WO2009076151A1 - Formulation of a metalworking fluid - Google Patents

Formulation of a metalworking fluid Download PDF

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Publication number
WO2009076151A1
WO2009076151A1 PCT/US2008/085483 US2008085483W WO2009076151A1 WO 2009076151 A1 WO2009076151 A1 WO 2009076151A1 US 2008085483 W US2008085483 W US 2008085483W WO 2009076151 A1 WO2009076151 A1 WO 2009076151A1
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WO
WIPO (PCT)
Prior art keywords
acid
composition
oil
volume
salts
Prior art date
Application number
PCT/US2008/085483
Other languages
English (en)
French (fr)
Inventor
Lloyd E. Hundley
Ji Cui
Original Assignee
Chemetall Corporation
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Publication date
Application filed by Chemetall Corporation filed Critical Chemetall Corporation
Priority to CA2708595A priority Critical patent/CA2708595C/en
Priority to BRPI0822063-8A priority patent/BRPI0822063A2/pt
Priority to KR1020167027230A priority patent/KR20160120787A/ko
Priority to JP2010538060A priority patent/JP5704921B2/ja
Priority to MX2010006315A priority patent/MX360113B/es
Priority to CN2008801264885A priority patent/CN101970621A/zh
Publication of WO2009076151A1 publication Critical patent/WO2009076151A1/en

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    • C10M2217/02Macromolecular compounds obtained from nitrogen containing monomers by reactions only involving carbon-to-carbon unsaturated bonds
    • C10M2217/024Macromolecular compounds obtained from nitrogen containing monomers by reactions only involving carbon-to-carbon unsaturated bonds containing monomers having an unsaturated radical bound to an amido or imido group
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    • C10M2217/00Organic macromolecular compounds containing nitrogen as ingredients in lubricant compositions
    • C10M2217/02Macromolecular compounds obtained from nitrogen containing monomers by reactions only involving carbon-to-carbon unsaturated bonds
    • C10M2217/026Macromolecular compounds obtained from nitrogen containing monomers by reactions only involving carbon-to-carbon unsaturated bonds containing monomers having an unsaturated radical bound to a nitrile group
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    • C10M2217/00Organic macromolecular compounds containing nitrogen as ingredients in lubricant compositions
    • C10M2217/02Macromolecular compounds obtained from nitrogen containing monomers by reactions only involving carbon-to-carbon unsaturated bonds
    • C10M2217/028Macromolecular compounds obtained from nitrogen containing monomers by reactions only involving carbon-to-carbon unsaturated bonds containing monomers having an unsaturated radical bound to a nitrogen-containing hetero ring
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    • C10M2219/00Organic non-macromolecular compounds containing sulfur, selenium or tellurium as ingredients in lubricant compositions
    • C10M2219/04Organic non-macromolecular compounds containing sulfur, selenium or tellurium as ingredients in lubricant compositions containing sulfur-to-oxygen bonds, i.e. sulfones, sulfoxides
    • C10M2219/044Sulfonic acids, Derivatives thereof, e.g. neutral salts
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    • C10M2223/00Organic non-macromolecular compounds containing phosphorus as ingredients in lubricant compositions
    • C10M2223/02Organic non-macromolecular compounds containing phosphorus as ingredients in lubricant compositions having no phosphorus-to-carbon bonds
    • C10M2223/04Phosphate esters
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    • C10M2223/00Organic non-macromolecular compounds containing phosphorus as ingredients in lubricant compositions
    • C10M2223/02Organic non-macromolecular compounds containing phosphorus as ingredients in lubricant compositions having no phosphorus-to-carbon bonds
    • C10M2223/04Phosphate esters
    • C10M2223/043Ammonium or amine salts thereof
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    • C10M2227/00Organic non-macromolecular compounds containing atoms of elements not provided for in groups C10M2203/00, C10M2207/00, C10M2211/00, C10M2215/00, C10M2219/00 or C10M2223/00 as ingredients in lubricant compositions
    • C10M2227/06Organic compounds derived from inorganic acids or metal salts
    • C10M2227/066Organic compounds derived from inorganic acids or metal salts derived from Mo or W
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    • C10N2010/02Groups 1 or 11
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    • C10N2020/00Specified physical or chemical properties or characteristics, i.e. function, of component of lubricating compositions
    • C10N2020/01Physico-chemical properties
    • C10N2020/055Particles related characteristics
    • C10N2020/06Particles of special shape or size
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    • C10N2020/00Specified physical or chemical properties or characteristics, i.e. function, of component of lubricating compositions
    • C10N2020/09Characteristics associated with water
    • C10N2020/091Water solubility
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    • C10N2030/00Specified physical or chemical properties which is improved by the additive characterising the lubricating composition, e.g. multifunctional additives
    • C10N2030/06Oiliness; Film-strength; Anti-wear; Resistance to extreme pressure
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    • C10N2030/00Specified physical or chemical properties which is improved by the additive characterising the lubricating composition, e.g. multifunctional additives
    • C10N2030/12Inhibition of corrosion, e.g. anti-rust agents or anti-corrosives
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    • C10N2030/00Specified physical or chemical properties which is improved by the additive characterising the lubricating composition, e.g. multifunctional additives
    • C10N2030/16Antiseptic; (micro) biocidal or bactericidal
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    • C10N2030/00Specified physical or chemical properties which is improved by the additive characterising the lubricating composition, e.g. multifunctional additives
    • C10N2030/24Emulsion properties
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    • C10N2040/00Specified use or application for which the lubricating composition is intended
    • C10N2040/20Metal working
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    • C10N2050/00Form in which the lubricant is applied to the material being lubricated
    • C10N2050/01Emulsions, colloids, or micelles

Definitions

  • This invention relates to non-oil containing metalworking fluids, also known as synthetic metalworking fluids.
  • Metalworking is defined as shaping metallic work-pieces to conform to a desired set of geometric specifications. Metalworking comprises two basic categories, cutting and forming. Cutting operations include grinding, turning, milling, tapping, broaching and hobbing. Forming operations include hot and cold rolling, drawing, forging, stamping and blanking. [0006] Metalworking fluids are essential in both cutting and forming operations. They must provide for lubrication between the work-piece and tool and also provide cooling by removing the heat generated during the metalworking operations.
  • Lubrication is defined as the reduction of friction between two moving surfaces.
  • the two main types of lubrication in metalworking operations are hydrodynamic and boundary or extreme pressure (EP).
  • Hydrodynamic lubrication involves separating the moving surfaces by a film of fluid lubricant. Boundary or EP lubrication minimizes the wear experienced when surfaces rub together.
  • Polymeric lubricity agents can provide both types of lubrication.
  • Metalworking fluids are classified into two main segments, oil containing and non-oil containing. The oil-containing segment comprises straight oils, soluble oils, and semi-synthetics, all of which utilize mineral oil as the primary lubricant.
  • the non-oil segment is known as synthetics, which include compositions of lubricity-producing additives in an aqueous transport system or diluent.
  • the soluble oil and semi-synthetic products enjoy an 80% share of the market, the non-water reducible straight oils segment have a 10% share, while the synthetics comprise 10% of the market.
  • An aspect of the invention relates to an entirely new class of metalworking fluid products.
  • This new chemistry incorporates a synergistic blend of carboxylic acid salts, boundary lube fatty acids, and EO/PO polymers, which react to form a moiety which, in certain embodiments, may optionally have enhanced particle size, exceptional lubricity or both.
  • use dilutions are opaque and mimic the appearance of oil-based solutions.
  • the metalworking fluid compositions can have a volume average particle size of 125 nm or greater when diluted between
  • compositions comprise:
  • Certain embodiments can be synthetic metalworking fluids that demonstrate an engineered increase in lubricity while still providing corrosion protection and microbial control.
  • the present metalworking lubricants can have a volume average particle size of 125 nm or greater when diluted between 0.1 and 50 percent by volume.
  • the compositions can comprise: (a) one or more polymeric lubricity agents;
  • compositions can comprise: (a) 1 to 80 percent by volume of one or more block copolymers as the polymeric lubricity agent;
  • compositions can comprise: (a) 5 to 40 percent by volume of one or more block copolymers as polymeric lubricity agents;
  • compositions can comprise:
  • the polymeric lubricity agents can be, for example, EO/PO copolymers.
  • the EO/PO polymers can comprise, for example one or more of the following.
  • the EO/PO copolymers can be block copolymers having a central polyoxypropylene block with a polyoxyethylene chain at either end.
  • the EO/PO copolymers can be block copolymers comprising a central polyoxyethylene block with a polyoxypropylene chain at either end.
  • the EO/PO copolymers can be tetrablock copolymers derived from the sequential addition of ethylene oxide and propylene oxide to ethylenediamine.
  • the EO/PO copolymers can be ethylene oxide / propylene oxide copolymers having at least one terminal hydroxyl group.
  • the EO/PO copolymers can be water-soluble lubricant base stocks of random copolymers of ethylene oxide and propylene oxide.
  • the EO/PO copolymers can be a water-soluble polyoxyethylene or polyoxypropylene alcohol or a water- soluble carboxylic acid ester of such alcohol.
  • the EO/PO copolymers can be alcohol-started base stocks of all polyoxypropylene groups with one terminal hydroxyl group.
  • the EO/PO copolymers can be monobasic or dibasic acid esters, polyol esters, polyalkylene glycol esters, polyalkylene glycols grafted with organic acids, phosphate esters, polyisobutylenes, polyacrylonitriles, polyacrylamides, polyvinylpyrrolidones, polyvinyl alcohols, or copolymers of acrylic acid or methacrylic acid and an acrylic ester.
  • Specifically contemplated polymers include a polypropylene glycol block copolymer, a polyethylene glycol block copolymer, or a polyethylene glycol/ polypropylene glycol block copolymer.
  • Partially neutralized carboxylic acid salts are contemplated to provide a lipophilic moiety for the polymeric lubricity agents to network with and provide for the engineering of a larger particle size.
  • the salts can be made, for example, by partial neutralization of free carboxylic acids, fats, or oils using any of the alkaline agents described in this specification.
  • cations of the salts include alkali metal or alkanolamine salts, such as a sodium salt (made for example by treating an acid with sodium hydroxide).
  • the pH of the partial neutralization is dependent upon the alkaline agent used.
  • Many of these carboxylic acid salts additionally provide their own boundary lubrication as well.
  • the carboxylic acids used as feedstocks can be linear or branched, saturated or unsaturated free carboxylic acids.
  • the acids can be saturated or unsaturated, and sites of unsaturation can be cis or trans configured.
  • the acids can be dicarboxylic acids, tricarboxylic acids, or ester, amine, amide, or ethoxylated derivatives of carboxylic acids.
  • fats or oils of animal or vegetable origin can be neutralized directly to provide the carboxylic acid salts.
  • caproic also known as hexanoic
  • enanthic also known as heptanoic
  • caprylic also known as octanoic
  • pelargonic also known as nonanoic
  • capric also known as decanoic
  • neodecanoic acid lauric
  • stearic also known as octadecanoic
  • arachidic also known as eicosanoic
  • palmitic also known as hexadecanoic
  • erucic acid oleic acid, arachidonic acid, linoleic acid, linolenic acid
  • myristic also known as tetradecanoic
  • behenic also known as docosanoic
  • Diluting the metalworking fluid composition with water forms an opaque emulsion. At a concentration above 10%, the emulsion may require stabilization. Emulsifying or dispersing agents are contemplated to provide stabilization of the engineered large particle emulsion.
  • the emulsifying or dispersing agents may be one or more of the following: alkanolamides, alkylaryl sulfonates, alkylaryl sulfonic acids, amine oxides, amide and amine soaps, block copolymers, carboxylated alcohols, carboxylic acids or fatty acids, ethoxylated alcohols, ethoxylated alkylphenols, ethoxylated amines or amides, ethoxylated fatty acids, ethoxylated fatty esters and oils, ethoxylated phenols, fatty amines and esters, glycerol esters, glycol esters, imidazolines and imidazoline derivatives, lignin and lignin derivatives, maleic or succinic anhydrides, methyl esters, monoglycerides and derivatives, naphthenic acids, olefin sulfonates, phosphate esters, polyalkylene glycol, carb
  • Oil-containing products rely heavily on the oil itself to form a barrier coating of corrosion protection.
  • Non-oil-containing products optionally can attain this corrosion protection by chemical means.
  • a corrosion inhibitor is a chemical compound that, when added in a small concentration, stops or slows down the corrosion of metals and alloys.
  • Some of the mechanisms for the corrosion inhibitors are the formation of a passivation layer (a thin film on the surface of the material that stops access of the corrosive substance to the metal), inhibiting either the oxidation or reduction part of the redox corrosion system (anodic and cathodic inhibitors), or scavenging the dissolved oxygen.
  • Alkalinity agents provide for the desired pH of the product and, in some cases for reserve alkalinity and pH buffering.
  • alkalinity agents include but are not limited to alkanolamines - primary, secondary and tertiary, aminomethylpropanol (AMP-95), diglycolamine (DGA), monoethanolamine (MEA), monoisopropanolamine (MIPA), butylethanolamine (NBEA), dicylclohexylamine (DCHA), diethanolamine (DEA), butyldiethanolamine (NBDEA), triethanolamine (TEA), metal alkali hydroxides, potassium hydroxide, sodium hydroxide, magnesium hydroxide, lithium hydroxide, metal carbonates and bicarbonates, sodium carbonate, sodium bicarbonate, potassium carbonate and potassium bicarbonate.
  • a preferred alkalinity agent for certain embodiments is a metal alkali hydroxide.
  • the pH contemplated for the composition optionally is 3 or greater, optionally from 3 to 10, optionally from
  • composition can also contain an anti-foaming agent and/or a biocide or a fungicide, as well as any other conventional or novel additives.
  • the preferred transport component which can also be referred to as the dispersion medium or vehicle, is largely, optionally entirely, water.
  • the composition may contain one or more oils, preferably at less than 10 percent by volume. These may be any conventional lubricating oils.
  • An emulsifier can be used to make a stable emulsion of the oil with water, if a composite oil and water transport component is contemplated.
  • the working metal fluid composition when diluted between 0.1 and 50 percent by volume can have a lubricity, measured by tapping torque instruments, of less than 8000 Newton-cm "1 .
  • the compositions may optionally have one or more of the following favorable properties in a low-oil (i.e. no more than 10% by volume oil) or an essentially or entirely oil-free formulation:
  • the present compositions as formulated contain particles, as will be seen in the Examples below. Larger particles are contemplated to provide greater lubricity, though the invention is not limited according to the accuracy of this theory.
  • the contemplated particles of any embodiment optionally have a volume average diameter of from 120 to 100,000 nanometers (nm), alternatively from 120 to 100,000 nm, alternatively from 1 20 to 10,000 nm, alternatively from 120 to 5000 nm, alternatively from 125 to 10,000 nm, alternatively from 125 to 5000 nm,, alternatively from 125 to 2000 nm, alternatively from 140 to 10,000 nm, alternatively from 140 to 5000 nm, alternatively from 140 to 2000 nm, alternatively from 200 to 10,000 nm, alternatively from 200 to 5,000 nm, alternatively from 200 to 2000 nm, alternatively from 220 to 10,000 nm, alternatively from 220 to 5,000 nm, alternatively from 220 to 2000 nm, alternatively from 350 to 10,000 nm, alternatively
  • the materials A through E of Table 1 were employed in a tapping torque operation involving the tapping of 6061 aluminum.
  • the concentrates were first diluted to a 7.5% by volume solution before testing.
  • the tapping torque test is a quantitative measure of the lubricity performance of metalworking fluids. It has an ASTM standard method designation of D5619.
  • Tapping torque reflects the industrial machining process in a better way than other tests, which commonly are carried out by rubbing two metal surfaces together. It is an excellent method of discriminating metalworking fluid (MWF) product machining performance in the laboratory. Tapping Torque results have been proven to correlate well with field machining performance.
  • the tapping torque instrument is designed to measure the lubricity of MWFs while actual cutting is performed. During the tapping operation, the
  • Tapping Torque instrument measures the instantaneous torque 250 times as the tap advances throughout the depth of the cut. Specialized software then facilitat ⁇ s data analysis. Tapping torque is expressed in units of N-m (Newton- meters) or N-cm (Newton-centimeters). Products with high lubricity will generate lower torque values. Conversely, low lubricity products will generate high torque values. In this way the instrument quantifies the differences in lubrication performance between products.
  • the lubricity data is presented in Table 1 , identified as E/A.
  • E/A The lower the E/A value, the better the lubricity and machining performance. All samples were diluted with water to 7.5% by volume before testing.
  • the materials of Table 1 were employed in a particle size operation involving the measurement of the volume average particle size in nanometer units.
  • the concentrates were first diluted with water to a 7.5% by volume solution before testing.
  • the particle-sizing instrument uses high efficiency dynamic light scattering to quantify particle sizes of 20 to 100,000 nanometers.
  • Material C from Table 1 was tested at two different concentrations for particle size, and evaluated at each concentration for appearance and emulsion stability. The results are shown in Table 2, which shows a large average particle size, opaque appearance, and excellent stability at each concentration. A larger particle size is characteristic of a better lubricant.
  • Typical synthetic MWFs when diluted, form clear solutions with particle size of less than 100 nanometers. Dilutions of sample C have particle sizes 3.5 to 20 times larger than the maximum size seen with typical synthetic MWFs.
  • the lubricity of a composition is a function of its volume average particle size. Increasing volume average particle size results in increased lubricity.
  • an increased concentration of sample C results in significantly larger volume average particle size. This explains the necessity of emulsifiers to stabilize higher concentrations of sample C. Without emulsifiers, it is believed that the particle size of higher concentrations would continue to agglomerate to an unstable state.
  • various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the invention and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Lubricants (AREA)
PCT/US2008/085483 2007-12-10 2008-12-04 Formulation of a metalworking fluid WO2009076151A1 (en)

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CA2708595A CA2708595C (en) 2007-12-10 2008-12-04 Formulation of a metalworking fluid
BRPI0822063-8A BRPI0822063A2 (pt) 2007-12-10 2008-12-04 Formulação de um fluido de beneficiamento de metal
KR1020167027230A KR20160120787A (ko) 2007-12-10 2008-12-04 금속 가공 유체의 포뮬레이션
JP2010538060A JP5704921B2 (ja) 2007-12-10 2008-12-04 金属加工流体の調製
MX2010006315A MX360113B (es) 2007-12-10 2008-12-04 Formulacion de un fluido para trabajo en metal.
CN2008801264885A CN101970621A (zh) 2007-12-10 2008-12-04 金属加工流体配制剂

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JP2012035336A (ja) * 2010-08-03 2012-02-23 Yushiro Chemical Industry Co Ltd 固定砥粒ワイヤソー用水溶性加工液
JP2012530817A (ja) * 2009-06-25 2012-12-06 クラリアント・ファイナンス・(ビーブイアイ)・リミテッド エーテルピロリドンカルボン酸含有の水混合金属処理液
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US20090149359A1 (en) 2009-06-11
MX2010006315A (es) 2010-10-05
KR20160120787A (ko) 2016-10-18
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CA2708595A1 (en) 2009-06-18
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