STLE 2008 Cleveland

Duong Nguyen, Luke Lester, John Nussbaumer, Lou Bona, Mark Harr, Don Stevenson

Nitro-EP

R-C-NO2

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.

Nitro-EPTesting Performance Data

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.

Acme Gridley Turret Machine

Six stations,

Multiple tasks

Turning, drilling, threading,shaping,etc

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.

Now Aluminum

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

THANK YOU Any question please?