the coeficient of friction is no longer that of lubricant between metal and contacting metal. Instead, it is the coefficient of friction between the plastic capsule about the metal workpiece and the metal of the die.
  • This coefiicient of friction is not the inherent value of the plastic material of the capsule since it is necessary, in accordance with the invention, to reduce the coefficient of friction between the plastic capsule and metal of the die to a value which permits the plastic material to remain dimensionally intact yet allows the underlying metal of the workpiece to flow under tensile forces which may be in excess of 100,000 pounds per square inch.
  • a unique surface treatment of the encapsulating film is effected by treatment with a lubricating surface modifier (hereinafter called the modifier) having a melting point in the range of 37110 C. and a lubricating action between the capsule and a steel die whereby an extremely low coefficient of friction is achieved.
  • the modifier a lubricating surface modifier having a melting point in the range of 37110 C. and a lubricating action between the capsule and a steel die whereby an extremely low coefficient of friction is achieved.
  • the lubricating modifier is characterized chemically by its low coeflicient of friction against plastic and metal, by its high degree of aflinity for the base plastic material of the capsule due to the presence of highly polar nitrogen or oxygen atoms or both types of atoms in the molecule of the modifier and is characterized physically by its uniquely narrow melting range lying between 37 C. and 110 C.
  • Examples of chemical species of modifier bearing polar nitrogen atoms and groups include fatty amines and nitriles substituted with long hydrocarbon radicals of melting point lying between 37 C. and 110 C., e.g., stearyl nitrile, nonadecylic nitrile, arachidyl nitrile and chlorinated and fluorinated derivatives of these nitriles within this melting range, distearyl amine, arachidylamine and chlorinated and fluorinated derivatives of these.
  • modifiers having melting point of 37 C.- 110 C. including both the polar oxygen and nitrogen group are the fatty amides and quaternary compounds substituted with fatty acid esters and preferably of polyamines and polyhydroxyamines.
  • fatty amide there may be used oleamide, ethylene stearamide, mixtures of oleamide and stearamide, hydroxy stearamide, mixtures of hydroxystearamide and stearamide.
  • These fatty amides may be mixed with fatty amines, for example, mixtures of stearamide with oleylamine (primary amine) in proportions as will give a melt ing point above 37 C.
  • quaternary ammonium compounds there may be used such compounds as fatty acid esters or wax esters of ethylene di-amine shown in US. Patent No. 2,695,243 or of N,N,N',N-tetrakishydroxyethyl ethylenediarnine as are shown in U.S. Patents Nos. 2,878,144 and 2,878,273.
  • the materials selected from these patents are those having a melting point above 37 C. and less than 110 C. Indeed, at a melting point of less than C. these ma terials appear to operate more effectively.
  • fatty nitrogen compounds, amides, amines, amine salts, nitriles and quaternary compounds in the melting point of 37/ll0 C. are generally operative as the lubricating modifier.
  • the modifier is preferably a low melting amide of oleic acid, a low melting polyglycol, a low melting, self-emulsifying wax such as myristyl myristate, or a low melting, low molecular weight linear polymer of ethylene or propylene, or equivalent low melting, low molecular weight copolymer of ethylene and propylene.
  • a volatile medium such as water, or an organic solvent, or as a hot melt.
  • the surface of the solid encapsulating film is physically altered to exhibit a kinetic coefficient of friction against a polished steel-forming a surface of about 0.01-0.02 and a static coefficient of friction of substantially the same order.
  • the lubricated surface stratum which is achieved by this treatment to impart high lubricity and a coefficient of friction lying between 0.01 and 0.02 is extremely thin and surprisingly may or may not be a continuous coating.
  • the low melting lubricant be it the low melting amide, or the low molecular weight polyglycol, or the low molecular weight ethylene polymer, when applied from dispersions form islands or particles, but that under cold-forming pressure or at slightly elevated temperature, e.g., up to about 100 C., either melts or softens to a very thin lubricating layer at the interface between the film encapsulated workpiece and the die.
  • these lubricants deposit continuous films when applied molten and said continuous films behave like the discontinuous films described above.
  • the encapsulating resin film must be substantially incompressible. Also a minimum adhesion shear strength of the solid lubricant-carrying film is needed to prevent separation from the underlying metal material which is thus protected during cold-forming. A high value of modulus of elasticity is a desirable characteristic of the resin.
  • the minimum value of adhesion strength of the encapsulating film to the base metal under cold-forming forces is at least 2 kilograms per square millimeter, or at least 600 pounds per square inch.
  • Incompressibility, adhesion, hardness and toughness in the film provide a non-destructible capsule which is uniquely suited for cold-forming of metals under forces beyond the tensile limit of the strongest metals.
  • the tensile strength of the tough encapsulating film material must be a minimum of 3000 pounds per square inch, preferably about 4500 pounds per square inch in order to maintain the integrity of the plastic capsule under metal flow conditions.
  • the elasticity of the encapsualting film as measured by percent elongation must be at least 3 percent to prevent rupture during the forming operation.
  • the encapsulating film must have a hardness value of at least Brinell in order to provide a substantially non-destructible film for carrying the surface lubricant having a low coefficient of friction against the metal die in order to prevent rub-off during the forming operation or wearing metal parts.
  • Chlorinated rubber is preferred as the encapsulating film material which is to be subjected to surface modification for providing a low coefficient of friction against metal.
  • the encapsulating film thickness is readily controlled between /2 to 3 mils in thickness.
  • this encapsulating film has a tensile strength of about 2500-5000 p.s.i., a modulus of elasticity of about 140,000 pounds, and elongation of up to about 4%.
  • Other hard, strong, and metal-tenacious resins may also be used, such as certain vinyl polymers, e.g., a copolymer of 87%95% vinyl chloride, 12%l3% vinyl acetate, and from 0.52.5% of an unsaturated carboxylic acid such as acrylic acid or maleic acid and a copolymer of 65-85% vinyl chloride and -15 of vinylidene chloride.
  • vinyl polymers e.g., a copolymer of 87%95% vinyl chloride, 12%l3% vinyl acetate, and from 0.52.5% of an unsaturated carboxylic acid such as acrylic acid or maleic acid and a copolymer of 65-85% vinyl chloride and -15 of vinylidene chloride.
  • operable film materials include polymethyl methacrylate, polyethyl methacrylate and their coploymers; polyvinyl acetals including formals, acetals, and butyrals;
  • bisphenol epoxides of the high molecular weight type like Epon 1009; cellulose acetobutyrate; vinyl chloride-vinyl acetate copolymer, like VYI-IH or Geon 428; chlorinated polyethylene or polypropylene.
  • a special coating preferably a separate formed surface of lubricating material which is capable of movement on the encapsulation film.
  • the film is converted to a capsule-bearing lubricant surface by the specific means taught by the invention to achieve a much lower coefficient of friction of plastic film against metal, e.g., steel, iron, copper, titanium, zirconium etc., than could be achieved by any known lubricant per se, liquid or solid, directly interposed between the two metal surfaces and being under the conditions of metal flow.
  • metal e.g., steel, iron, copper, titanium, zirconium etc.
  • lubricant solid encapsulating film and surface lubricant thereon are readily dissolved in common solvents either for coating purposes or for removal purposes at room temperature.
  • common organic solvents may be used as chlorinated hydrocarbon solvents, solvent naphtha, amyl acetate, ethyl acetate, ethylene glycol monomethyl ether, aromatic hydrocarbon solvents, mixtures of aromatic and high boiling aliphatic hydrocarbon solvents, and ketones such as acetone, methyl ethyl ketone, amyl ketone, etc.
  • the formation of the solid polymer encapsulating film and surface lubricant onto the base surface does not need elevated temperatures to create adhesion thereto.
  • Excellent adhesion is obtained by coating the base polymer from a solution or a water dispersion and by air drying at room temperatures.
  • the physical characteristics of the encapsulating film which have been discovered to be necessary in accordance with the invention are: (1) good hardness, (2) high tensile strength, (3) high film integrity (resistance to shear and creep), (4) good flexibility, and (5) resistance to thinning by compression.
  • Such polymers as polystyrene are wholly unsuitable by reason of excessive brittleness and low impact resistance. These cause the encapsulating film to fracture under load. Polyvinyl acetate and high butyrate-containing cellulose acetobutyrate encapsulating films are unsuitable because of excessive elongation and excessive cold flow.
  • Alcohol soluble nylon which is much more elastic than either of the suitable vinyl chloride-vinylidene chloride encapsulating polymers or suitable vinyl chloride carboxylic acid copolymer or the preferred chlorinated rubber polymer of the invention is also unsuitable because of excessive elongation.
  • the nylon base material has a high elongation and undergoes excessive cold flow.
  • the high tensile strength of the nylon base polymer about 4000- 7000 p.s.i., and its excellent adhesion to metal do not compensate for its excessive elongation.
  • the surface coating of oleic acid amide is present at room temperature as a non-tacky discontinuous thin coating which is dry to the touch and which can be scraped off readily.
  • the effective surface hardness is that of the main body of the film.
  • the lubricant coating remains on top of the encapsulating resin base as a hard film, much harder than Teflon for example.
  • the chlorinated rubber encapsulating body may be first applied as a base film to the metal part and the oleic acid amide thereafter applied as a top coating or the chlorinated rubber and the oleic acid amide may be mixed in the original coating solvent for encapsulation and lubrication by a single application.
  • the solids concentration and controlling the solvent selection By adjusting the solids concentration and controlling the solvent selection, a stratification of oleic acid amide over the encapsulating base resin is achieved, and the lubricant amide component effectively stratifies on the surface of the encapsulating film due to its difference in density and limited compatibility in the presence of organic solvent.
  • an organic solvent for depositing the lubricant coating on the solid encapsulating film base is not necessary and indeed, is not preferred in practice. It is preferred that there be used an aqueous volatile vehicle which does not soften the resin capsule. An oleamide emulsion works better than a solvent solution.
  • a low molecular weight polymer in the form of an aqueous emulsion of linear polyethylene, molecular weight 400-5000 and melting point about 90l05 C. also works well.
  • This latter emulsion or an aqueous solution of waxy polyethylene glycol or copolymer, molecular weight of MOO-20,000 can be used or can be blended with an organic solvent solution of chlorinated rubber or vinyl polymer as specified hereinabove to form an oil-in-Water emulsion by conventional emulsifying and mixing practice (preferably using a colloid mill).
  • These aqueous emulsions can dry to stratified condition in the same manner as the organic solvent solutions.
  • the type of chlorinated rubber which is preferably ernployed in the examples below to produce the substantially non-destructible solid encapsulating film of the invention is of medium to high molecular weight at a chlorine content of about 67% as evidenced by good solu bility in aromatic hydrocarbons such as benzene, toluene or xylene (up to about 40%) total solids by weight of hydrocarbon solvent and of medium to low viscosity in said hydrocarbon solution. Satisfactory encapsulating films have been produced as shown in Example 1 with chlorinated rubber having a specific viscosity value of 0.70 measured in dimethyl formamide solvent, 1 gram of chlorinated rubber per deciliter of dimethyl formarnide solvent.
  • the viscosity and molecular weight are such as pointed out above as will deposit a film up to about 3 mils in thickness by dip coating at solids, in xylol solvent onto clean steel.
  • the so-deposited encapsulating film is non-inflammable, stable to ultraviolet light, extremely impermeable to water and highly resistant to attack by alkali or acid.
  • the encapsulating film is plasticized with primary chemical plasticizers such as tricresyl phosphate or dibutyl phthalate or with such secondary plasticizers as lard oil, linseed oil, tung oil, etc. it is unsatisfactory because of softness and tends to tear away from the underlying metal causing seizing and galling.
  • primary chemical plasticizers such as tricresyl phosphate or dibutyl phthalate
  • secondary plasticizers such as lard oil, linseed oil, tung oil, etc.
  • the molecular weight of the preferred chlorinated rubber encapsulating resin is too low, e.g., substantially less than specific viscosity value of 0.50 measured in a dimethyl formamide, then the encapsulating film tends to flake off from the metal base and reproducible lubrication during metal forming without destruction of the capsule is not obtained.
  • the solutions become excessively viscous to make it difficult to brush, spray, dip or cast the coating from organic solvent solution such as xylol.
  • the metal workpiece is carefully cleaned and dried before encapsulating. Where rough metal surfaces are encountered it may be desirable to use heavier encapsulating film thicknesses, e.g., in excess of 3 to 4 mils in order to provide a smooth and level outer encapsulating film surface. In any event, the thicknes of the encapsulating film is always sufficient to obliterate surface imperfections or roughness in the underlying metal.
  • the solvent for the encapsulating resin should be completely volatile on standing at room temperature to facilitate air drying. If high boiling oily solvent residues remain after air drying, these soften the capsule and prevent attachment of the film to the base for cold-forming the encapsulated metal in a die.
  • the capsule for the metal workpiece when formed of vinyl chloride-vinyl acetate-carboxylic acid copolymer has the obvious advantage over chlorinated rubber in being capable of being adapted to be thermoset under the action of heat and thereby converted from a softer, fusible and solvent-soluble condition to a harder, infusible and solvent-resistant condition.
  • Carbamide res-ins and phenolic resin which are heat convertible and compatible with vinyl chloride resins of the VMCH type and of the VAGH type may be mixed with said vinyl resin, for example, m'elami-ne-formalde hyde resin, urea-formaldehyde resin and phenol-formaldehyde resins in the amounts recommended and known for addition to these tripolymer resins available commercially under these trade names VAGH and VMCH from Union Carbide Company.
  • these heat-setting resins When these heat-setting resins are added, the encapsulting films become thermoset by baking at elevated temperatures of 300-450 F. for 10- 30 minutes Without any substantial alteration of the necessary hardness, adhesion, elongation and tensile strength characteristics.
  • thermoset encapsulating films may in accordance with the invention be employed as permanent decorative coatings simultaneously with achieving the lubricant function by modifying with oleamide rather than as temporary removable lubricant coatings.
  • these thermoset encapsulating films after surface modifications by the amide, glycol or olefin polymer can serve for both solid encapsulating film and lubricant film and a decorative function for long lasting coating.
  • the lubricant encapsulating films of these vinyl polymer types are also useful where decorative protective finishes are desired.
  • the metal stock is designed to be finished, this may be done in accordance with the invention prior to fabricating, the thermoset coating fulfilling both protective and lubricating functions.
  • lacquer-coated corrugated iron or aluminum sheet, metal siding for the home, decorative paneling, cans, pails and enclosures may be first coated and then formed by cold-forming standard methods to provide a finished coated product.
  • thermoset coating for air conditioning and heating, metal hardware, metal wheels for automotive or farm equipment cold-stamped or cold-formed may be provided with the thermoset coating.
  • thermoplastic encapsulating film any of these articles which are to be put in final form of bare shiny metal are used with the thermoplastic encapsulating film and the encapsulating film is removed.
  • thermoplastic or thermoset may be used for lubricating and/ or finishing window framing of aluminum, magnesium or steel, for wire drawing and for temporary or permanent protection of die surfaces.
  • the lubricant encapsulating film is particularly adapted for coating air cylinders in recoil mechanisms and shock absorbers, for protecting gear trains and for hoists.
  • Lubrication may be beneficially applied to rollers and/ or sprockets coming into contact with hard metal in conveyer mechanisms. Valves and cam mechanisms may be lubricated. Bearing surfaces, whether straight journal, roller or taper type in use as wet or as dry bearings, may also be lubricated to good advantage. Leaf springs as are used in trucks and automobiles may be given a substantially indestructible solid encapsulating film lubricant coating to improve their performance. Similarly, rotating seals, stufiing boxes and packing glands for moving machine parts can be uniquely coated with a non-destructible coating and operate in a fashion as can entirely eliminate oil seals. By employing a fluid bed for the coated member of powdered amide oil is entirely eliminated, dirt and foreign matter which ordinarily are entrapped in liquid oil type lubricants can be completely excluded and an essentially dry lubrication system is achieved.
  • the encapsulating film is applied as a lacquer consisting of a xylol solution of chlorinated rubber (25% solids in solvent) in a single coat and a top coating of oleic acid amide solids) in 1,1,1- trichloroethane is applied thereto.
  • the first coat is completely dry before the second coat of lubricant is applied.
  • the base encapsulating coat is about 1 to 2 mils in thickness and the top lubricant coating, is about 1 mil thickness.
  • the total encapsulating plastic film and lubricant thickness is about 2 to 3 mils.
  • the upper stratum of high lubricity is formed in the top coating step as a dis- 2% continuous surface layer consisting of particles of oleic acid amide which, under high compressive forces at room temperature, becomes continuous.
  • the blank is then subjected to forming forces of 1,100 pounds and counterthrust forces of about 500-600 pounds in the apparatus of copending application Serial No. 286,880 and with a clearance of about 0.007-0.0l2 inch in the die.
  • the shorter length of 6% inches in the stainless steel is uniformly thickened by controlled metal flow up to an increase in thickness of about 30% in the 510 of are at the maximum bend and then is decreased uniformly in thickness to the original thickness value in the following 510 of are at the maximum bend.
  • the longer length is thinned by controlled metal flow to a value of about 5% less than original thickness at the maximum radius of bend, this slight thinning being gradual and continuous along the larger peripheral arc to merge into the unchanged area of stock having the original thickness. There is no measurable thinning of the composite solid film lubricant.
  • a second L was made in the same apparatus and using the identical encapsulating film of chlorinated rubber as in the first part of this example, but using conventional commercial, water-emulsified lard oil lubricant which is the recommended lubricant for tin shop cutting, punching and forming.
  • the commercial lard oil lubricant is identified as lube A and the forming of the L is described in detail below in comparison to the forming of the 90 L using oleamide lubricant coating, lube B, identified hereinafter.
  • the adhesion, hardness, toughness, incompressibility and low elasticity of the chlorinated rubber film constituting the preferred solid base encapsulating stratum is sutficient to permit the controlled flow of hard metal such as stainless steel at room temperature under metal forming forces beyond the elastic limit of the metal, e.g., of the order of about 100,000 pounds per square inch without any measurable decrease in film thickness as a result of shear and any noticeable compressive deformation of the film and without any breaking of the film.
  • the steel wearing surface of the die exposes the underlying base metal and causes harmful seizing, scoring and galling of the workpiece due exclusively to the failure of the solid film.
  • oleic acid amide e.g., 10% solids in 1,1,l-trichloroethane
  • oleic acid amide emulsified in water as the top coating.
  • This water emulsion is preferred for application to the organic solvent solution since the latter tends to leave residual solvent which must be driven off by thorough drying and/or baking. Residual solvent is not left behind upon evaporation of the emulsion.
  • a typical emulsion formula which is suitable is as follows:
  • Oleamide water emulsion lube B Oleamide 10.00 Nacconal NRSF (sodium salt of an alkylated napththaleue sulfonate) 3.00 Water 87.00 Concentrated aqua ammonia 0.04 Sodium nitrite 0.05
  • Emulsion Solids as used, in water Mixed polyethylene propylene glycols of melting points 37-110 C Low molecular Weight polyethylene, mo-
  • Atactic linear polypropylene of molecular weight range 400-1600 -20% there also may be used the homologous polymer atactic linear polypropylene of molecular weight range 400- 16,000 of the above table having a softening point range of above 37 C. and up to 110 C.
  • Various fractions of the polyethylene and polypropylene materials of the above characteristics are available commercially as by-products of low molecular weight recovered from commercial polymerizations. All of these materials are obtainable in aqueous emulsion containing conventional emulsifying agents, e.g., organic sulfonates or non-ionic detergents and in varying concentrations up to about 35 of polymer suspended in water.
  • the metal blank coated as outlined above was formed into an L and the coating was tested by non-destructive apparatus called the Dermitron non-destructive thickness 10 tester made by the Unit Process Assemblies, Inc.
  • the test disclosed that the straight blanks before forming had an encapsulating film coating thickness averaging 1 mil. These same blank pieces subsequently formed into Ls tested out as having a residual encapsulating film thickness of 1 mil.
  • EXAMPLE III This example illustrates the use of solid encapsulating film of waxy polyethylene glycol solution as lubricant over chlorinated rubber capsule in the method of Example I.
  • an aqueous emulsion of a waxy ethylene glycol polymer of molecular weight 4000-6000 was used.
  • This composition had a softening point within the preferred range, e.g., above 37 C. and below C.
  • Additional examples of polyalkylene glycols, of about the same molecular weight range, e.g., above 2500 and up to 6000, are phenolic terminated polyalkylene glycols of melting points 37110 C., such as:
  • EXAMPLE IV This example illustrates the use of a copolymer of vinyl chloride, vinyl acetate and carboxylic acid, VMCH and shows that a satisfactory bend was made using oleamide as the top layer by the method of Example I.
  • suitable lubricant modifiers such as oleamide, mixed polyethylene polypropylene glycols of melting points 37- 110 C., phenolic terminated polyalkylene glycols of melting points 37-110 C. like Tergitol XD, Tergitol NP-40, Tergitol N P-35; low molecular weight polyethylene and polyethylene glycols of melting points 37110 C.
  • lubricant modifiers are also suitable as the principal ingredient of the top coating deposited from either volatile organic solvent or water emulsion:
  • the cold-forming apparatus employs a novel non-destructible encapsulating medium as a means to suspend the metal workpiece in a nonscoring relation to the metal of the cold-forming die and the lubricant modifier in tightly adhering relationship to the encapsulating medium effectively provides a new and positive apparatus means for successfully achieving coldforming under stresses beyond the elastic limit of the workpiece.
  • a volatile solvent dispersion of a solid film-forming lubricant adapted to adhere as an encapsulating lubricating film to a clean metal base, said solution consisting of a mixture of (1) a hard, tough polymer selected from the group consisting of chlorinated rubber, a tripolymer of 87- 95% vinyl chloride, 12-5% vinyl acetate and 0.5-2.5 of unsaturated carboxylic acid and copolymer of 60-85% vinyl chloride with 40-15% vinylidene chloride; ('2) an organic lubricant material having a melting point in the range of 37-1 C. and a coefiicient of friction between said polymer and steel of 0.01-0.02, said lubricant material selected from the group consisting of oleic acid amide,
  • a solvent solution as claimed in claim 1 wherein the proportion of oleic acid amide to polymer is from 1:2 to about 1:9.
  • said lubricant selected from the group consisting of oleic acid amide mixed with polyethylene-propylene glycol, polyethylene of molecular weight 400-16,000, and atactic linear polypropylene of molecular weight 400-16,000, the ratio of said lubricant to said polymer varying from about 3:1 to about 1:3.

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US464849A 1961-06-12 1965-06-17 Multi-layer lubrication utilizing encapsulating coating Expired - Lifetime US3269943A (en)

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BE618785D BE618785A (enrdf_load_stackoverflow) 1961-06-12
DE19621444776 DE1444776A1 (de) 1961-06-12 1962-06-12 Verfahren zur Verringerung des Reibungskoeffizienten zwischen Metallflaechen und Schmiermittel zur Ausfuehrung des Verfahrens sowie mit diesem Schmiermittel behandelte Metallteile
GB22555/62A GB1035981A (en) 1961-06-12 1962-06-12 Multi-layer lubrication utilizing encapsulating coating
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Cited By (9)

* Cited by examiner, † Cited by third party
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US3466156A (en) * 1966-12-01 1969-09-09 Ncr Co Magnetic record members
US3488721A (en) * 1967-06-12 1970-01-06 Texaco Inc Preparation of a grease additive concentrate containing a water-soluble inorganic compound
US3923673A (en) * 1973-03-09 1975-12-02 Shell Oil Co Metal deforming process
US4056478A (en) * 1973-10-04 1977-11-01 Sargent Industries, Inc. Bearing material employing frangible microcapsules containing lubricant
US20080229796A1 (en) * 2007-03-22 2008-09-25 Stork David J Warm-Forming A1 Lubricant
US20090038228A1 (en) * 2005-12-29 2009-02-12 Kwang-Seok Lee Method and apparatus for window closing in the sliding window system
US9192973B1 (en) 2013-03-13 2015-11-24 Meier Tool & Engineering, Inc. Drawing process for titanium
US10316397B2 (en) * 2016-03-11 2019-06-11 Fuji Xerox Co., Ltd. Method of preparing cylindrical metal member, metallic ingot for impact pressing, and method of preparing electrophotographic photoreceptor
EP3578602A4 (en) * 2017-02-06 2020-09-30 Zeon Corporation COMPOSITION OF VINYL CHLORIDE RESIN, MOLDED BODY OF VINYL CHLORIDE RESIN, AND LAMINATE

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4191801A (en) 1977-02-08 1980-03-04 The Lubrizol Corporation Hot melt metal working lubricants
SE422420B (sv) * 1979-12-28 1982-03-08 Plm Ab Sett att fran ett emne av metall genom ett antal dragnings- och/eller pressningsforlopp under anvendning av smorjmedel forma en artikel, som derefter beleggs med ett skyddsskikt
JPS6099200A (ja) * 1983-11-02 1985-06-03 Nippon Parkerizing Co Ltd 金属の潤滑処理方法
JP6333305B2 (ja) 2016-04-28 2018-05-30 大同メタル工業株式会社 摺動部材

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GB445148A (en) * 1934-05-14 1936-04-03 Bataafsche Petroleum Process for preparing acid amides and anhydrous or substantially anhydrous alcohols
US2119149A (en) * 1935-04-09 1938-05-31 Hercules Powder Co Ltd Stabilized chlorinated paraffin wax and method of producing
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US3466156A (en) * 1966-12-01 1969-09-09 Ncr Co Magnetic record members
US3488721A (en) * 1967-06-12 1970-01-06 Texaco Inc Preparation of a grease additive concentrate containing a water-soluble inorganic compound
US3923673A (en) * 1973-03-09 1975-12-02 Shell Oil Co Metal deforming process
US4056478A (en) * 1973-10-04 1977-11-01 Sargent Industries, Inc. Bearing material employing frangible microcapsules containing lubricant
US20090038228A1 (en) * 2005-12-29 2009-02-12 Kwang-Seok Lee Method and apparatus for window closing in the sliding window system
US20080229796A1 (en) * 2007-03-22 2008-09-25 Stork David J Warm-Forming A1 Lubricant
US20110126604A1 (en) * 2007-03-22 2011-06-02 Stork David J Warm-Forming A1 Lubricant
US8205475B2 (en) 2007-03-22 2012-06-26 Stork David J Warm-forming A1 lubricant
US9192973B1 (en) 2013-03-13 2015-11-24 Meier Tool & Engineering, Inc. Drawing process for titanium
US10316397B2 (en) * 2016-03-11 2019-06-11 Fuji Xerox Co., Ltd. Method of preparing cylindrical metal member, metallic ingot for impact pressing, and method of preparing electrophotographic photoreceptor
EP3578602A4 (en) * 2017-02-06 2020-09-30 Zeon Corporation COMPOSITION OF VINYL CHLORIDE RESIN, MOLDED BODY OF VINYL CHLORIDE RESIN, AND LAMINATE
US10882988B2 (en) 2017-02-06 2021-01-05 Zeon Corporation Vinyl chloride resin composition, vinyl chloride resin molded product, and laminate

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DE1444776A1 (de) 1968-10-31
GB1035981A (en) 1966-07-13

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