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TheBMWPartnershipDryFilmLubricants08.03.2005PresentationoftheCastrol“DryFilm”projectatBMW,Oxford(UK)TheBMWPartnershipDryFilmLuHistoryofSteelMillAppliedLubricantsCORROSIONPREVENTIVESDRYFILMLUBRICANTSBASEDONPOLYMER2.GENERATIONPRELUBESSEMIDRYFILMLUBRICANTSTHIXOTROPICCORROSIONPREVENTIVESPRELUBES2.GENERATIONTHIXOTROPICCORR.PREVENTIVESDRYFILMLUBRICANTSBASEDONPARAFFINDRYFILMLUBRICANTSBASEDONWAXDISPERSIONDRYFILMLUBRICANTSBASEDONESTER1990199620002001HistoryofSteelMillAppliedAdvantagesoftheDryFilmTechnologySuperiorlubricationMultisubstratecompatibilityincludingaluminumDry-to-the-touchfilmReducedquantitiesappliedMechanicalsurfaceprotectionCleanworkingenvironmentAdvantagesoftheDryFilmTecTypesofDryFilmLubricantsEsterMineraloilbasedHotmeltPolymerOrganicsolvendbasedWaterbasedVOCEnergyTypesofDryFilmLubricantsEsTypesofDryFilmLubricantsSemiDryFilmLubricants-Greasy-KonusPenetrationappr.20mmDryFilmLubricants-Lacqueurorwaxy-NeedlePenetration<10mmTypesofDryFilmLubricantsSTypesofDryFilmLubricants
AdvantagesofesterbasedhotmeltsExtremedrawingperformanceExcellentcorrosionprotectionNodryingorcuringtimeNoemissions,noVOCEasyapplication(electrostaticorairless)EnvironmentallyfriendlyBasedonrenewablerawmaterialsTypesofDryFilmLubricants
R&DDemandsforDryFilmLubricantDesignSignificantlyimproveddrawingperformancecomparedtoprelubesApplicationwithexistingelectrostaticsprayequipmentCompatibilitywithexistingandfuturecataphoreticdippaintsystemsSealerandadhesivecompatibilityOneproductforsteelandaluminumEnvironmentallyfriendlyR&DDemandsforDryFilmLubriTypicalFrictionCoefficientsforLubricantsTypicalFrictionCoefficientsCastrolDryFilmLubricantIloformPN950DF
R+KTester–CupDrawingTest,SubstrateZECastrolDryFilmLubricantIloEvaluationofthedrawingperformancebyusingthe
stripdrawingtestCooperationwiththeUniversityofWaterloo(Canada).Usingthe“FlatDieRigg”,builtbyajointaction.Drawingspeed:0–500mm/sMaximumforce(witha10000mm²“Tool”):75N/mm²VariablecontactareaQuicktoolchangepossiblePossibletooltemperature:RT–appr.>300°CComputerisedcalculationofthefrictioncoefficientµQuickchangeofmaterial,lubricantandcoatingweightpossible EvaluationofthedrawingperfFlatDieRig
DrawingIFlatDieRig
DrawingIFlatDieRig
DrawingIIFlatDieRig
DrawingIITestFacilityattheUniversityofWaterloo(CAN)
“FlatDieRigg”modified80tpressTestFacilityattheUniversitDryFilmLubricantondifferentmaterials
FlatDieTestStation
-
UniversityofWaterloo
ResultsofIloformPN950DFacc.VDA230-201Forcelimitsetto400kNThemaximumforcewaslimitesduringthetestsduetosafetyreasons(40N/mm²).Ingeneralanmaximumfordeof75N/mm²ispossiblebyrespectingtheVDAparameters.Duringthetest,nostick-slipwereseenforCastrolIloformPN950DF.V=const.MineraloilbasedDryFilmLubricantsPrelubes**ConventionalPrelubes(mineraloilbased)DryFilmLubricantondifferenDryFilmLubricantonBareSteel
TestResultsIloformPN950DFanalogVDA230-201Maximumnormalforcewasonlylimitedbythesettingofthetestequipment,afteradjustingthissettingwewillbecapabletoperformtestsupto75N/mm².Duringourpreliminarytestingnostick-slipwasobserved.DryFilmLubricantonBareSteDryFilmLubricantonElectrogalvanizedMaterial
TestResultsIloformPN950DFanalogVDA230-201Maximumnormalforcewasonlylimitedbythesettingofthetestequipment,afteradjustingthissettingwewillbecapabletoperformtestsupto75N/mm².Duringourpreliminarytestingnostick-slipwasobserved.DryFilmLubricantonElectrogDryFilmLubricantonHot-dipGalvanizedMaterial
TestResultsIloformPN950DFanalogVDA230-20Maximumnormalforcewasonlylimitedbythesettingofthetestequipment,afteradjustingthissettingwewillbecapabletoperformtestsupto75N/mm².Duringourpreliminarytestingnostick-slipwasobserved.DryFilmLubricantonHot-dipDryFilmLubricantonGalvanealedMaterial
TestResultsIloformPN950DFanalogVDA230-20Maximumnormalforcewasonlylimitedbythesettingofthetestequipment,afteradjustingthissettingwewillbecapabletoperformtestsupto75N/mm².Duringourpreliminarytestingnostick-slipwasobserved.DryFilmLubricantonGalvaneaDryFilmLubricantonAluminum
TestResultsIloformPN950DFanalogVDA230-20Maximumnormalforcewasonlylimitedbythesettingofthetestequipment,afteradjustingthissettingwewillbecapabletoperformtestsupto75N/mm².Duringourpreliminarytestingnostick-slipwasobserved.DryFilmLubricantonAluminumInfluenceofDieTemperatureonFrictionCoefficient
IloformPN950DFonElectrogalvanizedMaterialFrictioncoefficientdeterminedat400mm/sdrawingspeedInfluenceofDieTemperatureoRemovabilityTestIloformPN950DF
acc.toVDA230-201andRenaultSpecificationSubstratebaresteelelectrogalv.hot-dipgalv.galvannealedRenaultSpec./Sollac-TestpassedpassedpassedpassedSubstratebaresteelelectrogalv.hot-dipgalv.galvannealedVDA-TestpassedpassedpassedpassedRemovabilityTestIloformPN9AdhesiveCompatibility
TestingaccordingtoVDA230-201AdhesiveIloformDFXW1185Epoxy(GEX)allsubstrateso.k.Terostat3216Rubber(Henkel)allsubstrateso.k.Terokal8552PVC(Henkel)allsubstrateso.k.AdhesiveCompatibility
TestingCataphoreticDipPaintCompatibility
accordingtoVDA230-202-IloformPN950DFTypeCraterPPGEnviroprime0PPGEnviroprime20000Source:PPGCataphoreticDipPaintCompatiIloformPN950DF
DryFilmLubricantAppearance white,solidViscosityat20°C solidViscosityat50°C 34mm²/sFlashpoint <200°CCorrosionprotection CondensationclimatechamberDIN51386-1 >20CyclesSaltspraytestASTMB-117 >24hOpenshedstorage min.12monthIndoorstorage min.18monthIloformPN950DF
DryFilmLuViscosityTemperatureChart
CastrolDryFilmLubricant:IloformPN950DFViscosityTemperatureChart
CTrials英国石油公司(BP石油)为某汽车公司提供的干式润滑方案DryFilmLubricantIloformPN950DF
CaseStudies1/1
ElectroluxHomeProducts-Swainsboro,GA
May2002Lawnmowerdecks,part#4055IFand404blanksize807x1000x1.9and825x750x1.9mm,baresteelsheetmetalcoatingweightvariable1.6–6.0g/m²,preparedbyelectrostaticspraying(Gencoat)
200partssuccessfullyproducedandassembledDryFilmLubricantIloformPNca.750mmca.160mm
ProfileofthepressingpartElectroluxHomeProducts,Swainsboro,GADryFilmLubricantIloformPN950DF
CaseStudies1/2ca.750mmca.160mm
Profileo
ElectroluxHomeProducts-Swainsboro,GAOctober2003Lawnmowerdecks„Hi-Vac“blanksize825x750x1.9mm,baresteelsheetmetalcoatingweightvariableappr.2.0g/m²,preparedmanualExtremedifficultpart,duetothehighfailurerateitiscalledinternally50:50deckResult:FailratewithCastrolDryFilmtechnologyreducedto„0“DryFilmLubricantIloformPN950DF
CaseStudies2/1ElectroluxHomeProducts-Swca.600mmca.300mm
ProfileofthepressingpartElectroluxHomeProducts,Swainsboro,GADryFilmLubricantIloformPN950DF
CaseStudies2/2ca.600mmca.300mm
ProfileDryFilmLubricantIloformPN950DF
CaseStudies2/3–PictureDryFilmLubricantIloformPN
FordStampingPlant-Saarlouis,Germany
June2003Inner-bodysidepanel,Focus3-doorhatchbackblanksize1525x3475x0.75mm,hot-dipgalvanizedsheetmetalcoatingweight1.2–1.4g/m²,preparedbyelectrostaticspraying(ThyssenKruppStahlNeuwied,sprayequipmentFaraTechnology)500partssuccessfullyproducedandassembledDryFilmLubricantIloformPN950DF
CaseStudies3/1FordStampingPlant-Saarlou
DryFilmLubricantIloformPN950DF
CaseStudies3/2-Picture
DryFilmLubricantIloformPNMetalsheetsdry-to-the-touchNoparticlecontaminationNoproblemsinthede-stackingprocessOnlyslightmodificationoftheclampforcewasnecessaryinthebeginningMaintrial550o.K.partsUsageofthepartswithoutproblemsDryFilmLubricantIloformPN950DF
CaseStudies3/3Metalsheetsdry-to-the-touchDAUDIStampingPlant-Ingolstadt,GermanyJune2003Inner-doorpanel,A4Blanksizeappr.1525x1735x0.75mm,hot-dipgalvanizedsheetmetalCoatingweight1.2–1.4g/m²,preparedbyelectrostaticSpraying(ThyssenKruppStahlNeuwied,sprayequipmentFaraTechnology)30partssuccessfullyproducedandpassedthrougttheadditionalprocesses(cleaning,phosphatingandpaintingo.K.)DryFilmLubricantIloformPN950DF
CaseStudies4/1AUDIStampingPlant-Ingolsta„MetallwerkHofmaninger,Austria“Pretrial:PressingofaconcetemixerpartDryFilmLubricantIloformPN950DF
CaseStudies5/1„MetallwerkHofmaninger,AustrDryFilmLubricantIloformPN950DF
CaseStudies5/2-PictureDryFilmLubricantIloformPN190mm390mmØ578mmpart:concretemixerMetallsheet:960x1mmDryFilmLubricantIloformPN950DF
CaseStudies5/3-Drawing190mm390mmØ578mmpart:concAspayablealternativeforthecurrentproduct„CastrolIloformPS158“.Duetotheamountofsolidadditivestheapplicationofthistheproductcouldonlybemademanuallyviarollerorbrush.Material:1,0mmDC03ofvoestalpineTheapplicationinthispretrialwasmademanualbybrushwithoutmeasuringthefilmthickness,therforewedonothaveanyinformationaboutthisfact.1punchFurtheractions:Trialswithadefinedproductamounttoevaluatetheminimumdryfilmquantityforasafeprocess.DryFilmLubricantIloformPN950DF
CaseStudies5/4Aspayablealternativeforthe
FordStampingPlant-Saarlouis,Germany
December2004Innerwheelhouseforthebackwheel,C-MAXgalvanealedsheetmetal,coatingweight0.6–1.4g/m²(nothomogenous),preparedbyairspray(ARCELORFlemalle),difficultoperationneedfortheconventionalproductionwithoilaamountof>5g/m²1000partssuccessfullyproduced(nofailpart,verycleantoolswithoutanydeposits)DryFilmLubricantIloformPN950DF
CaseStudies6/1FordStampingPlant-SaarlouVWStampingPlant-Emden,GermanyJanuary2005InnerpanelforthePassatdoor,HDGtailoredblank(thickness:0.7and1.6mm)Coatingweight(applicationmanuallywithaspraygun):0.9-1.2g/m²-comparisonwithcompetitorproducts10partssuccessfullyproducedduringthenormalproductionprocesswiththeadjustmentsusedforthenormal„oil“lubricationResult:nobreakswereseen/onlyslightwavinessoccured(noproductproblem,adjustmentsofthetoolforcesarenecessary)10partsarereadyfortheadjustmenttrialsinthe„Try-Out-Press“inthefutureDryFilmLubricantIloformPN950DF
CaseStudies6/1VWStampingPlant-Emden,GerCurrentlyweareworkinginthisspecialareaalsoin:EuropeUSAAustraliaKorea EspeciallyintheUSAweareworkingcloselywithThyssen.Acostreductionmorethan$1mio.peryearcouldberealised.CurrentlyweareworkinginthTheBMWPartnershipDryFilmLubricants08.03.2005PresentationoftheCastrol“DryFilm”projectatBMW,Oxford(UK)TheBMWPartnershipDryFilmLuHistoryofSteelMillAppliedLubricantsCORROSIONPREVENTIVESDRYFILMLUBRICANTSBASEDONPOLYMER2.GENERATIONPRELUBESSEMIDRYFILMLUBRICANTSTHIXOTROPICCORROSIONPREVENTIVESPRELUBES2.GENERATIONTHIXOTROPICCORR.PREVENTIVESDRYFILMLUBRICANTSBASEDONPARAFFINDRYFILMLUBRICANTSBASEDONWAXDISPERSIONDRYFILMLUBRICANTSBASEDONESTER1990199620002001HistoryofSteelMillAppliedAdvantagesoftheDryFilmTechnologySuperiorlubricationMultisubstratecompatibilityincludingaluminumDry-to-the-touchfilmReducedquantitiesappliedMechanicalsurfaceprotectionCleanworkingenvironmentAdvantagesoftheDryFilmTecTypesofDryFilmLubricantsEsterMineraloilbasedHotmeltPolymerOrganicsolvendbasedWaterbasedVOCEnergyTypesofDryFilmLubricantsEsTypesofDryFilmLubricantsSemiDryFilmLubricants-Greasy-KonusPenetrationappr.20mmDryFilmLubricants-Lacqueurorwaxy-NeedlePenetration<10mmTypesofDryFilmLubricantsSTypesofDryFilmLubricants
AdvantagesofesterbasedhotmeltsExtremedrawingperformanceExcellentcorrosionprotectionNodryingorcuringtimeNoemissions,noVOCEasyapplication(electrostaticorairless)EnvironmentallyfriendlyBasedonrenewablerawmaterialsTypesofDryFilmLubricants
R&DDemandsforDryFilmLubricantDesignSignificantlyimproveddrawingperformancecomparedtoprelubesApplicationwithexistingelectrostaticsprayequipmentCompatibilitywithexistingandfuturecataphoreticdippaintsystemsSealerandadhesivecompatibilityOneproductforsteelandaluminumEnvironmentallyfriendlyR&DDemandsforDryFilmLubriTypicalFrictionCoefficientsforLubricantsTypicalFrictionCoefficientsCastrolDryFilmLubricantIloformPN950DF
R+KTester–CupDrawingTest,SubstrateZECastrolDryFilmLubricantIloEvaluationofthedrawingperformancebyusingthe
stripdrawingtestCooperationwiththeUniversityofWaterloo(Canada).Usingthe“FlatDieRigg”,builtbyajointaction.Drawingspeed:0–500mm/sMaximumforce(witha10000mm²“Tool”):75N/mm²VariablecontactareaQuicktoolchangepossiblePossibletooltemperature:RT–appr.>300°CComputerisedcalculationofthefrictioncoefficientµQuickchangeofmaterial,lubricantandcoatingweightpossible EvaluationofthedrawingperfFlatDieRig
DrawingIFlatDieRig
DrawingIFlatDieRig
DrawingIIFlatDieRig
DrawingIITestFacilityattheUniversityofWaterloo(CAN)
“FlatDieRigg”modified80tpressTestFacilityattheUniversitDryFilmLubricantondifferentmaterials
FlatDieTestStation
-
UniversityofWaterloo
ResultsofIloformPN950DFacc.VDA230-201Forcelimitsetto400kNThemaximumforcewaslimitesduringthetestsduetosafetyreasons(40N/mm²).Ingeneralanmaximumfordeof75N/mm²ispossiblebyrespectingtheVDAparameters.Duringthetest,nostick-slipwereseenforCastrolIloformPN950DF.V=const.MineraloilbasedDryFilmLubricantsPrelubes**ConventionalPrelubes(mineraloilbased)DryFilmLubricantondifferenDryFilmLubricantonBareSteel
TestResultsIloformPN950DFanalogVDA230-201Maximumnormalforcewasonlylimitedbythesettingofthetestequipment,afteradjustingthissettingwewillbecapabletoperformtestsupto75N/mm².Duringourpreliminarytestingnostick-slipwasobserved.DryFilmLubricantonBareSteDryFilmLubricantonElectrogalvanizedMaterial
TestResultsIloformPN950DFanalogVDA230-201Maximumnormalforcewasonlylimitedbythesettingofthetestequipment,afteradjustingthissettingwewillbecapabletoperformtestsupto75N/mm².Duringourpreliminarytestingnostick-slipwasobserved.DryFilmLubricantonElectrogDryFilmLubricantonHot-dipGalvanizedMaterial
TestResultsIloformPN950DFanalogVDA230-20Maximumnormalforcewasonlylimitedbythesettingofthetestequipment,afteradjustingthissettingwewillbecapabletoperformtestsupto75N/mm².Duringourpreliminarytestingnostick-slipwasobserved.DryFilmLubricantonHot-dipDryFilmLubricantonGalvanealedMaterial
TestResultsIloformPN950DFanalogVDA230-20Maximumnormalforcewasonlylimitedbythesettingofthetestequipment,afteradjustingthissettingwewillbecapabletoperformtestsupto75N/mm².Duringourpreliminarytestingnostick-slipwasobserved.DryFilmLubricantonGalvaneaDryFilmLubricantonAluminum
TestResultsIloformPN950DFanalogVDA230-20Maximumnormalforcewasonlylimitedbythesettingofthetestequipment,afteradjustingthissettingwewillbecapabletoperformtestsupto75N/mm².Duringourpreliminarytestingnostick-slipwasobserved.DryFilmLubricantonAluminumInfluenceofDieTemperatureonFrictionCoefficient
IloformPN950DFonElectrogalvanizedMaterialFrictioncoefficientdeterminedat400mm/sdrawingspeedInfluenceofDieTemperatureoRemovabilityTestIloformPN950DF
acc.toVDA230-201andRenaultSpecificationSubstratebaresteelelectrogalv.hot-dipgalv.galvannealedRenaultSpec./Sollac-TestpassedpassedpassedpassedSubstratebaresteelelectrogalv.hot-dipgalv.galvannealedVDA-TestpassedpassedpassedpassedRemovabilityTestIloformPN9AdhesiveCompatibility
TestingaccordingtoVDA230-201AdhesiveIloformDFXW1185Epoxy(GEX)allsubstrateso.k.Terostat3216Rubber(Henkel)allsubstrateso.k.Terokal8552PVC(Henkel)allsubstrateso.k.AdhesiveCompatibility
TestingCataphoreticDipPaintCompatibility
accordingtoVDA230-202-IloformPN950DFTypeCraterPPGEnviroprime0PPGEnviroprime20000Source:PPGCataphoreticDipPaintCompatiIloformPN950DF
DryFilmLubricantAppearance white,solidViscosityat20°C solidViscosityat50°C 34mm²/sFlashpoint <200°CCorrosionprotection CondensationclimatechamberDIN51386-1 >20CyclesSaltspraytestASTMB-117 >24hOpenshedstorage min.12monthIndoorstorage min.18monthIloformPN950DF
DryFilmLuViscosityTemperatureChart
CastrolDryFilmLubricant:IloformPN950DFViscosityTemperatureChart
CTrials英国石油公司(BP石油)为某汽车公司提供的干式润滑方案DryFilmLubricantIloformPN950DF
CaseStudies1/1
ElectroluxHomeProducts-Swainsboro,GA
May2002Lawnmowerdecks,part#4055IFand404blanksize807x1000x1.9and825x750x1.9mm,baresteelsheetmetalcoatingweightvariable1.6–6.0g/m²,preparedbyelectrostaticspraying(Gencoat)
200partssuccessfullyproducedandassembledDryFilmLubricantIloformPNca.750mmca.160mm
ProfileofthepressingpartElectroluxHomeProducts,Swainsboro,GADryFilmLubricantIloformPN950DF
CaseStudies1/2ca.750mmca.160mm
Profileo
ElectroluxHomeProducts-Swainsboro,GAOctober2003Lawnmowerdecks„Hi-Vac“blanksize825x750x1.9mm,baresteelsheetmetalcoatingweightvariableappr.2.0g/m²,preparedmanualExtremedifficultpart,duetothehighfailurerateitiscalledinternally50:50deckResult:FailratewithCastrolDryFilmtechnologyreducedto„0“DryFilmLubricantIloformPN950DF
CaseStudies2/1ElectroluxHomeProducts-Swca.600mmca.300mm
ProfileofthepressingpartElectroluxHomeProducts,Swainsboro,GADryFilmLubricantIloformPN950DF
CaseStudies2/2ca.600mmca.300mm
ProfileDryFilmLubricantIloformPN950DF
CaseStudies2/3–PictureDryFilmLubricantIloformPN
FordStampingPlant-Saarlouis,Germany
June2003Inner-bodysidepanel,Focus3-doorhatchbackblanksize1525x3475x0.75mm,hot-dipgalvanizedsheetmetalcoatingweight1.2–1.4g/m²,preparedbyelectrostaticspraying(ThyssenKruppStahlNeuwied,sprayequipmentFaraTechnology)500partssuccessfullyproducedandassembledDryFilmLubricantIloformPN950DF
CaseStudies3/1FordStampingPlant-Saarlou
DryFilmLubricantIloformPN950DF
CaseStudies3/2-Picture
DryFilmLubricantIloformPNMetalsheetsdry-to-the-touchNoparticlecontaminationNoproblemsinthede-stackingprocessOnlyslightmodificationoftheclampforcewasnecessaryinthebeginningMaintrial550o.K.partsUsageofthepartswithoutproblemsDryFilmLubricantIloformPN950DF
CaseStudies3/3Metalsheetsdry-to-the-touchDAUDIStampingPlant-Ingolstadt,GermanyJune2003Inner-doorpanel,A4Blanksizeappr.1525x1735x0.75mm,hot-dipgalvanizedsheetmetalCoatingweight1.2–1.4g/m²,preparedbyelectrostaticSpraying(ThyssenKruppStahlNeuwied,sprayequipmentFaraTechnology)30partssuccessfullyproducedandpassedthrougttheadditionalprocesses(cleaning,phosphatingandpaintingo.K.)DryFilmLubricantIloformPN950DF
CaseStudies4/1AUDIStampingPlant-Ingolsta„MetallwerkHofmaninger,Austria“Pretrial:PressingofaconcetemixerpartDryFilmLubricantIloformP
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