U.S. patent application number 13/729119 was filed with the patent office on 2013-07-04 for aqueous solution lubricant for aluminum cold rolling.
This patent application is currently assigned to Quaker Chemical Corporation. The applicant listed for this patent is Quaker Chemical Corporation. Invention is credited to Laker Jin, Yewen Shen, Xi Wang, Yuming Zhang.
Application Number | 20130167605 13/729119 |
Document ID | / |
Family ID | 48675546 |
Filed Date | 2013-07-04 |
United States Patent
Application |
20130167605 |
Kind Code |
A1 |
Zhang; Yuming ; et
al. |
July 4, 2013 |
AQUEOUS SOLUTION LUBRICANT FOR ALUMINUM COLD ROLLING
Abstract
Compositions related to a water-based lubricant fluid for
aluminum cold rolling which is free from measurable particles or
oil droplets which can be applied in field production. A
single-phase lubricant fluid may include water-soluble polymers,
lubricating additives, anti-rust additives, anti-oxidant additives,
pH-adjust additives, or combinations thereof.
Inventors: |
Zhang; Yuming; (Shanghai,
CN) ; Shen; Yewen; (Suzhou, CN) ; Jin;
Laker; (Devon, PA) ; Wang; Xi; (Shanghai,
CN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Quaker Chemical Corporation; |
Conshohocken |
PA |
US |
|
|
Assignee: |
Quaker Chemical Corporation
Conshohocken
PA
|
Family ID: |
48675546 |
Appl. No.: |
13/729119 |
Filed: |
December 28, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61580799 |
Dec 28, 2011 |
|
|
|
Current U.S.
Class: |
72/41 ; 508/280;
508/304; 508/433 |
Current CPC
Class: |
C10M 2209/105 20130101;
C10M 2215/04 20130101; B21B 45/0242 20130101; C10N 2040/245
20200501; C10M 2215/223 20130101; C10M 145/26 20130101; C10N
2040/243 20200501; C10M 129/18 20130101; C10M 2209/104 20130101;
B21B 2003/001 20130101; C10M 2223/04 20130101; C10M 173/02
20130101; C10N 2030/12 20130101; C10M 2209/104 20130101; C10M
2209/105 20130101 |
Class at
Publication: |
72/41 ; 508/304;
508/280; 508/433 |
International
Class: |
C10M 129/18 20060101
C10M129/18; B21B 45/02 20060101 B21B045/02 |
Claims
1. A lubricant fluid for aluminum cold rolling comprising a
single-phase water-based solution, wherein the solution comprises a
water soluble polymer.
2. The lubricant fluid of claim 1, wherein the polymer comprises at
least one hydrophilic group.
3. The lubricant fluid of claim 2, wherein at least one hydrophilic
group comprises ethylene oxide.
4. The lubricant fluid of claim 1, wherein the polymer evaporates
at or below 240.degree. C.
5. The lubricant fluid of claim 1, comprising about 10 wt % to
about 99 wt % water soluble polymer.
6. The lubricant fluid of claim 1, wherein the solution further
comprises at least one lubricant additive.
7. The lubricant fluid of claim 6, wherein at least one lubricant
additive is water soluble.
8. The lubricant fluid of claim 6, wherein at least one lubricant
additive comprises organic acids or organic phosphoric ester having
a carbon chain of C.sub.6-C.sub.18.
9. The lubricant fluid of claim 6, comprising about 0.1 wt % to
about 10.0 wt % lubricant additive.
10. The lubricant fluid of claim 1, wherein the solution further
comprises at least one functional additive.
11. The lubricant fluid of claim 1, wherein at least one functional
additive comprises anti-rust additives, anti-oxidant additives,
pH-adjusting additives, or combinations thereof.
12. The lubricant fluid of claim 11, wherein the anti-rust additive
comprises inorganic or organic phosphorus compounds or derivatives
of triazole.
13. The lubricant fluid of claim 11, wherein the pH-adjusting
additive comprises ammonia, alkane amines or alkanol amines.
14. The lubricant fluid of claim 11, wherein the lubricant fluid
includes the pH-adjusting additive in an amount such that the
lubricant fluid has a pH value of about 4.0 to about 9.0 at
25.degree. C.
15. The lubricant fluid of claim 11, comprising about 0.05 wt % to
about 5.0 wt % functional additive.
16. A method of cold-rolling aluminum, comprising application the
lubricant fluid of claim 1 to an aluminum strip.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority benefit from U.S.
Provisional Patent Application No. 61/580,799, filed on Dec. 28,
2011, which is incorporated by reference in its entirety.
BACKGROUND
[0002] Aluminum cold rolling is one of the most important processes
of aluminum application. The lubricant is critical for continuous
production and good quality. Traditionally, there have been two
primary types of lubricating methods for the cold rolling
processes: 1) lubrication with neat oils and 2) lubrication with
oil-in-water emulsions. The first generation lubricant is neat oil.
Neat oil products provide good sheet surface quality but also have
critical defects: 1) easily combustible; and 2) higher rates of
consumption. The second generation product is oil-in-water emulsion
products. Compared with neat oil, emulsions avoid the issues
presented by the use of neat oil products. Potential shortcomings
of the emulsions include: 1) limited strip cleanliness after anneal
as a result of too high evaporation temperature; and 2) ease in
emulsification of tramp oil, which decreases rolling
performance.
[0003] U.S. Pat. No. 4,828,737 discloses the use of aqueous
products in aluminum cold rolling. However, according to that
patent, these aqueous products require a temperature of 360.degree.
C. before they evaporate. The aqueous solution lubricants of
embodiments of the present invention may be completely evaporated
at 240.degree. C., thereby allowing all process conditions that are
applied when (partially) annealing aluminum alloys.
[0004] The aqueous solution lubricant for aluminum cold rolling of
some embodiments of the present invention has addressed the
shortcomings of traditional lubrication.
SUMMARY OF THE INVENTION
[0005] According to some embodiments, a lubricant fluid for
aluminum cold rolling includes a single-phase water-based solution
with a water soluble polymer. In some embodiments, the polymer
includes at least one hydrophilic group, such as ethylene oxide. In
some embodiments, the polymer's molecular weight is about 200 or
greater. In certain embodiments, the lubricant fluid includes about
5 wt % to about 99 wt % water soluble polymer. In some embodiments,
the lubricant fluid includes at least one lubricant additive, which
may be water soluble. In some embodiments, the lubricant additive
includes one or more carbon chain structures, one or more
hydrophilic groups, or a combination thereof. A lubricant fluid may
include about 0.1 wt % to about 10.0 wt % lubricant additive. In
certain embodiments, the lubricant fluid includes at least one
functional additive, such as anti-rust additives, anti-oxidant
additives, pH-adjust additives, or combinations thereof. The
lubricant fluid may include about 0.05 wt % to about 5 wt %
functional additive.
DESCRIPTION OF THE FIGURES
[0006] FIG. 1 shows evaporation of lubricant fluids at different
temperatures.
[0007] FIG. 2 shows a rolled strip with a reference
formulation.
[0008] FIG. 3 shows a rolled strip with a formulation of the
present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0009] Compositions and methods of some embodiments of the present
invention relate to aluminum cold rolling processes with
single-phase water-based lubricant fluids. Compositions and methods
of the present invention may include a water-based lubricant fluid
for aluminum cold rolling which is free or substantially free from
measurable particles or oil droplets. In some embodiments, a
lubricant fluid includes one or more water-soluble polymers. A
lubricant fluid may also include one or more of lubricant
additives, and various functional additives.
[0010] Traditionally, oil-in-water emulsions are applied to the
strip during aluminum cold rolling. However, use of oil-in-water
emulsions may have disadvantages, such as limited strip cleanliness
after anneal, insufficient filterability, fluctuating emulsion
characteristics leading to inconsistency on the mill, high oil
consumption, etc. In some embodiments, such disadvantages may be
avoided by use of a single-phased water-based lubricant fluid
according to some embodiments of the present invention.
Single-phased water-based lubricant fluids according to some
embodiments of the present invention may be useful for application
in cold rolling of any type of aluminum and alloy.
[0011] According to the traditional lubrication theory of cold
rolling and industry experience, two regimes of lubrication exist
in the rolling process: boundary lubrication and
elastic-hydrodynamic lubrication ("EHD"). Many aluminum rolling
processes may be conducted in the mixed lubrication regime,
including characteristics of both boundary lubrication and EHD
lubrication. Therefore, in some embodiments, lubricant fluids of
the present invention may provide lubrication-boundary lubrication
and/or elastic-hydrodynamic lubrication. Due to aluminum
deformation stress, lubrication is inclined to boundary
lubrication. In some embodiments, lubricant fluids of the present
invention may provide the following characteristics: 1) provide
good surface quality with no obvious water-stain impression; 2)
show no residue on aluminum sheet after annealing, where all
materials should be eliminated before 240.degree. C.; and 3) reject
tramp oil, which should be easily separated from the solution.
[0012] Therefore, in some embodiments of the present invention,
single-phased water-based lubricant fluids may provide sufficient
lubrication properties in boundary lubrication for use in cold
rolling processes.
[0013] Lubricant Fluid Composition
[0014] In some embodiments, a lubricant fluid of the present
invention includes a single-phase water based lubricant fluid. In
some embodiments, a single-phase water based lubricant fluid may
include a water soluble polymer and optionally one or more
lubricant additives, and various functional additives.
[0015] Water Soluble Polymer
[0016] A lubricant fluid of the present invention may include one
or more water soluble polymers. In some embodiments, the polymers
may be dissolved or dispersed in a volume of water.
[0017] In some embodiments, a suitable water soluble polymer
includes one or more hydrophilic groups. Examples of suitable
hydrophilic groups include but are not limited to ethylene oxide,
propylene oxide, hydroxyl, carboxyl, acyl-amine and combinations
thereof. In some embodiments, the evaporation temperature of these
polymers is such that the final product is completely evaporated at
temperatures less than 240.degree. C.
[0018] In some embodiments, a lubricant fluid includes one or more
water soluble polymers in an amount of about 5 wt % to about 99 wt
%; 10 wt % to about 95 wt %; about 15 wt % to about 90 wt %; about
20 wt % to about 85 wt %; about 25 wt % to about 80 wt %; about 30
wt % to about 75 wt %; about 35 wt % to about 70 wt %; about 40 wt
% to about 65 wt %; about 45 wt % to about 60 wt %; about 50 wt %
to about 55 wt %; about 5 wt %; about 10 wt %; about 15 wt %; about
20 wt %; about 25 wt %; about 30 wt %; about 35 wt %; about 40 wt
%; about 45 wt %; about 50 wt %; about 55 wt %; about 60 wt %;
about 65 wt %; about 70 wt %; about 75 wt %; about 80 wt %; about
85 wt %; about 90 wt %; about 95 wt %; or about 99%.
[0019] Lubricant Additives
[0020] A lubricant fluid of the present invention may optionally
include one or more lubricant additives. Any suitable lubricant
additive may be used in the lubricant fluids of the present
invention. In some embodiments, a suitable lubricant additive
includes one or more types of carbon chain structures. Examples of
suitable lubricant additives may include but are not limited to
water soluble C.sub.6-C.sub.18 phosphoric ester, phosphorous ester,
phosphate ester, and organic acid.
[0021] In some embodiments, a suitable lubricant additive includes
one or more hydrophilic groups. Examples of suitable hydrophilic
groups include but are not limited to ethylene oxide, propylene
oxide, hydroxyl groups, carboxyl groups, and acyl amine groups.
[0022] In some embodiments, a lubricant fluid includes one or more
lubricant additives in an amount of about 0.05 wt % to about 10 wt
% of the lubricant fluid; about 0.1 wt % to about 8 wt % of the
lubricant fluid; about 0.1 wt % to about 6 wt % of the lubricant
fluid; about 0.1 wt % to about 4 wt % of the lubricant fluid; about
0.1 wt % to about 2 wt % of the lubricant fluid; about 0.05 wt % of
the lubricant fluid; about 0.1 wt % of the lubricant fluid; about
0.5 wt % of the lubricant fluid; about 1 wt % of the lubricant
fluid; about 2 wt % of the lubricant fluid; about 3 wt % of the
lubricant fluid; about 4 wt % of the lubricant fluid; about 5 wt %
of the lubricant fluid; about 6 wt % of the lubricant fluid; about
7 wt % of the lubricant fluid; about 8 wt % of the lubricant fluid;
about 9 wt % of the lubricant fluid; or about 10 wt % of the
lubricant fluid.
[0023] Functional Additives
[0024] A lubricant fluid of the present invention may include one
or more functional additives. Any suitable functional additive may
be included in the lubricant fluids of some embodiments of the
present invention. In some embodiments, such functional additives
may be chosen in order to cover boundary lubrication and other
process requirements of aluminum cold rolling. Examples of suitable
additives include but are not limited to anti-rust additives,
anti-oxidant additives, pH-adjusting additives, and the like. Any
suitable functional additive may be included to achieve the desired
result. Examples of a suitable corrosion inhibitor additive include
but are not limited to derivatives of triazole, tolutriazole,
organic and inorganic phosphorous compounds, and organic and
inorganic phosphate compounds. An example of a suitable antioxidant
additive includes but is not limited to alkylated amino phenol. An
example of a suitable pH-adjusting additive includes but is not
limited to ammonia, alkane amines, and alkanol amines like
trolamine.
[0025] In some embodiments, a lubricant fluid includes one or more
functional additives in an amount of about 0.01 wt % to about 10 wt
% of the lubricant fluid; about 0.05 wt % to about 9 wt % of the
lubricant fluid; about 0.05 wt % to about 8 wt % of the lubricant
fluid; about 0.05 wt % to about 7 wt % of the lubricant fluid;
about 0.05 wt % to about 6 wt % of the lubricant fluid; about 0.05
wt % to about 5 wt % of the lubricant fluid; about 0.1 wt % to
about 4 wt % of the lubricant fluid; about 0.5 wt % to about 3 wt %
of the lubricant fluid; about 1 wt % to about 2 wt % of the
lubricant fluid; about 0.01 wt % of the lubricant fluid; about 0.05
wt % of the lubricant fluid; about 0.1 wt % of the lubricant fluid;
about 0.5 wt % of the lubricant fluid; about 1 wt % of the
lubricant fluid; about 2 wt % of the lubricant fluid; about 3 wt %
of the lubricant fluid; about 4 wt % of the lubricant fluid; about
5 wt % of the lubricant fluid; about 6 wt % of the lubricant fluid;
about 7 wt % of the lubricant fluid; about 8 wt % of the lubricant
fluid; about 9 wt % of the lubricant fluid; or about 10 wt % of the
lubricant fluid. In some embodiments, the lubricant fluid has a pH
of about 4.0 to about 9.0; about 5.0 to about 8.0; about 6.0 to
about 7.0; about 4.0; about 5.0; about 6.0; about 7.0; about 8.0 or
about 9.0. In some embodiments, a lubricant fluid includes a
pH-adjusting additive in an amount such that the lubricant fluid
has a pH of about 4.0 to about 9.0 at 25.degree. C.
[0026] In some embodiments, lubricating fluids of the present
invention show, in a typical boundary test on different types of
aluminum strips, friction coefficients of about 0.05 to about 0.15;
about 0.06 to about 0.14; about 0.07 to about 0.13; about 0.08 to
about 0.12; about 0.09 to about 0.11; about 0.05; about 0.06; about
0.07; about 0.08; about 0.09; about 0.10; about 0.11; about 0.12;
about 0.13; about 0.14; or about 0.15.
[0027] In some embodiments, lubricant fluids also include water,
such as demineralized water.
[0028] The following examples are provided merely for the purpose
of describing some lubricant compositions representative of the
present invention in greater detail and are in no way to be
considered as setting a limitation on the scope of the
invention.
EXAMPLES
[0029] Single-phase water-based lubricant fluids were evaluated
using an array of experiments which are considered in the industry
to be highly predictive of the performance of a lubricant package
when applied in an aluminum cold rolling process, including: [0030]
a) intrinsic lubrication properties evaluated with boundary
lubrication tests; [0031] b) thermal stability and evaporation
properties with thermo gravimetric analysis TGA) equipment; [0032]
c) anti-staining properties with stack staining and energy
dispersive spectrum analysis (EDS) tests; and [0033] d) rolling
performance characteristics tested with a 2-high single reversing
rolling test mill with a test procedure correlating to the various
production mill processes. [0034] Two typical formulations were
prepared for use in the examples:
[0035] Formulation 1:
EO-PO polymer: 10.0 wt % Phosphoric ester: 1.0 wt %
Trolamine: 0.5 wt %
[0036] Demineralized water. 88.5 wt %
[0037] Formulation 2:
PEG 200: 90.0 wt %
[0038] Phosphoric ester: 1.0 wt %
Tolutriazole: 5.0 wt %
Trolamine: 1.5 wt %
[0039] Demineralized water: 3.5 wt %
[0040] An oil soluble conventional emulsion lubricant package,
widely used in multiple production high speed reversing mills with
good performance results is a product based on kerosene. This
product was used as reference product.
Example 1
Boundary Lubrication
[0041] The intrinsic lubrication properties of the lubricant
packages were evaluated in a boundary tester. The applied test
procedures are commonly used for evaluating lubrication properties
of lubricants for use in aluminum cold rolling.
TABLE-US-00001 Boundary tester T = 60 C. Reference Formulation 1
Formulation 2 SWA 1050* CoF** 0.127 0.106 0.098 SWA 3104 CoF 0.081
0.080 0.048 SWA 5052 CoF 0.110 0.097 0.051 *SWA 1050/3104/5052:
Different aluminum alloys **CoF: coefficient of friction
[0042] The reference (usually used in production mills) has
coefficients of friction of about 0.08-0.13 on different types of
aluminum strips. As shown in the table above, Formulation 1
demonstrated CoF's successfully within this standard range, while
Formulation 2 gave lower COF's.
Example 2
Anti Staining Properties
[0043] Anti staining properties are key parameters for strip
cleanliness after rolling and annealing. The anti staining
properties of the lubricant fluids were evaluated with stack
staining tests. This is a key parameter which evaluates strip
cleanliness after rolling and annealing. To test the lubricant
fluids, the fluid was applied between the surfaces of two aluminum
panels and wrapped tightly with adhesive tapes. The wrapped panels
were then placed in an oven at about 90.degree. C. while pressing
with a load of about 4.5 kg. After 24 hours, the wrapped panels
were removed and the surfaces observed. Energy dispersive spectrum
analysis (EDS) was applied to measure amount of different elements
on the stained surface. Oxygen was used as subject matter to
evaluate the degree of water-staining.
TABLE-US-00002 O content % Al content % Reference 14.30 85.70
Formulation 1 10.05 89.95 Formulation 2 16.52 83.48
[0044] The resulting oxygen contents illustrate that the two
single-phase water-based lubricant fluids (Formulations 1-2)
exhibit comparable anti staining properties as the traditional
products (Reference).
Example 3
TGA
[0045] For mills without cleaning line, the evaporation properties
of the water solution lubricant packages are important. In order to
be able to roll all aluminum alloys, all materials on the aluminum
surface must be removed below 240.degree. C. Thus, in terms of a
TGA curve, products should be volatilized before this temperature
is reached. Thermal stability and evaporation properties of the
water solution lubricant packages were evaluated by thermo
gravimetric analysis ("TGA"), to demonstrate the cleanliness of the
strip surface after annealing.
[0046] The above test results are obtained in air condition. Such
testing may also be conducted in an oxygen environment.
[0047] It can be seen from the results shown in FIG. 1 that the
single-phase water-based lubricant fluids of Formulations 1-2
evaporate at a higher temperature than the reference. However, they
are completely evaporated below 240.degree. C. Based on this
property, also a clean sheet surface can be expected after (batch)
anneal when using a single-phase water-based lubricant fluid.
Example 4
Tramp Oil Rejection Property
[0048] Tramp oil rejection properties of the lubricant fluids were
evaluated with anti-tramp oil tests. This is a key parameter which
evaluates the sensitivity of the lubricant for pollution. To test
the lubricant fluids, 1% tramp oil was mixed in reference and
Formulation 1 and 2. The mixtures were then placed in an oven at
about 60.degree. C. After 1 hour the amount of tramp oil floating
on top of the product was determined
TABLE-US-00003 Reference Formulation 1 Formulation 2 1 hour 0% 80%
79% Rejection percent
[0049] It can be seen from the results shown in table above that
the single-phase water-based lubricant fluids of Formulations 1-2
exhibit superior tramp oil rejection compared to Reference, because
in each of Formulations 1 and 2 about 80% tramp oil has been
rejected.
Example 5
Pilot Mill Test
[0050] Rolling performances of the water solution lubricant
packages were evaluated by a 2-high single stand reversing rolling
test mill from Southwest Aluminum Factory. The spraying system is a
PE pipe which has several holes on it (range interval 10 cm, bore
diameter <2 mm) hung above the roller (parallel). The liquid
flew from a 10 L barrel which was positioned higher than the pipe,
then went though the pipe and dropped on to the aluminum strip near
the entrance side. There was no blown-off at the exit side.
[0051] The original thickness of the aluminum strips was 0.57 mm.
The strip thickness after rolling one pass with the same force is
indicated in the table.
TABLE-US-00004 Thickness after 1 pass Reduction % Reference 0.408
28 Formulation 1 0.405 29 Formulation 2 0.405 29
[0052] The results above demonstrate that aluminum can be rolled
with Formulation 1 and 2 and that the exit thicknesses are
comparable with those obtained with the reference. Moreover the
surface of the aluminum strip rolled with the solutions shows a
homogeneous metal color which is comparable with the surface rolled
with the reference. The results demonstrate that the surface
quality is good.
Example 6
Production Mill Test
[0053] Rolling performances of the water solution lubricant
packages were evaluated on a 4-high single stand reversing rolling
production mill. The mill width is 1400 mm and work roll's diameter
is 300 mm. The maximum rolling speed is about 4.0 m/s, the maximum
rolling force is 1000 ton.
[0054] Rolling results are below:
[0055] Reference:
TABLE-US-00005 Entry Exit Roll Thickness Thickness Reduction Width
Speed Force mm mm % mm m/s (Ton) Pass 1 4.50 3.10 31% 1000 2.0 450
Pass 2 3.10 2.20 29% 1000 4.0 500 Pass 3 2.20 1.55 30% 1000 2.0
500
[0056] Formulation 1:
TABLE-US-00006 Entry Exit Roll Thickness Thickness Reduction Width
Speed Force mm mm % mm m/s (Ton) Pass 1 4.50 3.10 31% 1000 2.4 460
Pass 2 3.10 2.20 29% 1000 4.0 490 Pass 3 2.20 1.55 30% 1000 3.3
480
[0057] These results show that aluminum can be rolled under the
same conditions with Formulation 1 as with the reference.
[0058] The strip's quality is comparable as rolled with the
reference product. No obvious defect on the surface.
[0059] Neither Formulation 2 nor an aqueous dilution of it was
tested in this mill. Based on the experiments before, it is
expected that the rolling performance will be comparable with
Formulation 1.
* * * * *