US20090036338A1 - Metalworking Fluid Compositions and Preparation Thereof - Google Patents
Metalworking Fluid Compositions and Preparation Thereof Download PDFInfo
- Publication number
- US20090036338A1 US20090036338A1 US11/831,896 US83189607A US2009036338A1 US 20090036338 A1 US20090036338 A1 US 20090036338A1 US 83189607 A US83189607 A US 83189607A US 2009036338 A1 US2009036338 A1 US 2009036338A1
- Authority
- US
- United States
- Prior art keywords
- metalworking fluid
- base oil
- less
- molecules
- kinematic viscosity
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
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- 239000002904 solvent Substances 0.000 description 1
- 238000001228 spectrum Methods 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 125000001424 substituent group Chemical group 0.000 description 1
- 150000005846 sugar alcohols Polymers 0.000 description 1
- 150000003871 sulfonates Chemical class 0.000 description 1
- 230000002459 sustained effect Effects 0.000 description 1
- 239000010689 synthetic lubricating oil Substances 0.000 description 1
- 150000004867 thiadiazoles Chemical class 0.000 description 1
- 150000003558 thiocarbamic acid derivatives Chemical class 0.000 description 1
- 125000000026 trimethylsilyl group Chemical group [H]C([H])([H])[Si]([*])(C([H])([H])[H])C([H])([H])[H] 0.000 description 1
- JSPLKZUTYZBBKA-UHFFFAOYSA-N trioxidane Chemical class OOO JSPLKZUTYZBBKA-UHFFFAOYSA-N 0.000 description 1
- WMYJOZQKDZZHAC-UHFFFAOYSA-H trizinc;dioxido-sulfanylidene-sulfido-$l^{5}-phosphane Chemical compound [Zn+2].[Zn+2].[Zn+2].[O-]P([O-])([S-])=S.[O-]P([O-])([S-])=S WMYJOZQKDZZHAC-UHFFFAOYSA-H 0.000 description 1
- 235000013311 vegetables Nutrition 0.000 description 1
- 238000012795 verification Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 238000009736 wetting Methods 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
Images
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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
- C10M107/00—Lubricating compositions characterised by the base-material being a macromolecular compound
- C10M107/02—Hydrocarbon polymers; Hydrocarbon polymers modified by oxidation
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- 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
- C10M2205/00—Organic macromolecular hydrocarbon compounds or fractions, whether or not modified by oxidation as ingredients in lubricant compositions
- C10M2205/17—Fisher Tropsch reaction products
- C10M2205/173—Fisher Tropsch reaction products used as base material
-
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- 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
- C10M2209/00—Organic macromolecular compounds containing oxygen as ingredients in lubricant compositions
- C10M2209/02—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- C10M2209/08—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds containing monomers having an unsaturated radical bound to a carboxyl radical, e.g. acrylate type
- C10M2209/084—Acrylate; Methacrylate
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- 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
- C10M2219/00—Organic non-macromolecular compounds containing sulfur, selenium or tellurium as ingredients in lubricant compositions
- C10M2219/02—Sulfur-containing compounds obtained by sulfurisation with sulfur or sulfur-containing compounds
- C10M2219/022—Sulfur-containing compounds obtained by sulfurisation with sulfur or sulfur-containing compounds of hydrocarbons, e.g. olefines
-
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- 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
- C10M2219/00—Organic non-macromolecular compounds containing sulfur, selenium or tellurium as ingredients in lubricant compositions
- C10M2219/02—Sulfur-containing compounds obtained by sulfurisation with sulfur or sulfur-containing compounds
- C10M2219/024—Sulfur-containing compounds obtained by sulfurisation with sulfur or sulfur-containing compounds of esters, e.g. fats
-
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- 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
- C10M2219/00—Organic non-macromolecular compounds containing sulfur, selenium or tellurium as ingredients in lubricant compositions
- C10M2219/04—Organic non-macromolecular compounds containing sulfur, selenium or tellurium as ingredients in lubricant compositions containing sulfur-to-oxygen bonds, i.e. sulfones, sulfoxides
- C10M2219/046—Overbased sulfonic acid salts
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- 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
- C10N2020/00—Specified physical or chemical properties or characteristics, i.e. function, of component of lubricating compositions
- C10N2020/01—Physico-chemical properties
- C10N2020/017—Specific gravity or density
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- 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
- C10N2020/00—Specified physical or chemical properties or characteristics, i.e. function, of component of lubricating compositions
- C10N2020/01—Physico-chemical properties
- C10N2020/02—Viscosity; Viscosity index
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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
- C10N2020/065—Saturated Compounds
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- C10N2020/00—Specified physical or chemical properties or characteristics, i.e. function, of component of lubricating compositions
- C10N2020/01—Physico-chemical properties
- C10N2020/067—Unsaturated Compounds
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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
- C10N2020/069—Linear chain compounds
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- 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
- C10N2020/00—Specified physical or chemical properties or characteristics, i.e. function, of component of lubricating compositions
- C10N2020/01—Physico-chemical properties
- C10N2020/071—Branched chain compounds
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- C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
- C10N2030/00—Specified physical or chemical properties which is improved by the additive characterising the lubricating composition, e.g. multifunctional additives
- C10N2030/02—Pour-point; Viscosity index
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- 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
- C10N2030/00—Specified physical or chemical properties which is improved by the additive characterising the lubricating composition, e.g. multifunctional additives
- C10N2030/06—Oiliness; Film-strength; Anti-wear; Resistance to extreme pressure
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- 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
- C10N2030/00—Specified physical or chemical properties which is improved by the additive characterising the lubricating composition, e.g. multifunctional additives
- C10N2030/08—Resistance to extreme temperature
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- 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
- C10N2030/00—Specified physical or chemical properties which is improved by the additive characterising the lubricating composition, e.g. multifunctional additives
- C10N2030/18—Anti-foaming property
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- 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
- C10N2030/00—Specified physical or chemical properties which is improved by the additive characterising the lubricating composition, e.g. multifunctional additives
- C10N2030/30—Anti-misting
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- 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
- C10N2030/00—Specified physical or chemical properties which is improved by the additive characterising the lubricating composition, e.g. multifunctional additives
- C10N2030/64—Environmental friendly compositions
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- 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
- C10N2030/00—Specified physical or chemical properties which is improved by the additive characterising the lubricating composition, e.g. multifunctional additives
- C10N2030/74—Noack Volatility
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- 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
- C10N2040/00—Specified use or application for which the lubricating composition is intended
- C10N2040/20—Metal working
- C10N2040/22—Metal working with essential removal of material, e.g. cutting, grinding or drilling
Definitions
- the invention relates generally to metalworking compositions exhibiting improved anti-mist properties, having a low foaming tendency and excellent air release properties.
- Metalworking fluids can be used as cutting oils, rolling oils, drawing oils, pressing oils, forging oils, abrasive working oils for aluminium disks, abrasive oils for silicon wafers and coolants.
- Foaming is undesirable because it may reduce cooling at the workpiece-tool or chip-tool contact zones and cause containment transport and control problems.
- foam control agent(s) when manufacturing the product or while the fluid is in-service.
- foam control agent(s) such as such as silicon-based foam inhibitors, could leave a residue on machined parts and make subsequent painting of the parts difficult. Additionally, some foam control agent(s)may worsen a metalworking fluid's air release properties.
- a fluid's air release properties can also be critical to its in-service performance, especially for high-speed operations. In some cases, using a fluid with poor air release properties can lead to air entrainment issues and cavitation of machine parts.
- mist generation Besides foaming and air release, another common in-service problem associated with metalworking fluids is fog or mist generation.
- small amounts of cutting oil tend to escape into the surrounding air as micro-sized droplets known as mist. Workers in the vicinity are exposed to the mist and, unless a protective breathing apparatus is worn, a portion of the mist may be drawn into the workers' lungs.
- metal cutting fluids in the prior art are essential for machining, they are currently being examined with increased scrutiny because of possible hazards associated with worker exposure.
- Recent reforming processes have formed a new class of oil, e,g, Fischer Tropsch base oil (FTBO), wherein the oil, fraction, or feed originates from or is produced at some stage by a Fischer-Tropsch process.
- FTBO Fischer Tropsch base oil
- the feedstock for a Fischer-Tropsch process may come from a wide variety of hydrocarbonaceous resources, including biomass, natural gas, coal, shale oil, petroleum, municipal waste, derivatives of these, and combinations thereof.
- Crude product prepared from the Fischer-Tropsch process can be refined into products such as diesel oil, naphtha, wax, and other liquid petroleum or specialty products.
- an isomerized base oil is produced from a process in which the feed is a waxy feed recovered from a Fischer-Tropsch synthesis.
- the process comprises a complete or partial hydroisomerization dewaxing step, using a dual-functional catalyst or a catalyst that can isomerize paraffins selectively.
- Hydroisomerization dewaxing is achieved by contacting the waxy feed with a hydroisomerization catalyst in an isomerization zone under hydroisomerizing conditions.
- a metalworking fluid comprising a lubricant base oil having consecutive numbers of carbon atoms and less than 10 wt % naphthenic carbon by n-d-M; and 0.10 to 10 wt. %.
- metalworking fluid additive package a metalworking fluid additive package
- metal deactivators corrosion inhibitors; antimicrobial; anticorrosion; extreme pressure agents; antifriction; antirust agents; polymeric substances; anti inflammatory agents; bactericides; antiseptics; antioxidants; chelating agents such as edetic acid salts, and the like; pH regulators; antiwear agents; and mixtures thereof
- the metalworking fluid has an air release by ASTM D 3427-03 of less than 0.6 minutes at 50° C., and a sequence II foam tendency by ASTM D 892-03 of less than 50 mL.
- a method to improve the foam formation and air release properties of a metalworking fluid comprising blending a composition comprising a lubricant base oil having consecutive numbers of carbon atoms and less than 10 wt % naphthenic carbon by n-d-M; and 0.10 to 10 wt. %. of at least an additive selected from the group of a metalworking fluid additive package; metal deactivators; corrosion inhibitors; antimicrobial; anticorrosion; extreme pressure agents; antifriction; antirust agents; polymeric substances; anti inflammatory agents; bactericides; antiseptics; antioxidants; chelating agents such as edetic acid salts, and the like; pH regulators; antiwear agents; and mixtures thereof.
- FIGS. 1-3 are graphs illustrating the mist accumulation rates of Examples 7-13 in an aerosol mist formation test.
- metalworking fluid may be used interchangeably with “metalworking composition,” “metal removal fluid,” “cutting fluid,” “machining fluid,” referring to a composition that can be used in industrial metal cutting, metal grinding operations or in the semiconductor industry wherein the shape of the final object, e.g., silicon wafer or machine part, is obtained by with or without the progressive removal of metal or silicon. Metalworking fluids amongst other functions, are used to cool and to lubricate.
- Fischer-Tropsch derived means that the product, fraction, or feed originates from or is produced at some stage by a Fischer-Tropsch process.
- Fischer-Tropsch base oil may be used interchangeably with “FT base oil,” “FTBO,” “GTL base oil” (GTL: gas-to-liquid), or “Fischer-Tropsch derived base oil.”
- isomerized base oil refers to a base oil made by isomerization of a waxy feed.
- a “waxy feed” comprises at least 40 wt % n-paraffins. In one embodiment, the waxy feed comprises greater than 50 wt % n-paraffins. In another embodiment, greater than 75 wt % n-paraffins. In one embodiment, the waxy feed also has very low levels of nitrogen and sulphur, e.g., less than 25 ppm total combined nitrogen and sulfur, or in other embodiments less than 20 ppm.
- waxy feeds examples include slack waxes, deoiled slack waxes, refined foots oils, waxy lubricant raffinates, n-paraffin waxes, NAO waxes, waxes produced in chemical plant processes, deoiled petroleum derived waxes, microcrystalline waxes, Fischer-Tropsch waxes, and mixtures thereof
- the waxy feeds have a pour point of greater than 50° C. In another embodiment, greater than 60° C.
- “Kinematic viscosity” is a measurement in mm 2 /s of the resistance to flow of a fluid under gravity, determined by ASTM D445-06.
- Viscosity index (VI) is an empirical, unit-less number indicating the effect of temperature change on the kinematic viscosity of the oil. The higher the VI of an oil, the lower its tendency to change viscosity with temperature. Viscosity index is measured according to ASTM D 2270-04.
- CCS VIS Cold-cranking simulator apparent viscosity
- the boiling range distribution of base oil is determined by simulated distillation (SIMDIS) according to ASTM D 6352-04, “Boiling Range Distribution of Petroleum Distillates in Boiling Range from 174 to 700° C. by Gas Chromatography.”
- Noack volatility is defined as the mass of oil, expressed in weight %, which is lost when the oil is heated at 250° C. with a constant flow of air drawn through it for 60 min., measured according to ASTM D5800-05, Procedure B.
- Brookfield viscosity is used to determine the internal fluid-friction of a lubricant during cold temperature operation, which can be measured by ASTM D 2983-04.
- Pul point is a measurement of the temperature at which a sample of base oil will begin to flow under certain carefully controlled conditions, which can be determined as described in ASTM D 5950-02.
- Auto ignition temperature is the temperature at which a fluid will ignite spontaneously in contact with air, which can be determined according to ASTM 659-78.
- consecutive numbers of carbon atoms means that the base oil has a distribution of hydrocarbon molecules over a range of carbon numbers, with every number of carbon numbers in-between.
- the base oil may have hydrocarbon molecules ranging from C22 to C36 or from C30 to C60 with every carbon number in-between.
- the hydrocarbon molecules of the base oil differ from each other by consecutive numbers of carbon atoms, as a consequence of the waxy feed also having consecutive numbers of carbon atoms.
- the source of carbon atoms is CO and the hydrocarbon molecules are built up one carbon atom at a time. Petroleum-derived waxy feeds have consecutive numbers of carbon atoms.
- PAO poly-alpha-olefin
- the molecules of an isomerized base oil have a more linear structure, comprising a relatively long backbone with short branches.
- the classic textbook description of a PAO is a star-shaped molecule, and in particular tridecane, which is illustrated as three decane molecules attached at a central point. While a star-shaped molecule is theoretical, nevertheless PAO molecules have fewer and longer branches that the hydrocarbon molecules that make up the isomerized base oil disclosed herein.
- “Molecules with cycloparaffinic functionality” mean any molecule that is, or contains as one or more substituents, a monocyclic or a fused multicyclic saturated hydrocarbon group.
- “Molecules with monocycloparaffinic functionality” mean any molecule that is a monocyclic saturated hydrocarbon group of three to seven ring carbons or any molecule that is substituted with a single monocyclic saturated hydrocarbon group of three to seven ring carbons.
- “Molecules with multicycloparaffinic functionality” mean any molecule that is a fused multicyclic saturated hydrocarbon ring group of two or more fused rings, any molecule that is substituted with one or more fused multicyclic saturated hydrocarbon ring groups of two or more fused rings, or any molecule that is substituted with more than one monocyclic saturated hydrocarbon group of three to seven ring carbons.
- Molecules with cycloparaffinic functionality, molecules with monocycloparaffinic functionality, and molecules with multicycloparaffinic functionality are reported as weight percent and are determined by a combination of Field Ionization Mass Spectroscopy (FIMS), HPLC-UV for aromatics, and Proton NMR for olefins, further fully described herein.
- FIMS Field Ionization Mass Spectroscopy
- Oxidator BN measures the response of a lubricating oil in a simulated application. High values, or long times to adsorb one liter of oxygen, indicate good stability. Oxidator BN can be measured via a Dornte-type oxygen absorption apparatus (R. W. Dornte “Oxidation of White Oils,” Industrial and Engineering Chemistry, Vol. 28, page 26, 1936), under 1 atmosphere of pure oxygen at 340° F., time to absorb 1000 mL of O 2 by 100 g. of oil is reported. In the Oxidator BN test, 0.8 mL of catalyst is used per 100 grams of oil. The catalyst is a mixture of soluble metal-naphthenates simulating the average metal analysis of used crankcase oil. The additive package is 80 millimoles of zinc bispolypropylenephenyldithiophosphate per 100 grams of oil.
- Molecular characterizations can be performed by methods known in the art, including Field Ionization Mass Spectroscopy (FIMS) and n-d-M analysis (ASTM D 3238-95 (Re-approved 2005)).
- FIMS Field Ionization Mass Spectroscopy
- ASTM D 3238-95 Re-approved 2005
- the base oil is characterized as alkanes and molecules with different numbers of unsaturations.
- the molecules with different numbers of unsaturations may be comprised of cycloparaffins, olefins, and aromatics. If aromatics are present in significant amount, they would be identified as 4-unsaturations. When olefins are present in significant amounts, they would be identified as 1-unsaturations.
- the total of the 1-unsaturations, 2-unsaturations, 3-unsaturations, 4-unsaturations, 5-unsaturations, and 6-unsaturations from the FIMS analysis, minus the wt % olefins by proton NMR, and minus the wt % aromatics by HPLC-UV is the total weight percent of molecules with cycloparaffinic functionality. If the aromatics content was not measured, it was assumed to be less than 0.1 wt % and not included in the calculation for total weight percent of molecules with cycloparaffinic functionality.
- the total weight percent of molecules with cycloparaffinic functionality is the sum of the weight percent of molecules with monocyclopraffinic functionality and the weight percent of molecules with multicycloparaffinic functionality.
- Density is determined by ASTM D4052-96 (Reapproved 2002). The sample is introduced into an oscillating sample tube and the change in oscillating frequency caused by the change in the mass of the tube is used in conjunction with calibration data to determine the density of the sample.
- Weight percent olefins can be determined by proton-NMR according to the steps specified herein.
- the olefins are conventional olefins, i.e. a distributed mixture of those olefin types having hydrogens attached to the double bond carbons such as: alpha, vinylidene, cis, trans, and tri-substituted, with a detectable allylic to olefin integral ratio between 1 and 2.5. When this ratio exceeds 3, it indicates a higher percentage of tri or tetra substituted olefins being present, thus other assumptions known in the analytical art can be made to calculate the number of double bonds in the sample.
- the steps are as follows: A) Prepare a solution of 5-10% of the test hydrocarbon in deuterochloroform. B) Acquire a normal proton spectrum of at least 12 ppm spectral width and accurately reference the chemical shift (ppm) axis, with the instrument having sufficient gain range to acquire a signal without overloading the receiver/ADC, e.g., when a 30 degree pulse is applied, the instrument having a minimum signal digitization dynamic range of 65,000. In one embodiment, the instrument has a dynamic range of at least 260,000. C) Measure the integral intensities between: 6.0-4.5 ppm (olefin); 2.2-1.9 ppm (allylic); and 1.9-0.5 ppm (saturate).
- the wt % olefins by proton NMR 100 times the number of double bonds times the number of hydrogens in a typical olefin molecule divided by the number of hydrogens in a typical test substance molecule.
- the wt % olefins by proton NMR calculation procedure, D works particularly well when the percent olefins result is low, less than 15 wt %.
- Weight percent aromatics in one embodiment can be measured by HPLC-UV.
- the test is conducted using a Hewlett Packard 1050 Series Quaternary Gradient High Performance Liquid Chromatography (HPLC) system, coupled with a HP 1050 Diode-Array UV-Vis detector interfaced to an HP Chem-station.
- HPLC Hewlett Packard 1050 Series Quaternary Gradient High Performance Liquid Chromatography
- HP 1050 Diode-Array UV-Vis detector interfaced to an HP Chem-station.
- Identification of the individual aromatic classes in the highly saturated base oil can be made on the basis of the UV spectral pattern and the elution time.
- the amino column used for this analysis differentiates aromatic molecules largely on the basis of their ring-number (or double-bond number). Thus, the single ring aromatic containing molecules elute first, followed by the polycyclic aromatics in order of increasing double bond number per molecule.
- HPLC-UV Calibration can be used for identifying classes of aromatic compounds even at very low levels, e.g., multi-ring aromatics typically absorb 10 to 200 times more strongly than single-ring aromatics. Alkyl-substitution affects absorption by 20%. Integration limits for the co-eluting 1-ring and 2-ring aromatics at 272 nm can be made by the perpendicular drop method. Wavelength dependent response factors for each general aromatic class can be first determined by constructing Beer's Law plots from pure model compound mixtures based on the nearest spectral peak absorbances to the substituted aromatic analogs. Weight percent concentrations of aromatics can be calculated by assuming that the average molecular weight for each aromatic class was approximately equal to the average molecular weight for the whole base oil sample.
- the weight percent of all molecules with at least one aromatic function in the purified mono-aromatic standard can be confirmed via long-duration carbon 13 NMR analysis.
- the NMR results can be translated from % aromatic carbon to % aromatic molecules (to be consistent with HPLC-UV and D 2007) knowing that 95-99% of the aromatics in highly saturated base oils are single-ring aromatics.
- the standard D 5292-99 (Reapproved 2004) method can be modified to give a minimum carbon sensitivity of 500:1 (by ASTM standard practice E 386) with a 15-hour duration run on a 400-500 MHz NMR with a 10-12 mm Nalorac probe.
- Acorn PC integration software can be used to define the shape of the baseline and consistently integrate.
- Extent of branching refers to the number of alkyl branches in hydrocarbons.
- Branching and branching position can be determined using carbon-13 ( 13 C) NMR according to the following nine-step process: 1) Identify the CH branch centers and the CH 3 branch termination points using the DEPT Pulse sequence (Doddrell, D. T.; D. T. Pegg; M. R. Bendall, Journal of Magnetic Resonance 1982, 48, 323ff.). 2) Verify the absence of carbons initiating multiple branches (quaternary carbons) using the APT pulse sequence (Patt, S. L.; J. N. Shoolery, Journal of Magnetic Resonance 1982, 46, 535ff.).
- % in chloroform-d1 are excited by 30° pulses followed by a 1.3 seconds (sec.) acquisition time.
- the broadband proton inverse-gated decoupling is used during a 6 sec. delay prior to the excitation pulse and on during acquisition.
- Samples are doped with 0.03 to 0.05 M Cr (acac) 3 (tris (acetylacetonato)-chromium (III)) as a relaxation agent to ensure full intensities are observed.
- the DEPT and APT sequences can be carried out according to literature descriptions with minor deviations described in the Varian or Bruker operating manuals.
- DEPT is Distortionless Enhancement by Polarization Transfer.
- the DEPT 45 sequence gives a signal all carbons bonded to protons.
- DEPT 90 shows CH carbons only.
- DEPT 135 shows CH and CH 3 up and CH 2 180 degrees out of phase (down).
- APT is attached proton test, known in the art. It allows all carbons to be seen, but if CH and CH 3 are up, then quaternaries and CH 2 are down.
- the branching properties of the sample can be determined by 13 C NMR using the assumption in the calculations that the entire sample was iso-paraffinic.
- the content of unsaturates may be measured using Field Ionization Mass Spectroscopy (FIMS).
- the metalworking fluid comprises a number of components, including optional additives, in a matrix of base oil.
- the base oil or blends thereof forming the matrix comprises at least an isomerized base oil which the product itself, its fraction, or feed originates from or is produced at some stage by isomerization of a waxy feed from a Fischer-Tropsch process (“Fischer-Tropsch derived base oils”).
- the base oil comprises at least an isomerized base oil made from a substantially paraffinic wax feed (“waxy feed”).
- the base oil consists essentially of at least an isomerized base oil.
- Fischer-Tropsch derived base oils are disclosed in a number of patent publications, including for example U.S. Pat. Nos. 6,080,301, 6,090,989, and 6,165,949, and US Patent Publication No. US2004/0079678A1, US20050133409, US20060289337.
- the Fischer-Tropsch process is a catalyzed chemical reaction in which carbon monoxide and hydrogen are converted into liquid hydrocarbons of various forms including a light reaction product and a waxy reaction product, with both being substantially paraffinic.
- the isomerized base oil has consecutive numbers of carbon atoms and has less than 10 wt % naphthenic carbon by n-d-M.
- the isomerized base oil made from a waxy feed has a kinematic viscosity at 100° C. between 1.5 and 3.5 mm 2 /s.
- the isomerized base oil is made by a process in which the hydroisomerization dewaxing is performed at conditions sufficient for the base oil to have: a) a weight percent of all molecules with at least one aromatic functionality less than 0.30; b) a weight percent of all molecules with at least one cycloparaffinic functionality greater than 10; c) a ratio of weight percent molecules with monocycloparaffinic functionality to weight percent molecules with multicycloparaffinic functionality greater than 20 and d) a viscosity index greater than 28 ⁇ Ln (Kinematic viscosity at 100° C.)+80.
- the isomerized base oil is made from a process in which the highly paraffinic wax is hydroisomerized using a shape selective intermediate pore size molecular sieve comprising a noble metal hydrogenation component, and under conditions of 600-750° F. (315-399° C.) In the process, the conditions for hydroisomerization are controlled such that the conversion of the compounds boiling above 700° F. (371° C.) in the wax feed to compounds boiling below 700° F. (371° C.) is maintained between 10 wt % and 50 wt %.
- a resulting isomerized base oil has a kinematic viscosity of between 1.0 and 3.5 mm 2 /s at 100° C. and aNoack volatility of less than 50 weight %.
- the base oil comprises greater than 3 weight % molecules with cycloparaffinic functionality and less than 0.30 weight percent aromatics.
- the isomerized base oil has a Noack volatility less than an amount calculated by the following equation: 1000 ⁇ (Kinematic Viscosity at 100° C.) ⁇ 2.7 .
- the isomerized base oil has a Noack volatility less than an amount calculated by the following equation: 900 ⁇ (Kinematic Vicosity at 100° C.) ⁇ 2.8 .
- the isomerized base oil has a Kinematic Vicosity at 100° C.
- the isomerized base oil has a kinematic viscosity at 100° C. of less than 4.0 mm 2 /s, and a wt % Noack volatility between 0 and 100.
- the isomerized base oil has a kinematic viscosity between 1.5 and 4.0 mm 2 /s and a Noack volatility less than the Noack volatility calculated by the following equation: 160 ⁇ 40 (Kinematic Viscosity at 100° C.).
- the isomerized base oil has a kinematic viscosity at 100° C. in the range of 2.4 and 3.8 mm 2 /s and a Noack volatility less than an amount defined by the equation: 900 ⁇ (Kinematic Viscosity at 100° C.) ⁇ 2.8 ⁇ 15).
- the equation: 900 ⁇ (Kinematic Viscosity at 100° C.) ⁇ 2.8 ⁇ 15) provides a lower Noack volatility than the equation: 160 ⁇ 40 (Kinematic Viscosity at 100° C.)
- the isomerized base oil is made from a process in which the highly paraffinic wax is hydroisomerized under conditions for the base oil to have a kinematic viscosity at 100° C. of 3.6 to 4.2 mm 2 /s, a viscosity index of greater than 130, a wt % Noack volatility less than 12, a pour point of less than ⁇ 9° C.
- AIT in ° C. 1.6 ⁇ (Kinematic Viscosity at 40° C., in mm 2 /s)+300.
- the base oil as an AIT of greater than 329° C. and a viscosity index greater than 28 ⁇ Ln (Kinematic Viscosity at 100° C., in mm 2 /s)+100.
- the isomerized base oil has a traction coefficient of less than 0.023 (or less than 0.021) when measured at a kinematic viscosity of 15 mm 2 /s and at a slide to roll ratio of 40%.
- the isomerized base oil has a traction coefficient of less than 0.017 when measured at a kinematic viscosity of 15 mm 2 /s and at a slide to roll ratio of 40%. In another embodiment the isomerized base oil has a viscosity index greater than 150 and a traction coefficient less than 0.015 when measured at a kinematic viscosity of 15 mm 2 /s and at a slide to roll ratio of 40 percent.
- the isomerized base oil having low traction coefficients also displays a higher kinematic viscosity and higher boiling points.
- the base oil has a traction coefficient less than 0.015, and a 50 wt % boiling point greater than 565° C. (1050° F.).
- the base oil has a traction coefficient less than 0.011 and a 50 wt % boiling point by ASTM D 6352-04 greater than 582° C. (1080° F.).
- the isomerized base oil having low traction coefficients also displays unique branching properties by NMR, including a branching index less than or equal to 23.4, a branching proximity greater than or equal to 22.0, and a Free Carbon Index between 9 and 30.
- the base oil has at least 4 wt % naphthenic carbon, in another embodiment, at least 5 wt % naphthenic carbon by n-d-M analysis by ASTM D 3238-95 (Reapproved 2005).
- the isomerized base oil is produced in a process wherein the intermediate oil isomerate comprises paraffinic hydrocarbon components, and in which the extent of branching is less than 7 alkyl branches per 100 carbons, and wherein the base oil comprises paraffinic hydrocarbon components in which the extent of branching is less than 8 alkyl branches per 100 carbons and less than 20 wt % of the alkyl branches are at the 2 position.
- the base oil comprises greater than 10 wt. % and less than 70 wt. % total molecules with cycloparaffinic functionality, and a ratio of weight percent molecules with monocycloparaffinic functionality to weight percent molecules with multicycloparaffinic functionality greater than 15.
- the isomerized base oil has an average molecular weight between 600 and 1100, and an average degree of branching in the molecules between 6.5 and 10 alkyl branches per 100 carbon atoms. In another embodiment, the isomerized base oil has a kinematic viscosity between about 8 and about 25 mm 2 /s and an average degree of branching in the molecules between 6.5 and 10 alkyl branches per 100 carbon atoms.
- the isomerized base oil is obtained from a process in which the highly paraffinic wax is hydroisomerized at a hydrogen to feed ratio from 712.4 to 3562 liter H 2 /liter oil, for the base oil to have a total weight percent of molecules with cycloparaffinic functionality of greater than 10, and a ratio of weight percent molecules with monocycloparaffinic functionality to weight percent molecules with multicycloparaffinic functionality of greater than 15.
- the base oil has a viscosity index greater than an amount defined by the equation: 28 ⁇ Ln (Kinematic viscosity at 100° C.)+95.
- the base oil comprises a weight percent aromatics less than 0.30; a weight percent of molecules with cycloparaffinic functionality greater than 10; a ratio of weight percent of molecules with monocycloparaffinic functionality to weight percent of molecules with multicycloparaffinic functionality greater than 20; and a viscosity index greater than 28 ⁇ Ln (Kinematic Viscosity at 100° C.)+110.
- the base oil further has a kinematic viscosity at 100° C. greater than 6 mm 2 /s.
- the base oil has a weight percent aromatics less than 0.05 and a viscosity index greater than 28 ⁇ Ln (Kinematic Viscosity at 100° C.)+95.
- the base oil has a weight percent aromatics less than 0.30, a weight percent molecules with cycloparaffinic functionality greater than the kinematic viscosity at 100° C., in mm 2 /s, multiplied by three, and a ratio of molecules with monocycloparaffinic functionality to molecules with multicycloparaffinic functionality greater than 15.
- the isomerized base oil contains between 2 and 10% naphthenic carbon as measured by n-d-M.
- the base oil has a kinematic viscosity of 1.5-3.0 mm 2 /s at 100° C. and 2-3% naphthenic carbon.
- the isomerized base oil has an average molecular weight greater than 475; a viscosity index greater than 140, and a weight percent olefins less than 10.
- the base oil improves the air release and low foaming characteristics of the mixture when incorporated into the metalworking fluid.
- the isomerized base oil is a FT base oil having a kinematic viscosity at 100° C. between 2 mm 2 /s and 6 mm 2 /s; a kinematic viscosity at 40° C. between 7 mm 2 /s and 20 mm 2 /s; CCS viscosity of less than 2300 mPa ⁇ s at ⁇ 35° C.; pour point in the range of ⁇ 20 and ⁇ 40° C.; molecular weight of 300-500; density in the range of 0.800 to 0.820; paraffinic carbon in the range of 93-97%; naphthenic carbon in the range of 3-7%; Oxidator BN of 30 to 60 hours; and Noack volatility in wt. % of 8 to 20 as measured by ASTM D5800-05 Procedure B.
- the isomerized base oil is a FT base oil of “light” range viscosity having a kinematic viscosity at 100° C. between 2 mm 2 /s and 3 mm 2 /s; a kinematic viscosity at 40° C.
- the isomerized base oil is a FT base oil of “medium” range viscosity, having a kinematic viscosity at 100° C.
- the base oil comprises a mixture of “light” and “medium” range viscosity FT base oils.
- the metalworking fluid employs at least one of the isomerized base oils described above.
- the composition consists essentially of at least a Fischer-Tropsch base oil.
- the metalworking fluid employs at least an isomerized based oil as the base oil matrix and optionally 5 to 95 wt. % of at least another type of oil, e.g., lubricant base oils selected from Group I, II, III, IV, V, and VI lubricant base oils as defined in the API Interchange Guidelines, and mixtures thereof.
- the metalworking fluid employs an isomerized based oil and 5 to 20 wt. % of at least another type of oil.
- Mineral lubricating oil base stocks can be any conventionally refined base stocks derived from paraffinic, naphthenic and mixed base crudes.
- Synthetic lubricating oils that can be used include esters of glycols and complex esters.
- synthetic oils that can be used include synthetic hydrocarbons such as polyalphaolefins; alkyl benzenes, e.g., alkylate bottoms from the alkylation of benzene with tetrapropylene, or the copolymers of ethylene and propylene; silicone oils, e.g., ethyl phenyl polysiloxanes, methyl polysiloxanes, etc., polyglycol oils, e.g., those obtained by condensing butyl alcohol with propylene oxide; etc.
- Other suitable synthetic oils include the polyphenyl ethers, e.g., those having from 3 to 7 ether linkages and 4 to 8 phenyl groups.
- Other suitable synthetic oils include polyisobutenes, and alkylated aromatics such as alkylated naphthalenes.
- the metalworking fluid in one embodiment is characterized as having reduced mist formation, lower foaming tendency, and better air release properties compared to compositions of the prior art.
- the metalworking fluid may contain applicable additives known in the art to improve the properties of the composition in amounts ranging from 0.10 to 40 wt. %.
- additives include metal deactivators; corrosion inhibitors; antimicrobial; anticorrosion; emulsifying agents; couplers; extreme pressure agents; antifriction; antirust agents; polymeric substances; anti inflammatory agents; bactericides; antiseptics; antioxidants; chelating agents such as edetic acid salts, and the like; pH regulators; antiwear agents including active sulphur anti-wear additive packages and the like; a metalworking fluid additive package containing at least one of the aforementioned additives.
- Non-limiting examples include rhamsan gum, hydrophobic and hydrophilic monomers, styrene or hydrocarbyl-substituted styrene hydrophobic monomers and hydrophilic monomers, oil soluble organic polymers ranging in molecular weight (viscosity average molecular weight) from about 0.3 to over 4 million such as isobutylene, styrene, alkyl methacrylate, ethylene, propylene, n-butylene vinyl acetate, etc. In one embodiment, polymethylmethacrylate or poly(ethylene, propylene, butylene or isobutylene) in the molecular weight range 1 to 3 million is used.
- a small amount of foam inhibitors in the prior art can also be added to the composition in an amount ranging from 0.05 to 15.0 wt. %.
- Non-limiting examples include polydimethylsiloxanes, often trimethylsilyl terminated, alkyl polymethacrylates, polymethylsiloxanes, an N-acylamino acid having a long chain acyl group and/or a salt thereof, an N-alkylamino acid having a long chain alkyl group and/or a salt thereof used concurrently with an alkylalkylene oxide and/or an acylalkylene oxide, acetylene diols and ethoxylated acetylene diols, silicones, hydrophobic materials (e.g.
- silica fatty amides, fatty acids, fatty acid esters, and/or organic polymers, modified siloxanes, polyglycols, esterified or modified polyglycols, polyacrylates, fatty acids, fatty acid esters, fatty alcohols, fatty alcohol esters, oxo-alcohols, fluorosurfactants, waxes such as ethylenebistereamide wax, polyethylene wax, polypropylene wax, ethylenebisstereamide wax, and paraffinic wax, ureum.
- the foam control agents can be used with suitable dispersants and emulsifiers. Additional active foam control agents are described in “Foam Control Agents”, by Henry T. Kemer (Noyes Data Corporation, 1976), pages 125-162.
- the metalworking fluid further comprises anti-friction agents include overbased sulfonates, sulfurized olefins, chlorinated paraffins and olefins, sulfurized ester olefins, amine terminated polyglycols, and sodium dioctyl phosphate salts.
- the composition further comprises corrosion inhibitors including carboxylic/boric acid diamine salts, carboxylic acid amine salts, alkanol amines, alkanol amine borates and the like.
- the metalworking fluid further comprise oil soluble metal deactivators in an amount of 0.01 to 0.5 vol % (based on the final oil volume).
- oil soluble metal deactivators in an amount of 0.01 to 0.5 vol % (based on the final oil volume).
- Non-limiting examples include triazoles or thiadiazoles, specifically aryl triazoles such as benzotriazole and tolyltriazole, alkyl derivatives of such triazoles, and benzothiadiazoles such as R(C 6 H 3 )N 2 S where R is H or C 1 to C 10 alkyl.
- Suitable materials are available from Ciba Geigy under the tradenames Irgamet and Reomet or from Vanderbilt Chemical Corporation under the Vanlube tradename.
- a small amount of at least an antioxidant in the range 0.01 to 1.0 weight % can be added.
- antioxidants of the aminic or phenolic type or mixtures thereof e.g., butylated hydroxy toluene (BHT), bis-2,6-di-t-butylphenol derivatives, sulfur containing hindered phenols, and sulfur containing hindered bisphenol.
- the metalworking fluid further comprises 0.1 to 20 wt. % of at least an extreme-pressure agent.
- extreme pressure agents include zinc dithiophosphate, molybdenum oxysulfide dithiophosphate, molybdenum oxysulfide thithiocarbamate, molybdenum amine compounds, sulfurized oils and fats, sulfurized fatty acids, sulfurized esters, sulfurized olefins, dihydrocarbyl polysulfides, thiocarbamates, thioterpenes, dialkyl thiodipropionates, and the like.
- various other conventional additives can be added to such extent that they do not inhibit the effects of the metalworking fluid.
- examples include fatty acids and salts thereof, polyhydric alcohols such as propylene glycol, glycerin, butylene glycerol, and the like; surfactants such as anionic surfactants, amphoteric surfactants, nonionic surfactants, and the like; and boron nitride dispersed in a dispersant such as a surfactant.
- the optional additives used in formulating the metalworking fluid composition can be blended into the base oil matrix individually or in various sub-combinations.
- all of the components are blended concurrently using an additive concentrate (i.e., additives plus a diluent, such as a hydrocarbon solvent).
- an additive concentrate i.e., additives plus a diluent, such as a hydrocarbon solvent.
- the use of an additive concentrate takes advantage of the mutual compatibility afforded by the combination of ingredients when in the form of an additive concentrate.
- the metalworking fluid is prepared by mixing the base oil matrix with the optional additives and/or additive package(s) at an appropriate temperature, such as approximately 60° C., until homogeneous, for use as a straight oil cutting fluid.
- the emulsifying agents may be added to the metalworking fluid to form an oil-in-water emulsion.
- the metalworking fluid composition is characterized as having reduced mist formation, low foaming tendency and excellent air release properties.
- the foaming tendency of the metalworking fluids can be measured using the ASTM D892-95 foam test.
- the metalworking fluid when evaluated under ASTM D892-06 method shows a sequence II foam tendency foam height of less than 50 mL.
- the metalworking fluid shows a sequence II foam height of less than 40 mL.
- the sequence II foam height is less than 20 mL.
- the metalworking fluid shows a sequence I foam tendency by ASTM D 892-03 of less than 100 mL. In another embodiment, the fluid has a sequence I foam tendency of less than 50 mL. In a third embodiment, a sequence I foam tendency of less than 30 mL.
- the metalworking fluid has a number of minutes to 3 mL emulsion at 54° C. by ASTM D 1401-02 of equal or less than 30. In yet another embodiment, the fluid has a number of minutes to 3 mL emulsion at 82° C. by ASTM D 1401-02 equal to or less than 60.
- Air release properties can be measured using the ASTM D 3427 (2003) method for gas bubble separation time of petroleum oil to measure the ability of a fluid to separate entrained gas.
- the metalworking fluid has an air release time at 50° C. of less than 0.60 minutes as measured according to ASTM D 3427 (2003). In a second embodiment, an air release time of less than 1 ⁇ 2 minutes.
- the metalworking fluid exhibits reduced mist formation property and imparts aerosol control or particulate control to the fluid, e.g., having 5 to 50% mist reduction compared to metalworking fluids comprising base oil Group I in the prior art. Mist reduction experiments can be measured according to similar to the aerosol (mist) formation test as described in “Polymer Additives as Mist Suppressants in Metal Cutting Fluids,” by Marano et al., Journal of the Society of Tribologists and Lubrication Engineers, October 1995, pp. 25-35.
- the metalworking fluid without any addition of anti-mist additives has an average mist accumulation rate of less than 300 mg/mm 3 in the first 30 seconds (after start) of the aerosol mist formation test.
- the metalworking fluid without any mist additive has an average mist accumulation rate of less than 250 mg/mm 3 in the first 30 seconds of the aerosol mist formation test. In a third embodiment, the average mist accumulation rate is less than 200 mg/mm 3 in the first 30 seconds of the test. In a fourth embodiment, the average mist accumulation rate is less than 150 mg/mm 3 in the first 60 seconds of the test.
- the metalworking fluid composition is readily biodegradable, with the base oil having an OECD 301D level ranging from 30 to 95%.
- the metalworking fluid has a biodegradability of at least 30% as measured according to OECD 301D.
- Metalworking fluids can be characterized as suitable or unsuitable for extreme pressure applications.
- a fluid that is considered as suitable for extreme pressure is one that prevents sliding metal surfaces from seizing under extreme pressure conditions. The seizing of metal surfaces result from friction between opposing asperities. Asperities are microscopic projections on metal surfaces resulting from metalworking operations.
- One technique for measuring extreme pressure properties of a fluid is to measure a load force between sliding surfaces which can be sustained by lubricant without seizing of the sliding surfaces. Such a technique is described as a Falex load test, which is an ASTM standard test for fluid lubricants (ASTM D-3233 (2003)).
- the metalworking fluid is characterized has having a Falex reference wear of less than ten teeth.
- the metalworking fluid is characterized as having a Falex reference load of greater than about 4,500 pounds force.
- the metalworking fluid is characterized as having excellent lubricating property, specifically lubricating surfaces in sliding contacts, as measured in a Four-Ball Wear Test per ASTM D4172-94(2004)e1. In one embodiment, the metalworking fluid has a Four-Ball wear scar diameter of less than about 0.07 mm.
- the metalworking fluid is characterized has having a smooth liquid flow for excellent circulation in a pump. Moreover, the metalworking fluid has an excellent which can prevent frictional heat from being produced between a tool and a workpiece, so that the effective tool life can be increased.
- the metalworking fluid is used in the production of semiconductors, plant equipment, and auto parts, etc. wherein the shape of the final object, e.g., silicon wafer or machine part, is obtained by with or without the progressive removal of metal or silicon.
- Non-limiting examples of the operations include cutting, drilling, boring, honing, broaching, grinding, forming, stamping, casting, forging, rolling, piercing, coining, drawing, press forming, deburring, milling, grooving, tapping, chamfering, broaching, reaming, honing, lapping, straightening, and drawing.
- the metalworking fluid is applied to the contact zone between tool and workpiece.
- the fluid may be applied by a variety of methods, including immersing the contact zone in the fluid, spraying the fluid into the contact zone, flooding the contact zone with fluid, pumping a stream of fluid into the contact zone, periodically wetting the tool or the workpiece with lubricating fluid, or any means of constantly or intermittently applying the lubricant to the contact zone between the tool and the workpiece.
- compositions are prepared by mixing the components in the amounts indicated in the Examples/Tables.
- the components used in the Examples are listed below.
- EP agent is a commercially available sulfurized polymerized ester, 10% inactive sulphur extreme-pressure agent.
- HYNAPTM N100HTS hydrotreated, naphthenic oil (Group V) is from San Joaquin Refining Oil, Inc. of Bakersfield, Calif.
- AshlandTM 100SN Group 1 oil is from Ashland Inc.
- ChevronTM 100R group 2 oil, ChevronTM 100R group 3 oil, and Chevron Synfluid 4 cSt PAO oil are all from Chevron Corporation of San Ramon, Calif.
- Additive 2 is a sulfurized vegetable fatty acid ester.
- Defoamer is an acrylate oligomer antifoam/defoamer.
- Additive CAS is a commercially available overbased calcium sulphonate PEP metalworking additive containing carbonated alkylbenzene sulfonate.
- Additive SO is a sulfurized olefin.
- Mineral seal oil having a visocisty of 3.39 mm 2 /sec at 40° C., and basestock oils SN 100 (density of 0.864 and viscosity of 20.6 mm 2 /sec at 40° C.), SN 150 and SN 600 (API Group 1) are commercially available from a number of sources.
- GTL Fischer-Tropsch derived base oils GST0449, FTBO L, FTBO XL, FTBO XXL, and FTBO M are from Chevron Corp. Properties of the Fischer-Tropsch derived base oils used in the Examples are shown in Table 3.
- Anti-mist agent 1 is a methacrylate copolymer.
- Anti-mist agent 2 is a commercially available high molecular weight oil soluble polymer tackifier.
- a number of metalworking fluid compositions having components as listed in Table 1 were formulated and their properties were measured using various standard test methods: ASTM D1401-02 for Water Separability of Petroleum Oils and Synthetic Fluids; ASTM D 3427 (2003) Standard Test Method for Air Release Properties of Petroleum Oils; and ASTM D892-95 Foam Stability Sequence Test. As shown in the table, the example incorporating the isomerized base oil shows low foaming tendency (foam height of nil) and air release property that is comparable if not better than the prior art oil (in view of the test repeatability of 1 min.).
- Example 1 Example 2
- Example 3 Example 4
- Example 5 Example 6
- Group V Group 1 Group 2 Group 3 PAO GTL BST Sample ID wt % wt % wt % wt % wt % wt % SJR Hynap N100HTS - Group V 95 — — — — — Ashland 100 SN - Group 1 — 95 — — — — Chevron 100 R - Group 2 — — 95 — — — Chevron UCBO 4R - Group 3 — — — 95 — — Chevron Synfluid, 4 cSt - PAO — — — 95 — GTL BST isomerized base oil — — — — — 95 EP agent 5 5 5 5 5 5 5 5 5 5
- metalworking fluid compositions having components as listed in Table 2 were formulated and their properties were measured/recorded.
- Examples 11-13 compare the compositions each with 0.25 wt. % of an anti-mist agent added (a high molecular weight oil soluble polymer tackifier).
- the samples were subject to an aerosol (mist) formation experiment similar to the one described in “Polymer Additives as Mist Suppressants in Metal Cutting Fluids,” by Marano et al., Journal of the Society of Tribologists and Lubrication Engineers, October 1995, pp. 25-35.
- metalworking fluid in 100 mL sample
- a tube e.g., ID of 0.0011 m
- Compressed air was supplied through the annulus between the outer and inner tubes (ID 0.0021 m and OD 0.0013 m, respectively) at flow rates up to 35 litres/min.
- Mist generated by the atomizer was directed to a long wide plexiglass duct of square cross section or chamber (e.g., a 12′′ by 12′′ by 18′′ chamber).
- the amount of mist generated as a function of time was captured by a datalogger and recorded.
- a portable, real time aerosol monitor DataRAM® [MIE Instruments Inc., Bedford Mass.] was used as the datalogger to continuously quantify the mist levels generated.
- the DataRAM is a nephelometric monitor used to measure airborne particle concentration by sensing the amount of light scattered by the population of particles passing through a sampling volume.
- mist was generated at the beginning of the test. After atomizing, the mist tended to drop to the bottom of the container and thereby showing a drop in the amount of mist collected.
- FIGS. 1-3 Measurements from the aerosol (mist) formation experiments were plotted in FIGS. 1-3 as a function of time. The results show that generally, metalworking fluid compositions containing Fischer-Tropsch derived base oils result in significantly less mist formation than the base oils of the prior art, with a reduction in mist formation of at least 10% in some examples to up to 75% or more in the first 30 seconds of the aerosol mist formation test.
- Example 10 with the isomerized base oil performs better (with reduced mist formation) compared to Example 9 with a mineral group I base oil and even with 2 wt. % anti-mist additive.
- FIG. 3 all examples (#11-13) with the addition of a high molecular weight oil soluble polymer tackifier as a powerful (and expensive) anti-mist additive show comparable performance.
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Priority Applications (9)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US11/831,896 US20090036338A1 (en) | 2007-07-31 | 2007-07-31 | Metalworking Fluid Compositions and Preparation Thereof |
| BRPI0814277-7A2A BRPI0814277A2 (pt) | 2007-07-31 | 2008-07-15 | Fluido para o trabalho de metal |
| CA2694307A CA2694307A1 (en) | 2007-07-31 | 2008-07-15 | Metalworking fluid compositions of isomerized base oil with improved air release properties and preparation thereof |
| DE112008002081T DE112008002081T5 (de) | 2007-07-31 | 2008-07-15 | Zusammensetzung für Metallbearbeitungsfluid aus einem isomerisierten Basisöl mit besserem Luftabscheideverhalten und ihre Herstellung |
| MX2010001003A MX2010001003A (es) | 2007-07-31 | 2008-07-15 | Composiciones de fluido para trabajar metales de un aceite base isomerizado con propiedades mejoradas de liberacion del aire y su preparacion. |
| PCT/US2008/070080 WO2009017963A1 (en) | 2007-07-31 | 2008-07-15 | Metalworking fluid compositions of isomerized base oil with improved air release properties and preparation thereof |
| CN200880107421A CN101802148A (zh) | 2007-07-31 | 2008-07-15 | 金属加工液组合物及其制备 |
| JP2010520056A JP2010535276A (ja) | 2007-07-31 | 2008-07-15 | 改善された脱泡性を有する異性化基油の金属加工流体組成物及びその調製 |
| US13/112,548 US20120010113A1 (en) | 2007-07-31 | 2011-05-20 | Metalworking fluid compositions and preparation thereof |
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| US11/831,896 US20090036338A1 (en) | 2007-07-31 | 2007-07-31 | Metalworking Fluid Compositions and Preparation Thereof |
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| US11/831,910 Continuation-In-Part US20090036333A1 (en) | 2007-07-31 | 2007-07-31 | Metalworking Fluid Compositions and Preparation Thereof |
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| US (1) | US20090036338A1 (es) |
| JP (1) | JP2010535276A (es) |
| CN (1) | CN101802148A (es) |
| BR (1) | BRPI0814277A2 (es) |
| CA (1) | CA2694307A1 (es) |
| DE (1) | DE112008002081T5 (es) |
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Cited By (10)
| Publication number | Priority date | Publication date | Assignee | Title |
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| US20100081590A1 (en) * | 2008-10-01 | 2010-04-01 | Chevron U.S.A. Inc. | 110 neutral base oil with improved properties |
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Also Published As
| Publication number | Publication date |
|---|---|
| DE112008002081T5 (de) | 2010-11-11 |
| BRPI0814277A2 (pt) | 2015-02-03 |
| JP2010535276A (ja) | 2010-11-18 |
| MX2010001003A (es) | 2010-03-01 |
| CN101802148A (zh) | 2010-08-11 |
| CA2694307A1 (en) | 2009-02-05 |
| WO2009017963A1 (en) | 2009-02-05 |
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