CN106635320A - 金属加工流体配制剂 - Google Patents

金属加工流体配制剂 Download PDF

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Publication number
CN106635320A
CN106635320A CN201610971935.3A CN201610971935A CN106635320A CN 106635320 A CN106635320 A CN 106635320A CN 201610971935 A CN201610971935 A CN 201610971935A CN 106635320 A CN106635320 A CN 106635320A
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Prior art keywords
acid
composition
volumes
salt
block copolymer
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L.E.孔德利
J.崔
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Chemetall Corp
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Chemetall Corp
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Abstract

本发明涉及金属加工流体配制剂。不含油的金属加工流体，也称作合成的金属加工流体，其在稀释时具有大于120纳米的工程化粒度。该膨胀性粒度导致了润滑性的大幅增加，这适于重负荷操作，该重负荷操作以前仅能用含油产品来获得。此外，该不含油的金属加工润滑剂任选的带有含油产品的积极性能，包括优异的腐蚀抑制性和适于重负荷操作的润滑性。

Description

金属加工流体配制剂
本申请是申请号为200880126488.5(国际申请日为2008年12月4日)、发明名称为“金属加工流体配制剂”的进入国家阶段的PCT申请的分案申请
相关申请
[不适用]
联邦政府主办的研究或者开发
[不适用]
[缩微胶片/版权授权范围]
[不适用]
发明背景
本发明涉及不含油的金属加工(metalworking)流体，也称作合成的金属加工流体。
金属加工被定义为将金属工件成形以使其符合期望的一组几何规格。金属加工包含基本的两类：切削和成型。切削操作包括磨削，车削，铣削，攻丝，拉削和滚铣。成型操作包括热和冷轧，拉伸，锻造，冲压和冲切。
金属加工流体是切削和成型操作二者中都必需的。它们必须在工件和工具之间提供润滑，以及通过除去在金属加工操作过程中产生的热来提供冷却。
润滑被定义为在两个移动表面之间的摩擦力的降低。金属加工操作中两个主要类型的润滑是流体动力学润滑和边界或者极压(EP)润滑。流体动力学润滑涉及通过流体润滑剂膜来隔开移动表面。当表面一起摩擦时，边界或者EP润滑使得所遭受的磨损最小化。聚合物润滑剂可以提供这两种类型的润滑。
金属加工流体被分为两种主要的种类，含油的和不含油的。含油的种类包含直链油，可溶性油和半合成油，其全部都利用了矿物油作为主要的润滑剂。不含油的种类被称作合成加工流体，其包括在含水传送体系或者稀释剂中产生润滑性的添加剂的组合物。可溶性油和半合成产品占据了80％的市场份额，非水的可还原直链油种类具有10％的份额，而合成的加工流体占据了10％的市场份额。
现有类型的金属加工流体具有优缺点。含油产品的优点是优异的润滑性，宽范围的应用性，和保护贮槽(sump)抗腐蚀的屏障作用。含油的金属加工流体的缺点是水硬度经常影响该流体的稳定性，泡沫是一种经常性的问题，这归因于它们包含了更高级去垢性的乳化剂，它们携带了更大的污垢负荷，它们的处置和将它们从槽中清洁掉的成本更高，并且它们具有更大的微生物问题。
因为从环境问题到微生物优点的诸多因素，使用合成加工流体受到鼓励。但是，大部分消费者继续使用含油产品，这是因为它们在相对低的成本情况下具有良好的润滑性，以及因为与合成加工流体有关的增加的维护腐蚀问题。合成加工流体的贮槽，缺乏由油提供的保护性屏障膜，会腐蚀和“冷冻”机加工***螺栓，使得维护变困难。此外，高润滑性合成产品比类似润滑性的含油产品昂贵。半合成加工流体在成本基础上的物理润滑性的降低限制了它们在重负荷操作中的用途
发明内容
本发明的一方面涉及一种全新种类的金属加工流体产品。这些新型化学品并入了羧酸盐、边界润滑剂脂肪酸和EO/PO聚合物的增效共混物，其反应以形成这样的部分(moiety)，其在某些实施方案中可以任选地具有增加的粒度，优异的润滑性或者二者兼具。另外，某些实施方案使用的稀释剂是不透明的，并且模拟了油基溶液的外观。
在某些实施方案中，该金属加工流体组合物在稀释到0.1-50体积％时的体积平均粒度可以是125nm或者更大。该组合物包含：
(a)一种或多种聚合物润滑剂；
(b)一种或多种羧酸盐；
(c)一种或多种乳化剂或者分散剂；和
(d)传送组分。
某些实施方案可以是合成的金属加工流体，其展现出润滑性的工程化增加，同时仍然提供了腐蚀保护和微生物控制。
附图说明
[不适用]
具体实施方式
在一种实施方案中，本发明的金属加工润滑剂在稀释到0.1-50体积％时的体积平均粒度可以是125nm或者更大。在一种实施方案中，该组合物可以包含：
(a)一种或多种聚合物润滑剂；
(b)一种或多种羧酸盐；
(c)一种或多种乳化剂或者分散剂；和
(d)传送组分。
更具体的，该组合物可以包含：
(a)1-80体积％的一种或多种嵌段共聚物作为聚合物润滑剂；
(b)1-40体积％的一种或多种羧酸盐；
(c)1-20体积％的一种或多种乳化剂或者分散剂；和
(d)1-97体积％的传送组分。
在另外一种实施方案中，该组合物可以包含：
(a)5-40体积％的一种或多种嵌段共聚物作为聚合物润滑剂；
(b)3-30体积％的一种或多种羧酸盐；
(c)2-12体积％的一种或多种乳化剂；和
(d)18-90体积％的传送组分。
在又一种实施方案中，该组合物可以包含：
(a)15-25体积％的一种或多种嵌段共聚物作为聚合物润滑剂；
(b)5-15体积％的一种或多种羧酸盐；
(c)3-8体积％的一种或多种乳化剂或者分散剂；和
(d)52-77体积％的传送组分。
每种组分及其实例在下面进一步描述。
聚合物润滑剂
该聚合物润滑剂可以是例如EO/PO共聚物。该EO/PO聚合物可以包括例如下面的一种或多种。该EO/PO共聚物可以是具有在中心的聚氧丙烯嵌段和在两端的聚氧乙烯链的嵌段共聚物。该EO/PO共聚物可以是包含在中心的聚氧乙烯嵌段和在两端的聚氧丙烯链的嵌段共聚物。该EO/PO共聚物可以是衍生自环氧乙烷和环氧丙烷对1,2-乙二胺相继加成的四嵌段共聚物。该EO/PO共聚物可以是具有至少一个端羟基的环氧乙烷/环氧丙烷共聚物。该EO/PO共聚物可以是环氧乙烷和环氧丙烷无规共聚物的水溶性润滑剂基料(base stock)。该EO/PO共聚物可以是水溶性聚氧乙烯醇或者聚氧丙烯醇或者这样的醇的水溶性羧酸酯。该EO/PO共聚物可以是全部聚氧丙烯基团带有一个端羟基的醇起始基料。该EO/PO共聚物可以是一元或二元酸酯，多元醇酯，聚亚烷基二醇酯，用有机酸、磷酸酯、聚异丁烯、聚丙烯腈、聚丙烯酰胺、聚乙烯吡咯烷酮、聚乙烯醇、以及丙烯酸或甲基丙烯酸和丙烯酸酯的共聚物接枝的聚亚烷基二醇。
明确可以设想的聚合物包括聚丙二醇嵌段共聚物，聚乙二醇嵌段共聚物，或者聚乙二醇/聚丙二醇嵌段共聚物。
羧酸盐
部分中和的羧酸盐打算用来将用于聚合物润滑剂的亲脂性部分提供给具有更大粒度的网络和提供工程化的更大的粒度。该盐可以例如通过使用在本说明书中所述的任何碱性试剂(alkaline agent)来部分中和游离羧酸，脂肪或者油而制造。明确设想的该盐的阳离子包括碱金属或者链烷醇胺盐，例如钠盐(例如通过用氢氧化钠处理酸来制造)。该部分中和的pH取决于所使用的碱性试剂。许多这些羧酸盐还另外提供了它们本身的边界润滑。
作为原料使用的羧酸可以是线型的或者支化的，饱和的或者不饱和的游离羧酸。该酸可以是饱和的或者不饱和的，并且不饱和的部位可以是顺式或者反式构造的。该酸可以是二羧酸，三羧酸，或者羧酸的酯，胺，酰胺或者乙氧基化的衍生物。可供选择的是，动物或者植物来源的脂肪或者油可以直接中和来提供羧酸盐。
下面的是一些设想的羧酸或者其来源的例子：己酸(caproic acid)(也称为己酸(hexanoic acid))，庚酸(enanthic acid)也称为庚酸(heptanoic acid))，辛酸(caprylicacid)也称为辛酸(octanoic acid))，壬酸(pelargonic acid)也称为壬酸(nonanoicacid))，异壬酸，癸酸(capric acid)也称为癸酸(decanoic acid))，新癸酸，月桂酸(也称作十二烷酸)，硬脂酸(也称作十八烷酸)，花生酸(也称作二十烷酸)，棕榈酸(也称作十六烷酸)，芥酸，油酸，花生四烯酸，亚油酸，亚麻酸，肉豆蔻酸(也称作十四烷酸)，山萮酸(也称作二十二烷酸)，α-亚麻酸，二十六烷酸，蓖麻油酸，丁酸，猪油，牛油，黄油，椰子油，棕榈油，棉籽油，小麦胚芽油，大豆油，橄榄油，玉米油，葵花油和菜子油或者低芥酸菜子油。
乳化剂或者分散剂
用水稀释该金属加工流体组合物形成了不透明的乳液。在高于10％的浓度时，该乳液会需要稳定化。乳化剂或者分散剂打算用来提供对于工程化大颗粒乳液的稳定。
该乳化剂或者分散剂可以是下面的一种或多种：链烷醇酰胺，烷基芳基磺酸盐，烷基芳基磺酸，氧化胺，酰胺皂和胺皂，嵌段共聚物，羧基化的醇，羧酸或者脂肪酸，乙氧基化的醇，乙氧基化的烷基酚，乙氧基化的胺或者酰胺，乙氧基化的脂肪酸，乙氧基化的脂肪酯和油，乙氧基化的酚，脂肪胺和酯，甘油酯，二元醇酯，咪唑啉类和咪唑啉衍生物，木质素和木质素衍生物，马来酸酐或者琥珀酸酐，甲基酯，单酸甘油酯和衍生物，环烷酸，烯烃磺酸盐，磷酸酯，聚亚烷基二醇，聚乙二醇，多元醇，聚合的(多糖，丙烯酸，丙烯酰胺)，丙氧基化的和乙氧基化的脂肪酸，醇或者烷基酚，季盐表面活性剂，肌氨酸衍生物，皂类，山梨聚糖衍生物，蔗糖和葡萄糖的酯和衍生物，油和脂肪酸的硫酸盐和磺酸盐，乙氧基化的烷基酚的硫酸盐和磺酸盐，醇的硫酸盐，乙氧基化的醇的硫酸盐，或者脂肪酯的硫酸盐，十二烷基和十三烷基苯的磺酸盐，萘的磺酸盐，烷基萘的磺酸盐，石油的磺酸盐，磺基琥珀酰胺酸盐，磺基琥珀酸盐和衍生物，或者十三烷基和十二烷基苯磺酸。
腐蚀抑制性组分
含油产品很大程度上依靠该油本身来形成腐蚀保护的屏障涂层。不含油的产品任选地可以通过化学手段来获得这种腐蚀保护。腐蚀抑制剂是化学化合物，其在低浓度加入时能够阻止或者延缓金属和合金的腐蚀。
腐蚀抑制剂的某些机理是形成钝化层(在材料表面上的薄膜，其阻止腐蚀性物质接近该金属)，抑制氧化还原腐蚀体系的氧化或者还原部分(阳极和阴极抑制剂)，或者清除溶解的氧。
这里有落入这个组中的许多不同的材料。一些例子是羧酸的碱金属盐和链烷醇胺盐，十一烷二酸或十二烷二酸或者它们的盐，C4-22羧酸或者它们的盐，硼酸及其盐，甲苯基***及其盐，苯并***类及其盐，咪唑啉类及其盐，链烷醇胺和酰胺，磺酸盐，环烷酸的碱金属盐和链烷醇胺盐，磷酸酯胺盐，碱金属亚硝酸盐，碱金属碳酸盐，羧酸衍生物，烷基磺酰胺羧酸，芳基磺酰胺羧酸，脂肪肌氨酸(fatty sarkoside)，苯氧基衍生物和钼酸钠。
碱化剂(ALKALINITY AGENT)
碱化剂为产品提供了期望的pH，并且在某些情况中保持了碱度和pH缓冲。碱化剂的例子包括但不限于链烷醇伯胺、仲胺和叔胺，氨基甲基丙醇(AMP-95)，二甘醇胺(DGA)，单乙醇胺(MBA)，单异丙醇胺(MIPA)，丁基乙醇胺(NBEA)，二环己基胺(DCHA)，二乙醇胺(DEA)，丁基二乙醇胺(NBDEA)，三乙醇胺(TEA)，碱金属氢氧化物，氢氧化钾，氢氧化钠，氢氧化镁，氢氧化锂，金属的碳酸盐和碳酸氢盐，碳酸钠，碳酸氢钠，碳酸钾和碳酸氢钾。用于某些实施方案的优选的碱化剂是碱金属氢氧化物。
所述组合物设想的pH任选地是3或者更大，任选地是3-10，任选地是4-9，任选地是4-8。
其它成分
该组合物还可以包含消泡剂和/或杀生物剂或者杀真菌剂，以及任何其它常规的或者新的添加剂。
传送组分(TRANSPORT COMPONENT)
优选的传送组分(其也可以称作分散介质或者载体)大部分地、任选全部是水。但是，任选地，该组合物可以包含一种或多种油，优选小于10体积％的油。这些组分可以是任何常规的润滑油。如果设想的是复合的油和水传送组分，则乳化剂可以用来制造油和水的稳定乳液。
目前可以利用的非油产品的积极性能任选地保持在这种组合物中以及任选地包括下面的一种，大于一种或者全部性能：环境依从性(environmental compliance)，良好的冷却，良好的排屑或者沉降特性，长贮槽寿命和良好的抗生物性。
在请求保护的本发明中，该金属加工流体组合物在稀释到0.1-50体积％时能够具有小于8000牛顿-cm-1的润滑性，该润滑性是用攻丝扭矩测定仪来测量的。
该组合物在低油(即，不大于10体积％的油)或者基本上或者完全无油配制剂中可以任选的具有下面的一种或多种有利的性能：
·含油产品的润滑性，
·接近于含油产品的润滑性/成本性能点，
·减少对工人的刺激性(刺激性与高pH产品有关)，
·含油产品的生锈或者其它腐蚀保护性，或者
·无链烷醇胺的化学品。
粒度
如将在下面的实施例中所见的那样，所配置的本发明的组合物包含颗粒。较大的颗粒被打算用来提供更大的润滑性，虽然本发明不局限于这种理论的正确性。任何实施方案的设想颗粒任选地具有下面的体积平均直径：120-100000纳米(nm)，可供选择的是(alternatively)120-100000nm，可供选择的是120-10000nm，可供选择的是120-5000nm，可供选择的是125-10000nm，可供选择的是125-5000nm，可供选择的是125-2000nm，可供选择的是140-10000nm，可供选择的是140-5000nm，可供选择的是140-2000nm，可供选择的是200-10000nm，可供选择的是200-5000nm，可供选择的是200-2000nm，可供选择的是220-10000nm，可供选择的是220-5000nm，可供选择的是220-2000nm，可供选择的是350-10000nm，可供选择的是350-5000nm，可供选择的是350-2000nm。
实施例
通过参考下面的实施例能够更好的理解前述的内容，下面的实施例目的是说明实施本发明用的方法，并且目的并非限制本发明的范围。
实施例1
表1
表1的材料A-E被用于攻丝扭矩操作中，该攻丝扭矩操作涉及6061铝的攻丝。在测试之前将该浓缩物首先稀释成7.5体积％的溶液。该攻丝扭矩测试是金属加工流体的润滑性的定量测量。它的ASTM标准方法名称为D5619。攻丝扭矩以比其它测试更好的方式反映了工业机加工过程，其通常是通过一起摩擦两个金属表面来进行的。它是在实验室中辨别金属加工流体(MWF)产品机加工性能的优异方法。攻丝扭矩结果已经被证明是与现场(field)机加工性能密切相关的。
该攻丝扭矩测定仪被设计来测量MWF的润滑性，同时进行实际的切削。在攻丝操作过程中，在攻丝前进通过切削深度时，该攻丝扭矩测定仪测量了250次瞬间扭矩。专门的软件然后促进了对于数据的分析。攻丝扭矩是用N-m(牛顿-米)或者N-cm(牛顿-厘米)单位来表示的。高润滑性产品将产生低的扭矩值。相反，低润滑性产品将产生高扭矩值。以此方式，该仪器量化了产品之间的润滑性差异。
攻丝扭矩测定仪的一个缺点是所测量的绝对扭矩值依赖于并且将随着所用的攻丝的直径而变化。所以，为了消除掉这些几何影响，有效的是将润滑性表示为每单位面积上的扭矩，来描述攻丝旋转一周所消耗的能量。用于此的等式是
E/A＝(2’r)/r2，
这里t＝扭矩值，r＝攻丝半径，E/A＝每单位面积的能量，并且单位是N-m-1(牛顿/米)或者N-cm-1(牛顿/厘米)。
润滑性数据表示在表1中，确定为E/A。E/A值越低，润滑性和机加工性能越好。全部的样品在测试前用水稀释到7.5体积％。
实施例2：
将表1的材料用于粒度操作中，该粒度操作涉及以纳米为单位的体积平均粒度的测量。在测试之前首先将该浓缩物用水稀释到7.5体积％的溶液。颗粒测量仪器(particle-sizing instrument)使用高效动态光散射来量化20-100000纳米的粒度。
在测试之前将全部的样品稀释到7.5体积％。所形成的粒度表示在表1中。
实施例3
将表1的材料C在两个不同的浓度测试粒度，并且在每个浓度评价外观和乳液稳定性。结果表示在表2中，其在每个浓度显示出大的平均粒度，不透明的外观和优异的稳定性。较大的粒度是更好的润滑剂的特征。典型的合成MWF在稀释时形成了粒度小于100纳米的澄清溶液。稀释的样品C的粒度为对典型的合成MWF所观察到的最大尺寸的3.5-20倍大。
表2
从实施例1–3可以看出用样品C获得了最佳的润滑性和粒度，样品C将10％的羧酸-碱金属盐(carboxylic acid-alkali salt)和20％Pluronic“R”嵌段共聚物合并。这种比例得到了最大的体积平均粒度和最大的润滑性。
从该实施例中同样很显然的是组合物的润滑性在很大程度上是它的体积平均粒度的函数。提高体积平均粒度产生了提高的润滑性。
从实施例3中可以看出样品C浓度的增加导致了明显更大的体积平均粒度。这解释了乳化剂对于稳定高浓度样品C的必要性。没有乳化剂时，据信高浓度的粒度将连续的聚结成不稳定的状态。
应当理解的是本文所述的本发明的优选实施方案的不同变化和改变对于本领域技术人员来说将是显而易见的。可以进行这样的变化和改进而不脱离本发明的主旨和范围以及不减少它的目标优点。因此旨在用所附的权利要求来覆盖这样的变化和改变。

Claims (17)

1.金属加工流体组合物，其在稀释到0.1-50体积％时具有125nm或者更大的体积平均粒度，该组合物包含：
(a)一种或多种聚合物润滑剂，其中该聚合物润滑剂是嵌段共聚物，并且是下面的一种或多种：包含在中心的聚氧丙烯嵌段和在两端的聚氧乙烯链的嵌段共聚物、包含在中心的聚氧乙烯嵌段和在两端的聚氧丙烯链的嵌段共聚物、衍生自环氧乙烷和环氧丙烷对1,2-乙二胺相继加成的四嵌段共聚物、具有至少一个端羟基的环氧乙烷/环氧丙烷共聚物、环氧乙烷和环氧丙烷无规共聚物的水溶性润滑剂基料、以及水溶性聚氧乙烯醇或者聚氧丙烯醇或者这样的醇的水溶性羧酸酯；
(b)一种或多种羧酸盐；
(c)一种或多种乳化剂或者分散剂，其中该乳化剂或者分散剂是下面的一种或多种：乙氧基化的醇、乙氧基化的烷基酚、乙氧基化的胺或者酰胺、乙氧基化的脂肪酸、乙氧基化的脂肪酯和油、丙氧基化的和乙氧基化的脂肪酸和乙氧基化的醇的硫酸盐；
(d)传送组分；和
(e)碱化剂，其中该碱化剂是碱金属氢氧化物。
2.权利要求1的组合物，其包括小于10体积％的一种或多种油。
3.权利要求1的组合物，其中该传送组分包括水。
4.权利要求1的组合物，其包括腐蚀抑制性组分。
5.权利要求4的组合物，其中该腐蚀抑制性组分包含下面的一种或多种：羧酸的碱金属盐和链烷醇胺盐、十一烷二酸或者十二烷二酸和它们的盐、C4-22羧酸和它们的盐、硼酸类、含硼化合物和它们的盐、甲苯基***及其盐、苯并***类及其盐、咪唑啉类及其盐、链烷醇胺和酰胺、磺酸盐、环烷酸的碱金属盐和链烷醇胺盐、磷酸酯胺盐、碱金属亚硝酸盐、碱金属碳酸盐、羧酸衍生物、烷基磺酰胺羧酸、芳基磺酰胺羧酸、脂肪肌氨酸、苯氧基衍生物和钼酸钠。
6.权利要求1的组合物，其中pH是3-9。
7.权利要求1的组合物，其包括消泡剂。
8.权利要求1的组合物，其包括杀生物剂和/或杀真菌剂。
9.权利要求1的组合物，其中所述嵌段共聚物是聚丙二醇嵌段共聚物。
10.权利要求1的组合物，其中所述嵌段共聚物是聚乙二醇嵌段共聚物。
11.权利要求1的组合物，其中所述嵌段共聚物是聚乙二醇/聚丙二醇嵌段共聚物。
12.权利要求1的组合物，其中所述一种或多种羧酸盐包括C4-C22羧酸或者脂肪酸和酯的碱金属盐和/或链烷醇胺盐。
13.权利要求1的组合物，其中该羧酸盐包括下面的一种或多种：丁酸、己酸、庚酸、辛酸、壬酸、异壬酸、癸酸、新癸酸、十二烷酸、十四烷酸、十六烷酸、十八烷酸、油酸、亚油酸、亚麻酸、α-亚麻酸、蓖麻油酸、二十烷酸、二十二烷酸、二十六烷酸、芥酸以及花生四烯酸。
14.权利要求1的组合物，其中该金属加工流体组合物在稀释到0.1-50体积％时具有小于8000牛顿-cm-1的润滑性，该润滑性是用攻丝扭矩测定仪来测量的。
15.权利要求1的金属加工流体组合物，其包含：
(a)1-80体积％的所述一种或多种嵌段共聚物；
(b)1-40体积％的所述一种或多种羧酸盐；和
(c)1-20体积％的所述一种或多种乳化剂。
16.权利要求1的金属加工流体组合物，其包含：
(a)5-40体积％的所述一种或多种嵌段共聚物；
(b)3-30体积％的所述一种或多种羧酸盐；和
(c)2-12体积％的所述一种或多种乳化剂。
17.权利要求1的金属加工流体组合物，其包含：
(a)15-25体积％的所述一种或多种嵌段共聚物；
(b)5-15体积％的所述一种或多种羧酸盐；和
(c)3-8体积％的所述一种或多种乳化剂。
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