CN116144417A - 一种清净型环烷基铜冷轧乳化油及其制备方法与应用 - Google Patents
一种清净型环烷基铜冷轧乳化油及其制备方法与应用 Download PDFInfo
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Abstract
本发明属于金属加工润滑技术领域,具体涉及一种清净型环烷基铜冷轧乳化油及其制备方法与应用。所述清净型环烷基铜冷轧乳化油,其组成按质量百分比计,包括:乳化剂4%~6%,摩擦改进剂2%~5%,金属减活剂3%~5%,极压抗磨剂2%~4%,抗氧剂0~1%,杀菌剂0~1%,基础油余量。所述基础油为40℃运动粘度为40~50mm2/s的加氢处理环烷基油。本发明相比于传统石蜡基铜冷轧乳化油,具有倾点低、稳定性强、清洁度高、退火清净性好、减摩能力强、防铜带变色的优点,适用于铜及铜合金板带材冷轧过程的工艺润滑。
Description
技术领域
本发明属于金属加工润滑技术领域,具体涉及一种清净型环烷基铜冷轧乳化油及其制备方法与应用。
背景技术
铜及铜合金板带材冷轧加工过程中,在剧烈金属变形下,伴随着大量摩擦磨损、变形热与摩擦热的产生,必须兼顾润滑与冷却,因此需要使用乳化液进行冷轧工艺润滑,以达到降低轧制功耗、提高轧后板带表面质量、降低温度、保护轧辊等目的。
目前铜冷轧乳化油主要以石蜡基矿物油作为基础油,有时复配部分植物油或合成酯,存在倾点高、退火清净性不佳的问题。相比于石蜡基油,环烷基油具有含蜡少、密度大、溶解性强、蒸发损失大、粘度指数低、摩擦系数高的特点。作为铜冷轧乳化液基础油,相比于传统的石蜡基油,环烷基油具有以下优势:由于含蜡少,环烷基油具有较低的倾点,有利于在温度较低的季节或地区进行储存和使用;由于密度大,环烷基油密度与水更接近,有利于乳化油在稀释为乳化液后不易分层,具有更好的分散稳定性;冷轧生产中,经常出现如液压油、油膜轴承油等杂油漏入乳化液***的情况,环烷基油良好的溶解性可以提高乳化液的耐杂油能力,减小杂油对轧后铜带清洁性的影响;由于环烷基油蒸发损失大,轧制完成后残留在表面的油液可以在退火过程中充分挥发、分解,有利于提高退火清净性。
在设备润滑用油的应用场景中,润滑状态多处于弹流体润滑,由于环烷基油黏度指数较低,随设备运行温度升高,环烷基油黏度降低会造成不利影响。而冷轧润滑多处于极压润滑与流体润滑的混合润滑状态,乳化油稀释为乳化液作为润滑介质,水相可以提供良好的冷却能力,可使油液保持在相对稳定的温度范围,不会发生类似问题。相比于其他常见有色金属,铜冷轧过程变形抗力更大;相比于黑色金属,铜冷轧对于清洁性与轧后板带的表面质量要求更高。由于环烷基油摩擦系数高于石蜡基油,因此传统的铜冷轧工艺润滑常使用石蜡基油作为基础油,有时复配部分植物油或合成酯进一步改善润滑效果。然而基础油仅提供了最基础的润滑作用,可以通过对功能性添加剂的设计来弥补环烷基基础油的不足,同时让产品拥有倾点高、分散稳定性好、退火清净性好等诸多优点。
综上所述,环烷基油应用于铜冷轧润滑中有诸多优点,具有广阔的应用前景,目前环烷基油在国内主要应用于变压器油、冷冻机油、橡胶油领域,而在铜冷轧乳化油中应用较少。
发明内容
针对现有铜冷轧乳化油产品的局限性,本发明提供一种倾点低、退火清净性好、减摩能力强、防铜带变色的铜冷轧乳化油,同时提供一种该乳化油的制备方法与应用。
本发明技术方案如下:
首先,作为本发明目的之一,提供一种清净型环烷基铜冷轧乳化油,其组成按质量百分比计,包括:乳化剂4%~6%,摩擦改进剂2%~5%,金属减活剂3%~5%,极压抗磨剂2%~4%,抗氧剂0~1%,杀菌剂0~1%,基础油余量。
所述基础油为40℃运动粘度为40~50mm2/s的加氢处理环烷基油。
所述乳化剂为脂肪醇聚氧乙烯醚,其中脂肪醇基团为十二醇、十三醇、十四醇中的一种或多种组合。优选的,乳化剂亲水亲油平衡值在9~12范围内。
更优选的,所述乳化剂为两种或两种以上聚合度不同的脂肪醇聚氧乙烯醚复配,且各脂肪醇聚氧乙烯醚的环氧乙烷聚合度在3~9范围内。
所述摩擦改进剂为脂肪醇聚氧乙烯醚磷酸单酯,其脂肪醇基团为十二醇、十三醇、十四醇中的一种或多种。
所述金属减活剂选自1H-苯并***-1-基-N,N-二(2-乙基己基)-4-甲基甲胺、2,5-二(叔-十二烷基二硫代)-1,3,4-噻二唑中的一种或两种。
所述极压抗磨剂为磷系极压剂,具体选自二正丁基酸性磷酸酯正辛基胺盐、磷酸三甲酚酯、亚磷酸二正丁酯中的一种或多种混合。
作为本发明另一个目的,本申请还提供了如上所述铜冷轧乳化油的制备方法与应用。
其中,本发明所述铜冷轧乳化油的制备方法,具体包括:
将加氢处理环烷基油加热至40℃~70℃,加入杀菌剂、抗氧剂、极压抗磨剂、金属减活剂、摩擦改进剂、乳化剂,搅拌乳化油直至各组分充分溶解,即可制得清净型环烷基铜冷轧乳化油。
优选的,当乳化剂或摩擦改进剂或金属减活剂或极压抗磨剂或抗氧剂或杀菌剂为多种物质的组合时,首先将其进行复配并加热至40℃~70℃,持续搅拌直至组混合均匀再加入到基础油中。
上述铜冷轧乳化油应用使用时,使用脱盐水将乳化油稀释为质量分数为1%~5%的乳化液,推荐轧制时控制乳化液循环***温度在45~55℃。
经上述技术方案,本发明的有益效果在于:
1.本发明产品具有良好的清净性,包括轧机清洁性、轧后板带清洁性以及退火清净性。轧制过程中飞溅到设备上的油液具有较高倾点,不易凝固形成油泥,因而具有良好的轧机清洁性。本产品具有良好的耐杂油能力,能有效减小泄露的杂油对轧后板带清洁性造成影响,由于本产品乳化性好,轧制后残留在板带表面的油液易于在脱脂工序被去除。本产品各组分高温残留少,具有良好的退火清净性。
2.本发明产品乳化性能好、不易起泡。环烷基基础油具有良好的分散稳定性,可以在减少乳化剂添加量的同时具有良好的乳化性能。通过调控乳化剂的亲水亲油平衡值,可以提高乳化剂的乳化效率。脂肪醇聚氧乙烯醚磷酸单酯在作为摩擦改进剂的同时,作为一种表面活性剂也具有一定乳化作用。本发明属于非离子型的乳化体系,可以在一定水质硬度与pH值范围内保持良好的乳化效果。由于无需添加太多乳化剂,本发明产品在稀释为乳化液后不易起泡。
3.本发明产品具有良好的润滑性能。使用长碳链的脂肪醇聚氧乙烯醚磷酸单酯作为摩擦改进剂。不同于常见的合成酯摩擦改进剂,磷酸酯极性基团大大提高了分子对于金属表面的吸附性,而且基团位于分子链末端可以使分子紧密地垂直吸附于金属表面。长碳链的单酯结构有利于形成多层吸附提高吸附膜厚度,大大降低了摩擦系数,可以有效弥补环烷基油摩擦系数较高的缺点,而相近粘度下的环烷基油抗磨性能优于石蜡基油,可以弱化脂肪醇聚氧乙烯醚磷酸单酯摩擦化学反应带来的磨损。
4.本发明产品使用磷系极压剂而非硫系、氯系极压剂,并辅以苯并三氮唑衍生物与噻二唑衍生物作为金属减活剂,可以有效抑制活性元素对铜表面的化学腐蚀造成铜带变色。脂肪醇聚氧乙烯醚磷酸单酯在作为摩擦改进剂的同时,其磷酸酯基团作为典型的防锈基团可以提供工序间防锈作用,进一步提高铜板带的表面质量。
附图说明
图1是实施例1以及将实施例1中基础油替换为石蜡基油220N的乳化油制备成乳化液静置30分钟后的分层情况。
具体实施方式
下面结合具体实施例对发明作进一步说明,可以使本领域的技术人员进一步理解本发明,但不作为对发明内容的限制,凡基于本发明所述原理的技术均属于本发明的范围。
实施例1
分别将乳化剂、金属减活剂进行复配,加热至50℃搅拌均匀。向基础油中加入杀菌剂、抗氧剂、极压抗磨剂、复配金属减活剂、摩擦改进剂、复配乳化剂,加热至50℃,并搅拌使添加剂充分溶解,即制得清净型环烷基铜冷轧乳化油。使用时,根据具体的轧制工况,使用脱盐水将乳化油稀释至质量分数为1%~5%的乳化液即可用于铜及铜合金板带材的冷轧工艺润滑。
将实施例1中基础油替换为石蜡基油220N制备成乳化油,分别将其与实施例1产品制备为乳化液,静置30分钟后,观察分层情况如图1所示,为方便观察设置乳化液浓度为10%,可以发现本申请实施例1的加氢处理环烷基油制备的乳化液分散稳定性更优。
实施例2
分别将乳化剂、金属减活剂进行复配,加热至45℃搅拌均匀。向基础油中加入杀菌剂、抗氧剂、极压抗磨剂、复配金属减活剂、摩擦改进剂、复配乳化剂,加热至45℃,并搅拌使添加剂充分溶解,即制得清净型环烷基铜冷轧乳化油。使用时,根据具体的轧制工况,使用脱盐水将乳化油稀释至质量分数为1%~5%的乳化液即可用于铜及铜合金板带材的冷轧工艺润滑。
实施例3
分别将金属减活剂、极压抗磨剂进行复配,加热至55℃搅拌均匀。向基础油中加入杀菌剂、抗氧剂、复配极压抗磨剂、复配金属减活剂、摩擦改进剂、复配乳化剂,加热至55℃,并搅拌使添加剂充分溶解,即制得清净型环烷基铜冷轧乳化油。使用时,根据具体的轧制工况,使用脱盐水将乳化油稀释至质量分数为1%~5%的乳化液即可用于铜及铜合金板带材的冷轧工艺润滑。
实施例4
分别将乳化剂、金属减活剂、极压抗磨剂进行复配,加热至50℃搅拌均匀。向基础油中加入杀菌剂、抗氧剂、复配极压抗磨剂、复配金属减活剂、摩擦改进剂、复配乳化剂,加热至50℃,并搅拌使添加剂充分溶解,即制得清净型环烷基铜冷轧乳化油。使用时,根据具体的轧制工况,使用脱盐水将乳化油稀释至质量分数为1%~5%的乳化液即可用于铜及铜合金板带材的冷轧工艺润滑。
对比例1
某国产市售铜冷轧乳化油,检测指标如下:
项目 | 检测结果 | 实验方法 |
乳化油外观 | 浅黄色透明液体 | 目测 |
密度(g/cm3) | 0.89 | SH/T 0604 |
运动粘度(40℃,mm2/s) | 57 | GB/T 265 |
酸值(mgKOH/g) | 5.9 | GB/T 264 |
皂化值(mgKOH/g) | 49 | GB/T 8021 |
按照相应实验方法将实施例1-4与对比例1制备为浓度为5%的乳化液,做四球摩擦磨损实验中的摩擦学性能对比,结果如下表所示:
上述实施例均为本发明较佳实施例,但本发明的实施方式并不受上述实施例的限制,其它的任何未背离本发明的精神实质与原理下所作的改变、修饰、替代、组合、简化,均应为等效的置换方式,都包含在本发明的保护范围之内。
Claims (10)
1.一种清净型环烷基铜冷轧乳化油,其特征在于,其组成按质量百分比计,包括:乳化剂4%~6%,摩擦改进剂2%~5%,金属减活剂3%~5%,极压抗磨剂2%~4%,抗氧剂0~1%,杀菌剂0~1%,基础油余量。
2.根据权利要求1所述的一种清净型环烷基铜冷轧乳化油,其特征在于,所述基础油为40℃运动粘度为40~50mm2/s的加氢处理环烷基油。
3.根据权利要求1所述的一种清净型环烷基铜冷轧乳化油,其特征在于,所述乳化剂为脂肪醇聚氧乙烯醚,其中脂肪醇基团为十二醇、十三醇、十四醇中的一种或多种组合,乳化剂亲水亲油平衡值在9~12范围内。
4.根据权利要求1或3所述的一种清净型环烷基铜冷轧乳化油,其特征在于,所述乳化剂为两种或两种以上聚合度不同的脂肪醇聚氧乙烯醚复配,且各脂肪醇聚氧乙烯醚的环氧乙烷聚合度在3~9范围内。
5.根据权利要求1所述的一种清净型环烷基铜冷轧乳化油,其特征在于,所述摩擦改进剂为脂肪醇聚氧乙烯醚磷酸单酯,其脂肪醇基团为十二醇、十三醇、十四醇中的一种或多种。
6.根据权利要求1所述的一种清净型环烷基铜冷轧乳化油,其特征在于,所述金属减活剂选自1H-苯并***-1-基-N,N-二(2-乙基己基)-4-甲基甲胺、2,5-二(叔-十二烷基二硫代)-1,3,4-噻二唑中的一种或两种。
7.根据权利要求1所述的一种清净型环烷基铜冷轧乳化油,其特征在于,所述极压抗磨剂为磷系极压剂,具体选自二正丁基酸性磷酸酯正辛基胺盐、磷酸三甲酚酯、亚磷酸二正丁酯中的一种或多种混合。
8.如权利要求1所述的清净型环烷基铜冷轧乳化油的制备方法,其特征在于,具体包括:将加氢处理环烷基油加热至40℃~70℃,加入杀菌剂、抗氧剂、极压抗磨剂、金属减活剂、摩擦改进剂、乳化剂,搅拌乳化油直至各组分充分溶解,即可制得清净型环烷基铜冷轧乳化油。
9.根据权利要求8所述的清净型环烷基铜冷轧乳化油的制备方法,其特征在于,当乳化剂或摩擦改进剂或金属减活剂或极压抗磨剂或抗氧剂或杀菌剂为多种物质的组合时,首先将其进行复配并加热至40℃~70℃,持续搅拌直至组混合均匀再加入到环烷基基础油中。
10.权利要求1所述的清净型环烷基铜冷轧乳化油的应用方法,其特征在于,使用时,使用脱盐水将乳化油稀释为质量分数为1%~5%的乳化液,轧制时控制乳化液循环***温度在45~55℃。
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