NON-STAINING SOLID LUBRICANTS

Abstract: As a lubricant for cold-working of metal there is provided on the surface of the metal to be subjected to working a solid film of a saturated aliphatic monohydric alcohol having 14 to 18 carbon atoms. After the metal has been worked, the solid lubricant may be removed by heating without causing staining of the metal surface. The solid lubricant film may additionally contain from 1 to 10 % by weight of a polybutene, petroleum jelly or butyl stearate to modify the properties of the lubricant film.

Description: Non-Staining Solid Lubricants The present invention relates to non-staining solid lubricants suitable for use in metal working operations, for instance in cold-rolling, drawing or extrusion of metals, especially aluminium. Lubricants, usually liquid lubricants, are used in metal working operations to reduce friction between the surface of metal being worked and a surface of the apparatus carrying out the operation. A liquid lubricant reduces friction by separating the two surfaces with a thin fluid film having little resistance to shear. In many metal working operations the pressure between a surface of the metal being worked and a surface of the apparatus is so great that the fluid film of a liquid lubricant may be squeezed out s.o allowing actual metal-to-metal contact with the result that excessive damage to the surfaces may occur. Solid film lubricants having much greater load bearing properties have been developed to overcome this and other disadvantages associated with liquid lubricants. In addition to its lubrication characteristics, a lubricant may be expected to fulfil certain other requirements if it is to be useful industrially. For instance, it should be easy to apply and easy to remove, it should afford some protection to the metal surface during handling and storage, it should present no health hazard to persons coming into contact with it and, obviously, should be inert to the surfaces with which it comes into contact. Many lubricants produce severe stains on the surface of the metal during annealing thereof. It is, therefore, highly desirable to avoid such staining by using a lubricant having the properties demanded by SUBSTITUTE SHEET the particular conditions under which the lubricated metal is to be worked and which is also non-staining. The present invention is based on the discovery that a solid film of one or more saturated aliphatic monohydric alcohols having from 14 to 18 carbon atoms provided on the surface of the metal being worked has good lubrication characteristics under cold-working conditions and can be removed by heating to leave substantially no stain on the metal surface. The present invention provides the use, in the cold working of a metal workpiece, as a lubricant in the form of a solid film on the surface of the metal workpiece of a saturated aliphatic monohydric alcohol having from 14 to 18 carbon atoms. The present invention also provides the use, in the cold-working of a metal workpiece, of a composition capable of forming a solid deposit of lubricant on the surface of the metal workpiece when applied thereto which composition comprises a solution of a saturated aliphatic monohydric alcohol having from 14 to 18 carbon atoms in an inert volatile organic solvent. According to the invention, use is made of a saturated aliphatic monohydric alcohol having from 14 to 18 carbon atoms. Such alcohols have good lubricating and load-supporting properties, are solid at room temperatures (20-25°C) and may be, at worst, only slightly staining or, at best, totally non- staining. Examples of these alcohols include myristyl alcohol, cetyl alcohol and stearyl alcohol. Commercial purity compounds may be used and these generally contain proportions of higher and/or lower homologues as impurities. Cetyl alcohol (hexadecanol) is highly preferred for use in the present invention S UBSTITUTE SHEET in view of its melting point («v»49°C) and because of its excellent non-staining property. Typically, the 14-18C saturated aliphatic monohydric alcohol lubricant is applied to the surface of the metal workpiece by dip coating the workpiece in a solution of the alcohol lubricant in an inert volatile organic solvent. After removal of the volatile solvent by evaporation a film of the solid alcohol remains on the surface of the workpiece. It is possible that the film obtained in this way may not be of uniform thickness; the deposited alcohol lubricant being thicker in some regions than in other regions of the surface of the workpiece. We have observed, however, that in such cases where the thickness of the deposited film of solid alcohol is non-uniform the film flows at the point where pressure is applied to the workpiece during working thereof, e.g. at the die in a metal drawing operation or at the press platen in a metal pressing operation, with the result that the workpiece becomes evenly covered at the point of working. To form the lubricant coating composition, the 14-18C saturated aliphatic monohydric alcohol is dissolved in an inert volatile organic solvent. Generally, any organic solvent for the alcohol which is liquid at normal room temperature but which evaporates at a temperature just above that and which is inert to both the alcohol and the metal surface may be used. Examples of suitable solvents include diethyl ether, methanol and benzene and chlorinated hydrocarbons, such as trichloroethylene and 1,1,1- trichloroethane. The concentration of the 14-18C alcohol in the volatile organic solvent is not critical and, in principle, any concentration up to the solubility limit of the particular solvent may be SUBSTITUTE SHEET used. Typically, the concentration of alcohol in the organic solvent will be about 10% by weight. According to the present invention, it is possible to incorporate certain amounts of other substances in the lubricating film of 14-18C saturated aliphatic monohydric alcohol in order to modify the properties of the film. For instance, a liquid polybutene may be incorporated in an amount of up to 10% by weight of the total weight of the lubricant composition (excluding solvent) to modify the film properties of the lubricant on the surface of the workpiece and the flow characteristics of the lubricant film during the deformation without causing staining of the metal surface on annealing. The use of the liquid polybutene tends to soften any film containing it and the 14-18 saturated aliphatic monohydric alcohol and, therefore, if more than 10% by weight of the liquid polybutene is used the lubricant film obtained on the surface of the workpiece may become tacky and rather unstable. Any liquid polybutene may be used according to this embodiment of the invention. Liquid polybutenes are available commercially under the name Hyvis ("Hyvis is a registered trademark), for example Hyvis 200, having a molecular mass (number average) of 2400 and a Kinematic viscosity of 4300 cSt at 98.9°C. The non-staining solid lubricant according to the present invention may contain a small amount of a solid or se iliquid (e.g. gelatinous) alkane species or mixture of alkane species which does not leave a staining residue on annealing, for example petroleum jelly (petrolatum) , to modify the film properties of the lubricant. Such an alkane-based film modifier may be used together with or as an alternative to the liquid polybutene mentioned above. Generally, any : UBST1TUTE SHEET alkane-based film modifier if used will be used in an amount such that the combined weight of alkane-based film modifier and any liquid polybutene does not represent more than 10% of the weight of the total lubricant composition (excluding solvent). We have further found that the incorporation of an (liquid) ester, e.g. butyl stearate, methyl laurate or methyl yristate, in the 14-18C saturated aliphatic monohydric alcohol lubricant film tends to aid the production of a uniform film and also tends to soften the film. This tendency to soften the film is an additional advantage in the case where the lubricant also contains a polybutene additive since it makes it easier for the polybutene-containing lubricant to be removed from surfaces (including hands). If used, the ester may be used in an amount not exceeding 10% by weight based on the total weight of the lubricant (excluding solvent) and would be incorporated as an alternative to an equivalent amount of liquid polybutene. We refer, however, not to use more than about 1% by weight of the ester. The solid lubricant, after evaporation of the volatile carrier solvent, forms a tenaceous film on the surface of a metal workpiece. A typical lubricant coverage would be less than about lOgm "" ^. Preferably, however, the lubricant solution will be applied to a metal surface to provide about 5g of solid lubricant per square metre of surface. After deformation etc. of the workpiece the solid film lubricant does not require removal prior to annealing the metal since the component(s) of the solid lubricant, i.e. the alcohol and any optionally present polybutene, petroleum jelly and/or butyl stearate, will evaporate from or decompose on the metal surface cleanly without staining. SUBSTITUTE SHEET EXAMPLES Example 1 An aluminium tube was dipped in a 10% w/w solution of cetyl alcohol in trichloroethylene and then allowed to dry. The coated tube was passed four times through a drawing machine. After each pass, the tube was annealed by heating to 400°C, with no prior degreasing and no staining and then re-dipped in the cetyl alcohol solution. The following Table 1 shows the outside and inside diameters of the tube, the percentage reduction in the cross sectional area, and the length of the tube after each pass. The reductions are set by the size of the die used, which is why they are variable. However, the final reduction of 23% is excellent and the tube after the final pass showed no surface staining. Table 1 Outside Inside % Reduction Length diameter diameter (mm) (mm) (m) S UBSTITUTE SHEET Example 2 A series of disc compression tests was carried out using various lubricants. In each case, an aluminium disc having a diameter of 32mm and a thickness of 5mm was dipped into a solution of the lubricant under test in a volatile organic solvent so that both the upper and the lower surfaces of the disc were coated with the lubricant solution. The coated disc was then left until the organic solvent had evaporated to leave a coating of lubricant on the aluminium surface. Each disc was subjected to pressing at 5.6 x 10^ kg m ~ - over a period of 30 seconds and the thickness of the disc was then measured. The test was carried out 5 times for each lubricant and the mean reduction (%) was calculated. Each lubricated disc was annealed at 400°C and checked for any staining. The results are shown below in Table 2. Table 2 Lubricant Reduction (%) Staining of Mean Std.deviation Metal Surface *'Batoyl' *'Silkolene' 100% cetyl alcohol 90% cetyl alcohol 10% petroleum jelly 75% cetyl alcohol 59 0.62 none 25% petroleum jelly SUBSTITUTE SHEET * 'Batoyl' and 'Silkolene' are proprietory solid film lubricants based on a heavy oil containing extreme pressure additives. BS TITUTE SHEET

Claims: CLAIMS 1. The use, in the cold working of a metal workpiece, as a lubricant in the form of a solid film on the surface of the metal workpiece of a saturated aliphatic monohydric alcohol having from 14 to 18 carbon atoms. 2. The use according to claim 1, wherein the saturated aliphatic monohydric alcohol is cetyl alcohol. 3. The use according to either claim 1 or claim 2, wherein the lubricant also contains from 1 to 10% by weight of the total weight of the lubricant of a polybutene, petroleum jelly or butyl stearate. 4. The use, in the cold working of a metal workpiece of a composition capable of forming a solid deposit of lubricant on the surface of the metal workpiece when applied thereto which composition comprises a solution of a saturated aliphatic monohydric alcohol having 14 to 18 carbon atoms in an inert volatile organic solvent. 5. Thus use according to claim 4, wherein the saturated aliphatic monohydric alcohol is cetyl alcohol. 6. The use according to either claim 4 or claim 5, wherein the inert volatile organic solvent is selected from trichloroethylene and 1,1,1- trichloroethane. 7. The use according to any one of claims 4 to 6 , wherein the solution contains about 10% by weight of the saturated aliphatic monohydric alcohol. 8. The use according to any one of claims 4 to 7, wherein the solution additionally contains a material selected from a polybutene, petroleum jelly and butyl stearate in an amount of from 1 to 10% by weight based SUBSTITUTE SHEET on the combined weight of the saturated aliphatic monohydric alcohol and the said material. 9. The use according to any one of the preceding claims wherein the metal workpiece is formed of aluminium or an aluminium alloy. 10. The use according to any one of the preceding claims wherein a metal workpiece in the form of a tube is subjected to a cold drawing operation. 11. A method of cold forming a metal workpiece comprising providing on the surface of the workpiece to be subjected to forming a film of a lubricant, subjecting the workpiece to a forming operation and removing the film of lubricant from the metal surface characterised in that the lubricant film comprises a solid film of a saturated aliphatic monohydric alcohol having from 14 to 18 carbon atoms and in that the lubricant film is removed by the application of heat without staining of metal surface. 12. A method according to claim 11, wherein the solid lubricant film is caused to flow on the metal surface at a point where pressure, due to the forming operation, is applied. 13. A method according to either claim 11 or claim 12, wherein the saturated aliphatic monohydric alcohol is cetyl alcohol. 14. A method according to any one of claims 11 to 13, wherein the lubricant further contains from 1 to 10% by weight of a polybutene, petroleum jelly or butyl stearate.

Inventors: FOSTER MARK HOWARD, PARGETER CHRISTOPHER, FOSTER, MARK, HOWARD, PARGETER, CHRISTOPHER
Applicants: ALCAN INT LTD, ALCAN INTERNATIONAL LIMITED
Application year: 1990
Main classification: C10N40
IPC codes: B21B45, B21C23, C10M105, C10M169, C10N30, C10N40, C10N50