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Advanced Alloys
� Contains little iron, mostly Ti, Ni, Cr.� Inert, non-responsive to S-P, thin oxide layer (1%
thickness of iron oxides) (1)� Poor tribological properties, high wear, galling� Cl works but potential crack corrosion.
Stainless 50% Fe + 25%Ni + 15% Cr
Waspalloy 2% Fe + 60% Ni + 18% Cr
Inconel 0% Fe + 60% Ni + 25% Cr
Titanium <0.5% Fe + 99-100% Ti
(1) http://www.textorgroup.ch/pdf/publications/booksmonographs/6/Chap_07.pdf
Extreme-Pressure Additives
EPAdditives
%Element Steel Special Alloys
Notes
Sulfurized 10-40%S yes no Need Fe
Phosphates 4-12%P yes no Need Fe
Chlorinated 30-70%Cl yes yes Crackcorrosion
Nitro 1-2% N yes yes Non-corrosive
Novelties of Nitro-EP� Very low active element, 1-2% N, � No S,P,B, no metals, no complex esters� Reactive to Ti, Ni, Al, no need for trace of Fe,� Effective to both ferrous and non-ferrous,� Passive, non-penetrating, molecular or nano-level?,� Non-corrosive,� Low-toxic, LD50 = >2,000 mg/kg (dermal & oral)� Environmental, can be made from renewable RM
sources,� Synergistic to S/P� (S/P: Nitro) Blends work for
stainless.
Microtap on StainlessNon-Effectiveness of Conventional EP
� 10 % in 100 SUS oil,� 300 rpm,� Stainless
Tapping Efficiency Results:
Sulfurized Fat Tap seized
Phosphate Tap seized
Chlorinated Tapped
Nitro Tapped
Draw-Bead TestAluminum, 10% EP in Straight-Oil
� Draw metal strip thru sets of dies,� Less force, better EP� Chlorinated currently is the BEST,� Accuracy +/-5%
Chlorinated50%Cl
0(standard)
Phosphate, 4%P
+1%
Nitro-EP + 6%
Tapping Efficiency Results:
Draw-Bead Testwith Water-Based Formulas
� 8% EP in soluble oils, 10% dilutions
� +60% better than chlorinated , with aluminum
� +20% better than chlorinated, with steel
� 5182 Aluminum� Cold-rolled steel
CNC Drill &Tap Stainless
� Formula 1: 13% Sulfurized fat + 5% Chlorinated� Formula 2: 13% Sulfurized fat + 5% Nitro-EP� Formula 3: 18% Nitro-EP� Formula 4: 18% Sulfurized fat
� Drilling: All drilled 400 holes.
� Tapping: Formula 1-3: All 400 holesFormula 4: Tap bit broke after 5 holes.
FORMULA: 100 SUS oil + 18%EP
Field Trials, Multiple-Spindle Screw Machine
� One customer made aircraft engine parts out of titanium, A286 stainless, nickel-based Waspalloy & Inconel, compared the best S/Clmachining/cutting fluid to experimental fluid in which all Cl was substituted with Nitro-EP.
� Conclusion: Experimental fluid performed slightly better in all metals, with less smoke, less burn, less tool wears, no corrosion.
Field Trial: Finished Parts
Chlorinated Formula
Nitro-EP Formula
Parts show some corrosion on storage with CP Formula
No Corrosion on finished parts with Nitro-EP formula
Nitro-EP yields improved surface finish
Field Trials: Burning on Form Tool
Chlorinated Formula Nitro-EP Formula
Nitro-EP yields less wear on form tools
Field Trials: Carbide Cut-Off
Chlorinated Formula Nitro-EP Formula
Comparable wear on Carbide cut-off
Synergy of Nitro-EP
� Nitro-EP can enhance the performance of conventional S/P additives.
� Nitro-EP can make S/P work for Stainless.� Nitro-EP gives very interesting results on
aluminum.
Synergism on Stainless CoolantConditions: 300-350 rpm, Stainless Steel, 5% dilutions
Formulations of Soluble Oils & Microtap Testing Results
Compositions% A B C D E F G H
Soluble Oil Base (*)
Ba. Ba. Ba. Ba. Ba. Ba. Ba. Ba.
Nitro-EP 0.0 1.5 15.0 0.0 1.5 0.0 1.5 0.0
Sulfurized Fat 0.0 0.0 0.0 15.0 13.5 0.0 0.0 0.0
Phosphates 0.0 0.0 0.0 0.0 0.0 15.0 13.5 0.0
Chlorinated 0.0 0.0 0.0 0.0 0.0 0.0 0.0 15.0
RESULTS:Average Tapping Torque , N-cm
A B C D E F G H
@300 rpm seized seized 293 seized seized seized 285 seized
@350 rpm seized seized 285 seized 267 seized 260 275
(*) Base: 100 SUS oil plus 10% petro. sodium sulfonate % 10% PEG 600 esters.
What conclusions can we draw from the synergy study?
� Nitro-EP is just as effective as chlorinated on tapping stainless steel.
� 10:1 Combinations of the conventional S/P with minor component Nitro-EP performed even better than Nitro itself.
EP-interactions on Aluminum Coolant, Microtap Efficiency, 2% dilutions
� Cl /NO2: 2 strong adverse oxidants; P/NO2: mutual stabilizing effects; S/NO2: No S-reaction on aluminum
� Same conclusions on oil-based formulas used tapping aluminum� No interactions on steel
TEA soap of chlorinated oleic acid alone
vs 10:1 TEA-Cl-oleic : TEA-nitro-oleic acid - 15%TEA soap of ethoxylated phosphate esters alone
vs 10:1 TEA-Phosphate : TEA-nitro-oleic acid + 15%TEA soap of sulfurized oleic acid alone
vs 10:1 TEA-sulfurized oleic : TEA-nitro oleic acid 0%
OBSERVATIONS:
Synergy on Aluminum Coolant
� Microtap, 350 RPM, 2% additive in water
�Additive 1: Alkyl sodium sulfonate
�Additive 2: Additive 1+ 10% Nitro-EP,
� Tapping Efficiency: 15% improvementSame as the best commercial coolant
Recommendations for MWFOperation Metal Option 1 Option 2 Option 3
Metal Removal
Steel, SS, Ti, Ni, Cr 10% Nitro-EP 10% S/P:Nitro
(10:1)X
Metal Forming
Steel, SS, Ti, Ni, Cr 15% P:Nitro
(1:1)X X
All Alum 1-10% Nitro1-10% P:Nitro
(10:1) 10%
Sulfonate/Nitro(10:1)
Chlorine Replacement All metals
1:1Replacement based on weights of
products
Most cases, Nitro-EP alone in oil will give a complete cutting /machining fluid, no other additive is needed.
Nitro-EP Summary
� Nitro-EP contains no Cl, S, P, B, metals� Designed for hard-to-machine alloys� Nitro-EP offers excellent EP and lubricity� Effective Cl replacement, alone or with S/P� Proven on variety of metals: stainless,
aluminum, nickel, chromium, titanium� Blended in petroleum oil or fatty esters
Recommended