Hot Metal Lubricant Composition Using Borosilicate Glass and Calcium Phosphate
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Solution Overview
Problem
Existing lubricants for hot metal processing face challenges such as scale formation, environmental and health risks from boron compounds, poor flow behavior, and graphite-related issues like dust and altered metal surfaces, which affect the quality and safety of metalworking processes.
Innovation Solution
A composition comprising secondary or tertiary calcium phosphate, fatty acid, ground borosilicate glass, condensed alkali metal phosphates, and a minimal amount of graphite, designed to provide effective scale protection and lubrication with improved flow characteristics and reduced boron compound risks, applied in powder form to ensure efficient coating and melting on hot metal surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If water-soluble boron compounds are used in high proportions for scale protection and lubrication, then effective scale dissolution and lubrication are achieved, but environmental and health risks increase due to water solubility and reproduction toxicity
Solution Approach 1:
The patent extracts and removes water-soluble boron compounds from the composition entirely, replacing them with water-insoluble alternatives such as boron nitride and boron carbide. This extraction eliminates the environmental and health risks associated with water-soluble boron while maintaining the scale protection and lubrication functions through the insoluble boron compounds.
2Ease of operation
If graphite is used as a lubricant for hot metal processing, then good forging properties and temperature stability are achieved, but graphite carbon is absorbed into the metal surface altering its composition and properties
Solution Approach 1:
The patent removes graphite from the composition to prevent carbon absorption into the metal surface. Instead, it uses alternative lubricants such as boron nitride, boron carbide, and metal soaps that provide adequate lubrication without altering the metal surface composition.
Solution Approach 2:
The patent employs composite material systems combining water-insoluble boron compounds with other lubricating agents like metal soaps and oxides. This composite approach provides the necessary lubrication and forging properties without the harmful effects of graphite carbon absorption.
3Ease of operation
If graphite powder is used for lubrication, then good lubrication action is achieved, but graphite dust creates working hygiene issues and slipping risks
Solution Approach 1:
The patent extracts graphite powder from the composition to eliminate dust generation and associated safety hazards. Water-insoluble boron compounds and other non-dusty lubricating materials are used instead, providing effective lubrication without creating airborne dust that poses hygiene and slipping risks.
4Productivity
If fine-powder materials are applied to glowing metal surfaces for rapid melt formation, then effective lubrication and scale protection are achieved, but boron compounds pass into waste water representing danger for water sources
Solution Approach 1:
The patent removes water-soluble boron compounds from the composition to prevent contamination of water sources. Water-insoluble boron compounds are used instead, which can still be applied as fine powders for rapid melt formation but will not dissolve into waste water, thereby eliminating the environmental hazard.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composition effectively reduces boron compound risks, enhances lubrication and scale protection, improves flow behavior, and maintains stability and safety, adhering to environmental regulations by minimizing water solubility and graphite usage, while ensuring efficient application and storage without lump formation.
Implementation Method 1
to guarantee the rapid formation of a melt for lubrication and for protection from scale
Implementation Method 2
as a lubricant for the hot processing of metals
Implementation Method 3
a protective coating is formed on the heated metal surface, which dissolves scale and protects from further scale formation
Data Source
AI summary
A composition for protection from scale and as a lubricant for the hot processing of metals is disclosed. The composition includes a mixture of fine-powder materials containing at least the following constituents:(a) 0 to 15% by weight of secondary or tertiary calcium phosphate compound, hydroxyapatite or a mixture thereof,(b) 0.1 to 35% by weight of fatty acid, fatty acid salt or a mixture thereof,(c) 1 to 90% by weight of ground borosilicate glass which in relation to the borosilicate glass contains Na, B, Si and Al in the following proportions by weight expressed by their respective oxides:1 to 30% by weight of Na2O,2 to 70% by weight of B2O3,10 to 70% by weight of SiO2, and0 to 10% by weight of Al2O3,(d) 9 to 85% by weight of condensed alkali metal phosphates,(e) boric acid, boric acid salt or a mixture thereof in an amount corresponding to a boron content, expressed by the oxide, of 0 to 3.2% by weight of B2O3, and(f) 0 to 10% by weight of graphite. The mixture has a mean particle size D50 of <300 μm.