Title of Invention	LUBRICANT FOR HOT FORGING APPLICATIONS
Abstract	Abstract LUBRICANT FOR HOT FORGING APPLICATIONS A substantially lead-free lubricant for use in hot forging of metals, especially forging of aluminum and aluminum alloy components. The lubricant comprises one or more oils, graphite, and one or more phosphorus- based additives. Additional additives, such as metallic lubricants and dispersants may also be included. The lubricant does not bum when subjected to temperatures in excessof300°C.

Title of Invention

LUBRICANT FOR HOT FORGING APPLICATIONS

Abstract

Abstract LUBRICANT FOR HOT FORGING APPLICATIONS A substantially lead-free lubricant for use in hot forging of metals, especially forging of aluminum and aluminum alloy components. The lubricant comprises one or more oils, graphite, and one or more phosphorus- based additives. Additional additives, such as metallic lubricants and dispersants may also be included. The lubricant does not bum when subjected to temperatures in excessof300°C.

Full Text	LUBRICANT FOR HOT FORGING APPLICATIONS FIELD OF THE INVENTION Forged metal articles are frequently used for various parts in many items, including airplanes, autorrsobiles, electronic components, etc. Iron has traditionally been the metal of choice for most forged metal applications, however the preferred material for many recent applications is changing from iron to lighter alloys, such as aluminum alloys, in order to meet the demand for reducing the overall weight of the material. In recent years, the demand for lightweight products of high quality with good workability has increased and has led to a similar increase in the use of aluminum alloy forging technology. In the metal forging work or process, a lubricant or lubricating oil is disposed betv/een the metal mold and the workpiece to be molded so as to avoid adhesion between them and to improve the separation ability of the forged article from the metal mold. The proper lubricant is critical in order to allow for proper movement in ihe die cavities and to allow the forging process to be repeated as many times as possible in succession -1- water-soiubie lubricants cons sang cf SyTfratic esters, silicone oils, graphite, extreme-pressure additives and surface active agents, have been typicaOy used as lubricants in aluminum alloy forging. It is difficult to satisfy the demands of hot aluminum forging by using conventional lubricants. With hot aluminum forging, the existing oil-soluble luoricants have disadvantages, such as flammability, causing smoking and/or workshop contamination, etc. in particular, many oil-soluble lubricants that contain graphite burn vi/hen the application temperature is greater than 300°C, such as is required for iiot forging of aluminum, causing unsafe working conditions and an increased risk of accidents. Furthermore, the existing water-soluble lubricants have disadvantage induding the requirement for treatment of waste water to control water pollution after use which results in cost inaeases, equipment investment and processing inefficiency. Many non-flammable additives have been unsuccessfully tested for use in hot forging. For example, haiogenated products have been tested, but they produce haiogenated 3 general are not effective because they are not designed to work at temperatures above 300°C. Further, antimony and barium based products are generally not effective in hot forging applications. Conventional hot aluminum forging lubricants that best 0 facilitate die movement typically include one or more organic lead compounds, such as lead naphthenate and lead stearate. The use of lead In lubricating compositions has come into disfavor because of the health hazards caused by the release of lead into the atmosphere. During the hot forging of aluminum 5 some of the organic lead present in the lubricant is dispersed into the air in quantities which are unacceptable to most local and national governmental regulatory agendes. Such agencies have banned the use of lead in many industries and, where it is still allowed, severely limited the concentrations that may be >o discharged into the atmosphere. In order to continue using lead-containing lubricants, the hot forging industry would be required to install very expensive exhaust and air filtration -3- It would therefore be advantageous to provide a substantially lead-free lubricant for use in the aluminum and aluminum alloy hot forging in-dustry. Such lubricants provide superior lubrication properties and should not produce smoke or be flammable at temperatures at or above ZQO°Q. SUMMARY OF THE INVENTION The present invention discloses a lubricant for use in hot forging or metal deformation of metals, especially aluminum and aluminum alloy components, titanium and superalloys. The i lubricant comprises one or more oils, graphite, and one or more phosphorus-based additives. Additional additives, such as metallic lubricants, dispersants, thickeners and wetting agents may also be included. Tne lubricant of the present invention is substantially lead-free and does not bum when subjected to ) temperatures in excess of 300°C. DETAILED DESCf^FTfOh 0? TnE iNYEKTION The present invenjc" csocses = 'i-c-CHnrfor use in noi-forging applications, suc^ as trosc utitizsd In forging aluminum and aluminum workpieces into t The lubricant of the present invention Is an oil-based lubricant. The oil utilized may be virtually any composition known in the art, including but not limited to mineral oil, such as naphtenic, aliphatic, paraffinic or steam cylinder oil, vegetable oil, such as sunflower oil, olive oil or rapeseed oil, animal oil, such as lard oil, synthetic oil, such as polyalphaolefins and silicone oil, semi-synthetic oil, such as glycerol trioleate and mixtures thereof. Preferred oils indude vegetable, mineral and animal oils. Such oils are commercially available as Process Oil 1000 from Texaco (UK), Lard oil from Wekti, Holm and Clark Co. (USA), Soybean oil from BG International (USA.). A second component of the lubricant is a graphite additive. The graphite may be in any form known in the art, including but not limited to coarse, fine, milled, unmilled, natural. graphite having a particle size distribution 'Aith about 90% of the particles below 15 microns In size is espedally preferred. Such graphite is connmercially available from Acheson Industries, Inc. One or more phosphorus-based additives are included in the lubricant. The phosphorus additive reduces and eliminates burning of the lubricant at high temperatures. The phosphorus can be in any desired form, such as phosphate, ester phosphate, phosphate amine, ammonium phosphate or mixtures thereof. One preferred phosphorous-based material is phosphate ester. Such phosphorous is commercially available from Connect Chemical (F), Ferro (USA). The hot forging lubricant composition optionally contains one or more metallic lubricating additives. The metallic additives may be chosen from one or more of the metallic elements, including tin, bismuth, zinc, aluminum or any alloys thereof. The lubricant composition may optionally contain additional ingredients such as dispersants, rheology modifiers, biocides, anticon'osives, extreme pressure additives, antifoam agents, wetting agents, metal soaps and mixtures thereof. -6- graphite, preferably in the range of about 1 to about 30 weight percent graphite and most preferably in the range of about 3 to about 20 weight percent graphite. Fne lubricant contains in the range of about 1 to about 99 v/eight percent phosphorous additive, preferably in the range of about 1 to about 80 weight percent phosphorous additive and most preferably in the range of about 30 to about 80 weight percent of the phosphorous additive. A further embodiment of the invention comprises a method for forging an article. The method comprises the steps of applying the lead-free lubricant to one or both of the forging apparatus or the wori limiting example: Example. A lubricant composition may be produced by adequately mixing the raw materials togetlier via standard mixing techniques, such as mastication of stirring. The composition of the samples is shown in Table 1. Table 1. Lubricant Sample Composition Ingredient I Weight Percent Vegetable/Animal 15% jO\| Fine Graphite 4.4% Mineral Oil 3.2% Metal containing 3.2% Fatty Acid Derivative Phosphate Ester 73% Dispersant \| 0.2% The lubricant composition of Table 1was applied on hot forging dies at temperatures of 440°C + 40'C. The dies were utilized for a series of hot aluminum forging applications and the lubricant did not produce flames during the process. In addition, the lubricant properties relating to the die and the aluminum part being forged were superior. described herein are offered by way of exampie only, and the invention is to be limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled. We claim: 1. A lead-free lubricant for hot forging comprising one or more oils, graphite and one or more phcsphorus-based additives. 2. The lubricant of claim 1, further comprising one or more metallic lubricating additives. 3. The lubricant of claim 1, wherein the one or more oils are selected from the group consisting of mineral oil, vegetable oil, animal oil, synthetic oil, semi-synthetic oil or mixtures thereof. 4. The lubricant of claim 1, wherein the graphite is selected from the group consisting of coarse, fine, milled, unmilled, natural, synthetic or mixtures thereof. 5. The lubricant of claim 1, wherein the phosphorus-based additive is selected from the group consisting of phosphate, ester phosphate, phosphate amine, ammonium phosphate or mixtures thereof. 6. The lubricant of claim 1, wherein the phosphoois-based additive is phosphate ester. 10' 7. The i jbricant of dai~. Z n-^s^r. tr:5 zne ~ norB netalHc aQdnrv-es are selected frDnr- me g^jz- ayn^Su^ -r' DJs-uth, zinc, tin, aluminum or any a;!cys tnerecf. 8. The lubricant of daim 1, vvherein the one or more oils comprise in the range of about 1 to about 99 weight percent of the lubricant. 9. The lubricant of claim 1, wherein the one or more oils comprise In the range of about 1 to about 70 weight percent of the lubricant. 10. The lubricant of claim 1, wherein the one or more oils comprise in the range of about 15 to about 40 weight percent of the lubricant. 11. The lubricant of claim 1, wherein the graphite comprises in the range of about 1 to about 99 weight percent of the lubricant. 12. The lubricant of claim 1, wherein the graphite comprises in the range of about 1 to about 30 weight percent of the lubricant. 13. The lubricant of claim 1, wherein the graphite comprises in the range of about 3 to about 20 weight percent of the lubricant 11- CrrcspnOi js oasec adGrtives cc-^rss ~, u,€ rsns z' scc-i.!' ._■ about 99 weight percent of ths iiibncani. 15. Ths lubricant of claim 1. wherein the one or more phosphorus based additives comprise in the range of about 1 to about 80 weight percent of the lubricant. 16. The lubricant of daim 1, wt.erein the one or more phosphoms based additives comprse in the range of about 30 to about 80 weight percent of the lubricant. 17. The lubricant of daim 1, further comprising one or more of the group consisting of dispersants, rheology modifiers, bioddes, anticon'osives, extreme pressure additives, antifoam? agents, wetting agents, metal soaps or mixtures thereof. 18. The lubricant of daim 1, wherein the lubricant does not burn at temperatures greater than about 300°C 19. The lubricant of daim 1, wherein the lubricant does not burn at temperatures in the range of about 300°C to about 600'C. 20. A method of hot forging an aluminum or aluminum alloy comprising the steps of applying a coating of the lead-free lubricant of daim 1 to a hot forging apparatus, inserting a -12- wor 2'. The method of claim 20, further- ^Dn^prising t^ie step of coating the workpiece with the iutxicant.

Full Text

LUBRICANT FOR HOT FORGING APPLICATIONS FIELD OF THE INVENTION
Forged metal articles are frequently used for various parts in many items, including airplanes, autorrsobiles, electronic components, etc. Iron has traditionally been the metal of choice for most forged metal applications, however the preferred material for many recent applications is changing from iron to lighter alloys, such as aluminum alloys, in order to meet the demand for reducing the overall weight of the material. In recent years, the demand for lightweight products of high quality with good workability has increased and has led to a similar increase in the use of aluminum alloy forging technology.
In the metal forging work or process, a lubricant or lubricating oil is disposed betv/een the metal mold and the workpiece to be molded so as to avoid adhesion between them and to improve the separation ability of the forged article from the metal mold. The proper lubricant is critical in order to allow for proper movement in ihe die cavities and to allow the forging process to be repeated as many times as possible in succession
-1-

water-soiubie lubricants cons sang cf SyTfratic esters, silicone oils, graphite, extreme-pressure additives and surface active agents, have been typicaOy used as lubricants in aluminum alloy forging.
It is difficult to satisfy the demands of hot aluminum forging by using conventional lubricants. With hot aluminum forging, the existing oil-soluble luoricants have disadvantages, such as flammability, causing smoking and/or workshop contamination, etc. in particular, many oil-soluble lubricants that contain graphite burn vi/hen the application temperature is greater than 300°C, such as is required for iiot forging of aluminum, causing unsafe working conditions and an increased risk of accidents. Furthermore, the existing water-soluble lubricants have disadvantage induding the requirement for treatment of waste water to control water pollution after use which results in cost inaeases, equipment investment and processing inefficiency.
Many non-flammable additives have been unsuccessfully tested for use in hot forging. For example, haiogenated products have been tested, but they produce haiogenated

3 general are not effective because they are not designed to work at temperatures above 300°C. Further, antimony and barium based products are generally not effective in hot forging applications.
Conventional hot aluminum forging lubricants that best
0 facilitate die movement typically include one or more organic lead compounds, such as lead naphthenate and lead stearate. The use of lead In lubricating compositions has come into disfavor because of the health hazards caused by the release of lead into the atmosphere. During the hot forging of aluminum
5 some of the organic lead present in the lubricant is dispersed into the air in quantities which are unacceptable to most local and national governmental regulatory agendes. Such agencies have banned the use of lead in many industries and, where it is still allowed, severely limited the concentrations that may be
>o discharged into the atmosphere. In order to continue using lead-containing lubricants, the hot forging industry would be required to install very expensive exhaust and air filtration
-3-

It would therefore be advantageous to provide a substantially lead-free lubricant for use in the aluminum and aluminum alloy hot forging in-dustry. Such lubricants provide superior lubrication properties and should not produce smoke or be flammable at temperatures at or above ZQO°Q.
SUMMARY OF THE INVENTION
The present invention discloses a lubricant for use in hot forging or metal deformation of metals, especially aluminum and aluminum alloy components, titanium and superalloys. The
i lubricant comprises one or more oils, graphite, and one or more phosphorus-based additives. Additional additives, such as metallic lubricants, dispersants, thickeners and wetting agents may also be included. Tne lubricant of the present invention is substantially lead-free and does not bum when subjected to
) temperatures in excess of 300°C.

DETAILED DESCf^FTfOh 0? TnE iNYEKTION
The present invenjc" csocses = 'i-c-CHnrfor use in noi-forging applications, suc^ as trosc utitizsd In forging aluminum and aluminum workpieces into t The lubricant of the present invention Is an oil-based lubricant. The oil utilized may be virtually any composition known in the art, including but not limited to mineral oil, such as naphtenic, aliphatic, paraffinic or steam cylinder oil, vegetable oil, such as sunflower oil, olive oil or rapeseed oil, animal oil, such as lard oil, synthetic oil, such as polyalphaolefins and silicone oil, semi-synthetic oil, such as glycerol trioleate and mixtures thereof. Preferred oils indude vegetable, mineral and animal oils. Such oils are commercially available as Process Oil 1000 from Texaco (UK), Lard oil from Wekti, Holm and Clark Co. (USA), Soybean oil from BG International (USA.).
A second component of the lubricant is a graphite additive. The graphite may be in any form known in the art, including but not limited to coarse, fine, milled, unmilled, natural.

graphite having a particle size distribution 'Aith about 90% of the particles below 15 microns In size is espedally preferred. Such graphite is connmercially available from Acheson Industries, Inc.
One or more phosphorus-based additives are included in the lubricant. The phosphorus additive reduces and eliminates burning of the lubricant at high temperatures. The phosphorus can be in any desired form, such as phosphate, ester phosphate, phosphate amine, ammonium phosphate or mixtures thereof. One preferred phosphorous-based material is phosphate ester. Such phosphorous is commercially available from Connect Chemical (F), Ferro (USA).
The hot forging lubricant composition optionally contains one or more metallic lubricating additives. The metallic additives may be chosen from one or more of the metallic elements, including tin, bismuth, zinc, aluminum or any alloys thereof.
The lubricant composition may optionally contain additional ingredients such as dispersants, rheology modifiers, biocides, anticon'osives, extreme pressure additives, antifoam agents, wetting agents, metal soaps and mixtures thereof.
-6-

graphite, preferably in the range of about 1 to about 30 weight percent graphite and most preferably in the range of about 3 to about 20 weight percent graphite. Fne lubricant contains in the range of about 1 to about 99 v/eight percent phosphorous additive, preferably in the range of about 1 to about 80 weight percent phosphorous additive and most preferably in the range of about 30 to about 80 weight percent of the phosphorous additive.
A further embodiment of the invention comprises a method for forging an article. The method comprises the steps of applying the lead-free lubricant to one or both of the forging apparatus or the wori

limiting example:
Example. A lubricant composition may be produced by adequately mixing the raw materials togetlier via standard mixing techniques, such as mastication of stirring. The composition of the samples is shown in Table 1.
Table 1. Lubricant Sample Composition
Ingredient I Weight
Percent
Vegetable/Animal 15%
jO|
Fine Graphite 4.4%
Mineral Oil 3.2%
Metal containing 3.2%
Fatty Acid
Derivative
Phosphate Ester 73%
Dispersant | 0.2%
The lubricant composition of Table 1was applied on hot forging dies at temperatures of 440°C + 40'C. The dies were utilized for a series of hot aluminum forging applications and the lubricant did not produce flames during the process. In addition, the lubricant properties relating to the die and the aluminum part being forged were superior.

described herein are offered by way of exampie only, and the invention is to be limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled.

We claim:
1. A lead-free lubricant for hot forging comprising one or more oils, graphite and one or more phcsphorus-based additives.
2. The lubricant of claim 1, further comprising one or more metallic lubricating additives.
3. The lubricant of claim 1, wherein the one or more oils are selected from the group consisting of mineral oil, vegetable oil, animal oil, synthetic oil, semi-synthetic oil or mixtures thereof.
4. The lubricant of claim 1, wherein the graphite is selected from the group consisting of coarse, fine, milled, unmilled, natural, synthetic or mixtures thereof.
5. The lubricant of claim 1, wherein the phosphorus-based additive is selected from the group consisting of phosphate, ester phosphate, phosphate amine, ammonium phosphate or mixtures thereof.
6. The lubricant of claim 1, wherein the phosphoois-based additive is phosphate ester.
10'

7. The i jbricant of dai~. Z n-^s^r. tr:5 zne ~ norB netalHc aQdnrv-es are selected frDnr- me g^jz- ayn^Su^ -r' DJs-uth, zinc, tin, aluminum or any a;!cys tnerecf.
8. The lubricant of daim 1, vvherein the one or more oils comprise in the range of about 1 to about 99 weight percent of the lubricant.
9. The lubricant of claim 1, wherein the one or more oils comprise In the range of about 1 to about 70 weight percent of the lubricant.
10. The lubricant of claim 1, wherein the one or more oils comprise in the range of about 15 to about 40 weight percent of the lubricant.
11. The lubricant of claim 1, wherein the graphite comprises in the range of about 1 to about 99 weight percent of the lubricant.
12. The lubricant of claim 1, wherein the graphite comprises in the range of about 1 to about 30 weight percent of the lubricant.
13. The lubricant of claim 1, wherein the graphite comprises in the range of about 3 to about 20 weight percent of the lubricant
11-

CrrcspnOi js oasec adGrtives cc-^rss ~, u,€ rsns z' scc-i.!' ._■ about 99 weight percent of ths iiibncani.
15. Ths lubricant of claim 1. wherein the one or more phosphorus based additives comprise in the range of about 1 to about 80 weight percent of the lubricant.
16. The lubricant of daim 1, wt.erein the one or more phosphoms based additives comprse in the range of about 30 to about 80 weight percent of the lubricant.
17. The lubricant of daim 1, further comprising one or more of the group consisting of dispersants, rheology modifiers, bioddes, anticon'osives, extreme pressure additives, antifoam? agents, wetting agents, metal soaps or mixtures thereof.
18. The lubricant of daim 1, wherein the lubricant does not burn at temperatures greater than about 300°C
19. The lubricant of daim 1, wherein the lubricant does not burn at temperatures in the range of about 300°C to about 600'C.
20. A method of hot forging an aluminum or aluminum alloy comprising the steps of applying a coating of the lead-free lubricant of daim 1 to a hot forging apparatus, inserting a
-12-

wor 2'. The method of claim 20, further- ^Dn^prising t^ie step of coating the workpiece with the iutxicant.

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Patent Number

277180

Indian Patent Application Number

1995/CHENP/2009

PG Journal Number

48/2016

Publication Date

18-Nov-2016

Grant Date

15-Nov-2016

Date of Filing

09-Apr-2009

Name of Patentee

HENKEL AG & Co. KGaA

Applicant Address

HENKELSTRASSE 67, 40589 DUESSELDORF

Inventors:

#	Inventor's Name	Inventor's Address
1	HUGUES, LAURENT	15A RUE DU FORT, F-67120 SOULTZ LES BAINS
2	HEIDEMAN, GEERT	FEIKO CLOCKSTRAAT 141I, NL-9665 BJ QUDE PEKELA
3	ODINK, GERKO	SLEEDOOMWEG 179, NL-9674 JN WINSCHOTEN
4	KOK, DOUWE, MARTEN	TORUM 8, NL-9679 C1 SCHEEMDA
5	GANKEMA, HAROLD	BOSLAAN 13, NL-7822 EN EMMEN

PCT International Classification Number

C10M169/04

PCT International Application Number

PCT/US07/78113

PCT International Filing date

2007-09-11

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1	11/545,883	2006-10-11	U.S.A.