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Lubricant system for cold forming, process and composition therefor

a technology of cold forming and lubricant, which is applied in the direction of lubricant composition, additives, metal material coating processes, etc., can solve the problems of inability to form or otherwise be practicable, calcium in the coating, and the inability to significantly improve the refinement of grain refinement, so as to improve the adhesion the life of the second lubricant bath, the effect of low calcium conten

Inactive Publication Date: 2006-03-23
HENKEL KGAA
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The patent describes a process for lubricating ferrous-base metal articles before cold forming. The process involves contacting the surface of the metal article with a conditioning rinse, followed by a first lubricant that forms a phosphate coating with low calcium content. A second lubricant is then applied to the phosphate coated metal article. The process provides finer-grained zinc phosphate coatings with low calcium content, improved adherence, and reduced dust. The patent also describes a conditioning rinse that is made from a titanium compound and a phosphate compound in aqueous dispersion with a surfactant and alkaline builder. The phosphate coating has a platelet-type morphology with crystals ranging in size from about 5-25 microns. The article of manufacture comprises a ferrous-base metal article with an outer surface coated with a uniform layer of phosphate conversion coating containing low calcium content and having an average grain size of 5-25 microns.

Problems solved by technology

This reduction in friction allows shapes to be made by cold forming which would otherwise not be possible or practicable.
Heretofore the use of a conditioner treatment comprising titanium salt conditioners as a pretreatment prior to phosphating with a conventional calcium modified phosphating bath has not been found to significantly improve grain refinement as compared to the use of either known conditioners alone or adding calcium alone.
A drawback of including calcium in the coating is its effect on the second lubricant formed in the second lubricant bath.
The lower reactivity results in less lubricant formation, which renders the second lubrication step less effective on calcium containing metal phosphate coatings.
The poor adherence of calcium and sodium stearates causes flaking off of these stearates which reduces the amount of lubricant on the article to be formed and is a source of dust in the workplace.
Another drawback of including calcium in the phosphate coating is its effect on the second lubricant bath, itself.

Method used

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  • Lubricant system for cold forming, process and composition therefor
  • Lubricant system for cold forming, process and composition therefor
  • Lubricant system for cold forming, process and composition therefor

Examples

Experimental program
Comparison scheme
Effect test

example 1

Specimens: 4″×6″ steel panels, 4130 alloy

Phosphate Bath 1 Preparation:

[0068] Into 75 gallons of water were mixed 150 pounds of Phosphate Makeup Mix 1 containing the components listed in Table A measured in weight percent:

TABLE APhosphate Makeup Mix 1ComponentWt %Zinc Oxide8.75067% Nitric Acid (aq)11.31075% Phosphoric Acid (aq)21.10014% Nickel Nitrate (aq)0.230Hydroxylamine Sulfate0.600(powder)Waterbalance

and 70 pounds of calcium nitrate. Sufficient water to make 100 gallons of working solution was then mixed in. Sufficient heat was added to bring the bath to the operation temperature. Total Acid=34.8, Free Acid=5.9

Specimen Coating Processes:

example 1a

[0069] With Conditioner. “Phosphate Only”. The specimen was treated according to the following: [0070] 1. Clean: Parco Cleaner 2077X, a commercial aqueous alkaline cleaner available from Henkel Corporation, 4 oz / gal, 180° F., 5 minutes [0071] 2. Hot Water Rinse: approx. 130° F., 1 min [0072] 3. Pickle: 10% v / v concentrated sulfuric acid inhibited with Rodine 195@0.25% v / v of concentrated acid used (i.e., 0.25% of 10%=0.025% v / v of working pickle) [0073] 4. Cold Water Rinse: approx 60-70° F., 30 seconds [0074] 5. Conditioner: Fixodine Z (nominal Ti 1-10 wt %), a commercial titanium salt containing conditioner available from Henkel Corporation, 1 g / L, 125° F., 1 min [0075] 6. Phosphate: Phosphate Bath 1, 180° F., 5 min [0076] 7. Cold Water Rinse [0077] 8. Forced Air Dry Off

example 1b

[0078] With Conditioner, “Phosphate+Lube”. The specimen was treated as in Steps 1-7 of Example 1A, followed by: [0079] 8. Bonderlube 234, a commercial aqueous sodium stearate lubricant available from Henkel Corporation 60 g / L, 180° F., 5 min. [0080] 9. Bake: 212° F., 5 min.

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Abstract

The invention is directed to a combination of a conditioner bath and a calcium modified zinc phosphating solution optionally containing hydroxylamine which provide an improved phosphate coating on the surface of ferrous metal articles. In a preferred embodiment, the treatment process further comprises coating the workpiece with a second lubricant. The three treatments work together to provide finer grained phosphate coatings, longer life of the second lubricant bath and improved adherence of the second lubricant, as compared to a similar phosphating bath that is used alone or with a similar second lubricant.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of U.S. Provisional Application Ser. No. 60 / 612,134 filed Sep. 21, 2004, incorporated herein by reference.FIELD OF THE INVENTION [0002] The invention is directed to a combination of a conditioner bath and a calcium modified zinc phosphating solution containing hydroxylamine which provide an improved phosphate coating on the surface of ferrous metal articles. BACKGROUND OF THE INVENTION [0003] Metal phosphate coating solutions are dilute solutions of phosphoric acid and other chemicals which are applied to the surface of metal; the surface of the metal reacts with the solution and forms an integral layer (on the surface of the metal) of substantially insoluble crystalline or amorphous phosphate. This layer is applied primarily for protection from corrosion, or as a base for the application of a second coating (e.g., paint), or for lubrication purposes. The metal substrate can be contacted with the acid...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): C23C22/78
CPCC10M129/40C10M2207/126C10N2240/405C10N2240/408C23C22/80C10N2250/14C10N2280/00C23C22/13C10N2250/121C10N2040/243C10N2040/246C10N2050/02C10N2050/023C10N2080/00
Inventor CHURCH, RICHARDRUSSELL, WILLIAM C.KULONGOWSKI, PAULHACIAS, KENNETH J.
Owner HENKEL KGAA
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