Abstract: The present invention relates to a cold rolling process for rolling hard metal or metal alloys, comprising applying an effective amount of an oil composition comprising a base stock oil and, based on the total weight of the composition, from 1 to 80% by weight of di(2-ethylhexyl)adipate. Example of hard base metals include steel and nickel.

Abstract: The present invention relates to a water-soluble aluminium and aluminium alloys hot rolling composition comprising a base stock oil and, based on the total weight of the composition, from 1 to 80% by weight of a combination of: a monoester of a fatty acid with a polyol and a tetraester of a fatty acid with pentaerythritol; the weight monoester:tetraester ratio of said combination ranging from 1:20 to 10:1. The invention also relates to an oil-in-water emulsion, to a hot rolling process and to the use of the oil-in-water emulsion in a hot rolling process.

Abstract: The invention concerns the use as extreme pressure additive in aqueous lubricants used for deforming or transforming metals, lamellar crystallites having a length (L) ranging between 0.1 and 100 &mgr;m, a width (I) ranging between 0.

Abstract: A new additive for water based metal cutting and grinding coolant comprises a combination of soybean oil and surfactant, the surfactant being a nonoxynol or alcohol based detergent that is biodegradable. The proportion of soybean oil to surfactant is adjusted for metal cutting or grinding and the proportion of additive to water is also adjusted for metal cutting or grinding. A small amount of bacteriocide may be added to the additive to avoid rancidity.

Abstract: A lubricant composition for metal forming and cutting has at least one compound of the formula (I): R1—(AO)n—OOC—(CH2)m—Ph—(R2)p where R1 is a C1 to C15 alkyl group AO is an alkyleneoxy group which may vary along the (poly) alkylenoxy chain; n is 0 or from 1 to 100; m is 0, 1 or 2; and Ph is a phenly group, which may be substituted with groups (R2)p; where each R2 is independently an alkyl, halogen, haloalky or alkoxy group; and p is 0 or from 1 to 3; The lubricant composition also includes at least one lubricant additive selected from the group consisting of an organic ester additive, a polyalkylene glycol additive, a sulphur-containing synthetic additive, a sulphur-containing oleochemical additive, a sulphonate, a phosphorus-containing additive and a chlorinated paraffin additive. Also described are a method of using the lubricant composition in metal forming and cutting applications and the use of the lubricant composition in metal forming and cutting applications.

Abstract: Non-staining, active metal-working compositions are disclosed. The compositions contain active sulfur to provide extreme pressure properties for metal-working fluids. A metal corrosion inhibitor is disclosed that reduces the corrosivity of free sulfur on non-ferrous metallic objects.

Abstract: A process for the cutting or non-cutting forming of metals using two cooling lubricants, wherein an oil or a first emulsion having an oil content of at least 10 wt. % is applied to the workpiece, as a first cooling lubricant, at the tribo-zone and, at the same time, an oil-free cooling lubricant or a second emulsion that is an oil-in-water emulsion having an oil content of less than 10 wt. % is applied, as a second cooling lubricant, adjacent to the tribo-zone. Depending on the metal-working technique, a two-component nozzle is preferably used for supplying the first and second cooling lubricants, the jet of second cooling lubricant surrounding the jet of first cooling lubricant concentrically. Alternatively, it is possible to supply the first cooling lubricant directly to the tribo-zone through channels in the tool, while the second cooling lubricant is applied at the periphery.

Abstract: This invention relates to novel water soluble metal working fluid compositions, their use to work metal, a process for working metal using such compositions and the metal worked article of manufacture. More particularly, this invention relates to fluid compositions useful in cutting, grinding, shaping and other metal working operations which require a lubricant. The terms “first Group A” and “second Group B” are used herein to denote different groups and not to indicate any sequence of use or selection as any possible combination or sequence of use of a component(s) is envisioned without limit of any kind. The disclosed fluid compositions are also anticorrosive and environmentally more acceptable than current oil based fluids.

Abstract: A method of making high carbon content steel engine components is disclosed. The method includes pre-processing a supply wire of high strength steel having a spheroidized carbide microstructure and high-strength mechanical properties, applying a lubricant on the surface of the supply wire, and cold-forming the blank to substantially reduce or eliminate the need for any additional surface grinding operations.

Abstract: The present invention provides a nonflammable water-based cutting fluid composition which affords excellent dispersion property of abrasives, which does not cause problems involving in flammability upon the use for cutting process of a hard and brittle materials, which can be readily washed, and which can achieve sufficient rust preventive property even if it is used in an equipment for oil use. Provided by the present invention is a nonflammable water-based cutting fluid composition containing a polycarboxylic acid-based polymer compound and/or a salt thereof having a weight-average molecular weight of 1,000-200,000, and additionally a carboxylic acid and/or a salt thereof upon needs for a rust preventive property.

Abstract: A method of cold fabricating an intermetallic alloy composition, comprising steps of coating an article of an intermetallic alloy composition with a viscous medium which provides a moisture resistant barrier on the surface of the article, fabricating the coated article into a desired shape, and optionally removing the coating from the shaped article. The coating step can be carried out by applying oil to the surface of the article or immersing the article in oil. The intermetallic article can be an iron aluminide and the fabrication step can include stamping, bending, drawing, forming, cutting, shearing or punching. During the fabrication step a surface oxide film is cracked and metal surfaces exposed by the cracked oxide film are protected from exposure to moisture in the air by the viscous medium.

Abstract: A coating for superplastic forming (SPF) and quick plastic forming (QPF) tooling and an SPF/QPF process made possible with the coating. The coating defines the forming surface of an SPF/QPF tool, and consists essentially of either a tungsten carbide cermet or a chromium carbide cermet. The coating preferably comprises a metal matrix containing tungsten carbide or chromium carbide particles having a particle size of not more than 0.1 micrometer, and is preferably prepared to have a surface finish of not rougher than 0.3 micrometer Ra. An SPF/QPF process that makes use of a tool whose forming surface is provided with the coating can be performed without depositing any lubricant on the forming surface or workpiece.

Abstract: The present invention relates to a coating solution to be applied on the surface of metals or metal alloys, a process for cold forming of metals and metal alloys using said coating solution, and a coated blank made of a metal or a metal alloy.

Abstract: The present invention discloses a hydroforming process for metal parts that uses liquid-film and solid-film lubricants. The lubricants used in the invention are particularly useful for die-side lubrication. The process includes a step in which a ductile metal part is over-coated with either the liquid-film or solid-film lubricant. The liquid lubricants preferably include an oil and a optionally a surfactant. The solid lubricants preferably include a hard wax and optionally a surfactant.

Abstract: An effective and simple controlling process for an aqueous lubricant of one process type used for cold forging of metallic material are explained.

Abstract: This invention relates to novel water soluble metal working fluid compositions, their use to work metal, a process for working metal using such compositions and the metal worked article of manufacture. More particularly, this invention relates to fluid compositions useful in cutting, grinding, shaping and other metal working operations which require a lubricant. The terms “first Group A” and “second Group B” are used herein to denote different groups and not to indicate any sequence of use or selection as any possible combination or sequence of use of a component(s) is envisioned without limit of any kind. The disclosed fluid compositions are also anticorrosive and environmentally more acceptable than current oil based fluids.

Abstract: The invention provides a cutting and lubricating composition with abrasive particles for cutting hard and brittle workpieces with a wire saw or other cutting or grinding tool. The composition provides electrostatic and steric repulsion between the abrasive particles to maintain the particles in suspension without forming hard settled cakes from suspension “fall-out”.

Abstract: The present invention is directed to a method for mechanical working of a metal containing copper, aluminum or an alloy thereof. The method is carried out in the presence of an aqueous cooling lubricant containing an alkanol amine. The lubricant is capable of preventing and reducing the corrosion of both metals and iron.

Abstract: The invention concerns a method for forming metal parts by cold deformation, consisting in: (i) mechanically depositing a metal zinc layer on the free surface of the blank of the part to be produced; and (ii) forming said part by plastic deformation.

Abstract: The invention relates to an aqueous mixture of esters and acids from the reaction of at least one polyhydric alcohol and at least one monoacid and at least one diacid coupled with a surfactant and an effective amount of base to solubilize the mixture.

Abstract: The present invention relates to a cold rolling process for rolling hard metal or metal alloys, comprising applying an effective amount of an oil composition comprising a base stock oil and, based on the total weight of the composition, from 1 to 80% by weight of di(2-ethylhexyl) adipate. Example of hard metals include steel and nickel.

Abstract: This invention provides a tapping composition, a method of making the tapping composition and a method of using the tapping composition to cut internal threads on the surface of a hole drilled in metal. The tapping composition of this invention is comprised of a uniform blend of a glyceride, a liquid hydrocarbon oil and a polyvinyl chloride resin.

Abstract: Provided is a metal working oil composition not containing a chlorine compound. Its working capabilities in low-speed cutting or heavy cutting operations such as broaching or gun-drilling operations are comparable to or better than those of chlorine compound-containing lubricant oil. The composition comprises 100 parts by weight of a lubricant base oil that comprises from 0 to 30% by weight of (a) a mineral base oil and from 70% to 100% by weight of (b) a &pgr; electron-containing synthetic base oil, from 0.1 to 25 parts by weight of (c) a sulfur-containing extreme-pressure agent, and from 0.1 to 7 parts by weight of (d) an alkali metal and/or alkaline earth metal sulfonate.

Abstract: Metal working fluids being oil-in-water emulsions comprising alkylated polyvinylpyrrolidones as surfactants for emulsifying the oil in water. The alkylated polyvinyl-pyrrolidones having a molecular weight of about 1,000 up to 50,000 provide emulsions showing a high emulsion stability under varying and severe processing conditions of metal working fluids. Further, advantages of the metal working fluids are the narrow distribution of the droplet size, the high stability against varying temperature, the high stability against varying quality/composition of the make-up water, a high capacity of dispersing metal fines in the metal working fluid as well as excellent film forming characteristics.

Abstract: A process of mechanical hydroforming, in which a hollow tube is caused to expand against the interior surface of a die that surrounds the tube by hydraulic pressure applied to a liquid that fills the interior of the tube, is improved by coating the part of the exterior surface of the tube that comes into contact with the die surface against which it expands with a wax that is solid at normal room temperature but can be maintained fully melted and in contact with air, without showing any visible evidence of decomposition, at a temperature that is at least 75 degrees C. Preferably, the wax is applied to the surface to be hydroformed by spraying from melt onto the surface while the latter is maintained above the melt temperature of the wax. Shortly after the wax has been thus applied to the surface, the wax is cooled until it solidifies.

Abstract: The invention concerns a steel plate coated with a metal layer based on zinc and a zinc hydroxysulphate layer, whereof the surface density of sulphur is more than 0.5 mg/m2. The invention also concerns a method for obtaining said plate by treating a zinc coated sheet metal: either in a highly alkaline sulphate solution under polarization; or in a sulphate solution containing Zn2+ ions without polarization. The hydroxysulphate deposit brings about a pre-lubricating effect applicable to operations for forming sheet metal.

Abstract: A lubricant composition comprises (1) at least one member selected from the group consisting of carboxylic acid compounds each obtained by the addition of an oxyalkylene group to a hydroxyl group of a hydroxy carboxylic acid and alkali metal salts and amine salts thereof; and (2) at least one base oil selected from the group consisting of alkyl benzene, normal paraffin, isoparaffin and &agr;-olefin. The lubricant composition is highly resistant to putrefaction when it is used as a metal-processing oil composition and shows excellent cutting characteristics in the metal-processing, which requires an extremely high lubricating action, such as form-rolling tap and deep hole boring. Moreover, the composition makes operations such as metal-processing operations easy since the liquid obtained by diluting it with water is transparent or translucent.

Abstract: Described is a water-miscible cooling lubricant concentrate which comprises natural or synthetic mineral oils, emulsifying agents, corrosion protection additives, solubilizers, means of preservation, metal inhibitors and other conventional additives, and, after dilution to form a 2 to 25% by weight aqueous solution, has a pH value between 7.0 and 7.5 as well as additionally as means of preservation and/or anticorrosive additive comprises a mixture of a) a conversion product of boric acid and a primary or tertiary alkanolamine and/or b) an ethoxylated and/or propoxylated fatty acid or a fatty acid alkanolamide as well as at least one further compound selected from the group comprised of c) a carboxylic acid imide, a phosphoric acid ester, a triazole, a thiadiazole, an isothiazolinone, an imidazole, a guanidine, an aromatic carboxylic acid and the 3-iodo-2-propinyl-carbamate and/or d) a methylol urea derivative.

Abstract: A lubricant composition for the plastic working of metals that does not require a phosphate undercoating, is waterborne, requires only a simple application process of immersion or spraying followed by drying, and provides an excellent lubricating performance comprises synthetic resin, water-soluble inorganic salt, and water. The weight ratio of the content of salt to that of synthetic resin is from 0.25:1 to 9: 1. This composition can also contain liquid and/or solid lubricating agent(s) and an extreme pressure additive.

Abstract: A roller cage (6) is provided for a minimum of one work roller (3) of a tool for deep rolling of grooves or radii of a crankshaft bearing (1) where the work roller (3) at a section of its circumference is loosely guided by the roller cage (6) or inside a concave void of the roller cage (6). Portions of the roller cage (6) by which the work roller (3) is guided, consist of a material that dispenses solid lubricant to the work roller (3).

Abstract: The present invention relates to a method for mechanically working of cobalt-containing metals or performing metalworking with a tool made of a metal containing cobalt. The method is carried out in the presence of an aqueous cooling lubricant containing a combination of an alkanolamine, a mono- or diphosphate ester and a mono- or dicarboxylic acid. The combination is capable of reducing both the release of cobalt ions and the corrosion of iron. In addition it also contributes essentially to the lubrication.

Abstract: The present invention provides a sulfur-based extreme-pressure additive that is completely soluble in water without using a surfactant, and has satisfactory odor and hue. In addition, the present invention provides a cutting liquid and grinding liquid having superior defoaming property and rust preventive characteristics, while also having high load resistance and lubrication performance comparable to cutting oils and grinding oils of the prior art. The above objects are achieved by an extreme-pressure additive comprising the salt of a condensation product of a sulfurized hydroxy-unsaturated fatty acid, the condensation product having a sulfur content of 8 to 15% by weight (mass), color of 6 or less, and acid value of 80 to 200, and a grinding liquid comprising that extreme-pressure additive and water.

Abstract: A method is provided for lubricating a die cavity that includes applying a lubricant composition containing a high melting point polymeric wax lubricant to the wall of a die cavity. Preferably, the lubricant is a polyamide lubricant that has a melting temperature greater than the temperature of the die wall during use. The present invention also provides a method of making a compacted metal part that includes applying the lubricant composition to an internal wall of a die cavity, introducing a metal-based powder composition into the die cavity; and compacting the powder composition at a pressure sufficient to form a compacted part from the metal powder composition.

Abstract: The present invention discloses a hydroforming process for metal parts that uses liquid-film and solid-film lubricants. The lubricants used in the invention are particularly useful for die-side lubrication. The process includes a step in which a ductile metal part is over-coated with either the liquid-film or solid-film lubricant. The liquid lubricants preferably include an oil and a optionally a surfactant. The solid lubricants preferably include a hard wax and optionally a surfactant.

Abstract: The present invention relates to a cutting oil comprising (a) a polyether compound represented by the formula (I): R1O(EO)m(AO)nR2  (I) wherein each of R1 and R2, which may be identical or different, is hydrogen atom or a hydrocarbon group having 1 to 24 carbon atoms, at least one of which is a hydrocarbon group; EO is oxyethylene group; AO is an oxyalkylene group having 3 or 4 carbon atoms; and each of m and n is 1 to 50, wherein a sum of m and n is from 4 to 100; a cutting oil composition comprising the above cutting oil and an abrasive; a cutting method using the above cutting oil composition; and a process of cleaning a wafer, comprising the steps of cleaning a wafer obtainable by cutting an ingot with a wire saw using the above cutting oil composition; heating the resulting waste water to a temperature equal to or higher than a cloud point of a polyether compound represented by the formula (I) contained in the waste water, to allow separation into an oil phase and an aqueous phase; and removi

Abstract: A two- or a one-step process and composition which coats metal workpiece surfaces (aluminum, copper, steel, stainless steel, etc.) with a thin lubricant film capable of allowing the metal to be deformed at room temperature. The lubricant consists essentially of polymers, dispersants, high molecular weight waxes and insoluble metallic stearates. With some ferrous surfaces, a separate coating layer is simultaneously formed (in the one-step process) or pre-formed (in the two-step process) at the metal interface, acting as a base for the lubricant. The process, after pickling in a mineral acid to remove scale and oxides, comprises the step(s) of immersing the workpiece either once or twice. The workpiece is then dried in a heated, forced air dryer.

Abstract: Disclosed is a machining fluid admixture for cooling and lubricating a workpiece/tool interface, wherein the admixture comprises a major amount of n-propyl bromide and a minor amount of a lubricant. In other embodiments, the machining fluid consists essentially of about 30.0 to about 99.99 weight percent n-propyl bromide; from about 0.01 to about 30.0 weight percent of a lubricant; and optionally from 0.0 to about 70.0 weight percent of a fluorinated chemical. In still further embodiments, the machining fluid consists essentially of about 45.0 to about 50.0 weight percent n-propyl bromide; from about 0.01 to about 2.0 weight percent of a lubricant; and from 45.0 to about 50.0 weight percent of a fluorinated chemical. In other aspects, the present invention is directed to methods for cooling and lubricating a tool/workpiece interface.

Abstract: The invention relates to a method for treating and conditioning circulated rolling oil, comprising removing dirt and abrasion particles from the returned rolling oil by filtration, feeding filter aids in a controlled manner, and adjusting an electric conductivity preventing electrostatic charging in the purified rolling oil. So that conductivity additives can be omitted, a flocculating agent is employed as the filter aid, and the amounts in which the agent is added depends on the residual contamination remaining in the filtrate, so that a preset minimum conductivity caused by the remaining residual contamination is preserved in the filtrate.

Abstract: Processes for working of refractory metals and other metals employing a lubricant comprising perfluorocarbon compounds (PFCs), including aliphatic perfluorocarbon compounds (&agr;-PFCs) having the general formula: CnF2n+2, perfluoromorpholines having the general formula: CnF2n+1ON, perfluoroamines (PFAs) and highly fluorinated amines (HFAs), and perfluoroethers (PFEs) and highly fluorinated ethers (HFEs), and their polymerization products.

Abstract: A system for applying metalworking lubricants to working surfaces of tools, dies and/or workpieces prior to forming said workpiece in a metal forming operation, particularly forging, is described. The system comprises lubricant particles, each comprising a lubricant coated with a protective surface having poor electrical conductivity, and electrostatic deposition means for applying such particles to working surfaces of tools and/or dies, or to the workpiece.

Abstract: A lubricant is provided which has a hardness in the range 0.1-10 N/mm at all temperatures in the range 15-40° C. The lubricant consists of at least one full ester of a glycol with a fatty acid, e.g. ethylene glycol dilaurate, optionally mixed with a minor amount of a fatty acid such as stearic acid, and/or a minor amount of a partial ester of a glycol with a fatty acid. The lubricant is useful in the production of press-formed components, and particularly in techniques for converting aluminium sheet to adhesively bonded aluminium structures.

Abstract: Disclosed is a machining fluid admixture for cooling and lubricating a workpiece/tool interface, wherein the admixture comprises a major amount of n-propyl bromide and a minor amount of a lubricant. In other embodiments, the machining fluid consists essentially of about 30.0 to about 99.99 weight percent n-propyl bromide; from about 0.01 to about 30.0 weight percent of a lubricant; and optionally from 0.0 to about 70.0 weight percent of a fluorinated chemical. In still further embodiments, the machining fluid consists essentially of about 45.0 to about 50.0 weight percent n-propyl bromide; from about 0.01 to about 2.0 weight percent of a lubricant; and from 45.0 to about 50.0 weight percent of a fluorinated chemical. In other aspects, the present invention is directed to methods for cooling and lubricating a tool/workpiece interface.

Abstract: A waterborne lubricant for the cold plastic working of metals that contains alkali metal salts of dimer(s) and/or trimer(s) of unsaturated fatty acids with from 10 to 24 carbon atoms per molecule has a lubrication performance at least as good as that of prior lubricants, even at generally lower lubricating film weights, has a long bath life, and generates little dust during cold plastic working operations. Even as little as 5% of these salts of dimer(s) and/or trimer(s) of unsaturated fatty acids, when mixed with conventional alkali metal salts of saturated fatty acids with from 10-24 carbon atoms per molecule, can provide these benefits.

Abstract: A synthetic aqueous machining fluid admixture, that is free of sulfur containing and chlorine containing lubricants, and usable in heavy duty machining (e.g. stamping, punching and drawing) operations comprises a) water, b) a water soluble or dispersible fatty acid or water soluble or dispersible fatty acid salt, c) a water soluble or dispersible ethylene oxide propylene oxide copolymer having at least one terminal hydroxyl group or water soluble or dispersible derivative of an ethylene oxide propylene oxide copolymer and d) a water soluble or dispersible organic phosphate ester. Methods for heavy duty machining comprise the steps of applying a force to a workpiece by a tool contacting the workpiece and applying the synthetic aqueous fluid admixture to the interface between the tool and workpiece. The fluid exhibits safety and environmental advantages in use compared to prior art fluids comprising vanishing oils while providing equal or superior lubricity.

Abstract: Aerosol compositions containing fluorinated oils are disclosed. At least one fluorinated component compatible with the fluorinated oil and a propellant are included in the aerosol composition. Fluorinated oil-containing non-aerosol compositions are also disclosed. In a particularly desirable form, the compositions are single-phase.

Abstract: A continuous in-drawing line process and system for drawing stainless steel wire is provided wherein wire is (1) brushed in an inlet brush station to remove oxide film from the wire surface; (2) coated with a lubricant carrier coating which is dried then subsequently cooled; (3) drawn through a drawing machine using a lubricant; and (4) brushed to remove residual carrier compounds from the surface of the drawn wire. The system for carrying out this process includes a wire payoff; an inlet brush station having two pairs of brushes that rotate in a direction opposite to that of the wire to remove oxide film therefrom; a coating device; a dryer; a cooler; a drawing machine; first and second outlet brush stations each having two pairs of brushes that rotate in a direction opposite to that of the wire to remove residual drawing compounds therefrom; and a wire take-up device.

Abstract: In one aspect, this invention provides a fluid comprising one or more hydrofluoroether(s) and one or more lubricious additive(s) for the cutting and abrasive treatment of metal, cermet, or composite materials. In another aspect, the present invention provides a method of cutting and abrasively treating metal, cermet, or composite materials comprising applying to the metal, cermet, or composite workpiece and tool a fluid comprising a hydrofluoroether and a lubricious additive.

Abstract: A metal wire or a metal strip having a lubricating surface layer is disclosed wherein the surface layer comprises a mixture of a fatty acid having 10-22 carbon atoms and an alkali metal soap of said fatty acid. Furthermore a method of preparing such a wire or strip is disclosed wherein the wire/strip is contacted with a mixture of fatty acid and alkali metal soap according to the above to the formation of the surface layer containing the mixture on the surface of the wire/strip, which surface layer is allowed or caused to dry. The invention also relates to the use of a mixture of fatty acid and an alkali metal soap according to the above for coating as a lubricating surface layer on metal wires or metal strips.

Abstract: A broaching tool has a plurality of cutting teeth for broaching a small, deep hole with high precision and surface finish. Three to eight teeth are engaged in the hole for cutting at any one time. For broaching sticky metals such as stainless steel, each cutting tooth has a face angle, backoff angle and rise which are sufficiently large to prevent thermal hardening of the hole surface. A ring is provided between the front face and land of each cutting tooth having a width selected to prevent formation of axial and ring-shaped tool traces. V-shaped notches having a large radial angle and a small backoff angle are formed in the land of each cutting tooth to break chips and prevent clogging. The tool further includes a rear pilot having a plurality of smoothing teeth with a diameter larger than the finished diameter of the hole. A set of rough and fine broaching tools can be provided, with the fine tool being processed to convert it to a rough tool when it is worn beyond tolerance.

Abstract: A metal forming lubricant suitable for extreme condition use is formulated to contain one or more differential solid lubricants composed of a high melt temperature, substantially halogen-free thermoplastic in addition to conventional lubricants such as organic phosphate esters and natural and synthetic polymer waxes. The lubricants offer superior performance while resisting the tendency to foul metal working dies with gummy deposits.