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Claims  |
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What we claim is:
1. An additive composition for imparting a combination of extreme pressure,
antiwear and corrosion-inhibiting properties to a metalworking
composition, said additive comprising:
a. a phosphate ester having the following formula:
##EQU4##
wherein EO is ethylene oxide; R is selected from the group consisting of
linear or branched chain alkyl groups having from 6 to 30 carbon atoms,
phenyl, alkylphenyl, wherein the alkyl group has from 1 to 10 carbon
atoms, and dialkyl phenyl wherein the alkyl groups have a total of from 2
to 20 carbon atoms; X is selected from hydrogen, ammonium, amines and
metals from groups I-A, I-B, II-A and II-B of the periodic table; n is a
number from 0 to 50; a is 1, 2 or 3, and b is 0, 1 or 2 with the proviso
that said a plus said b equals 3; and
b. a sulphur-containing compound selected from the group consisting of
elemental sulphur; sulphurized mineral oils; 2-mercaptobenzothiazole;
5-substituted, 6-substituted and 7-substituted 2-mercaptobenzothiazole
wherein the substituent is selected from the group consisting of chloro,
bromo, sulfonic acid, amido, methyl, carboxylic acid, and ethoxy;
2-mercaptobenzothiazole derivatives having the following formula:
##SPC4##
wherein X is selected from hydrogen, hydroxymethyl and metals of groups
I-A, I-B, II-A and II-B of the periodic table; derivatives of
2-mercaptothiazole having the formula:
##SPC5##
wherein X is selected from hydrogen, hydroxymethyl and metals from groups
I-A, I-B, II-A and II-B of the periodic table; R is selected from hydrogen
and an alkyl group having from 1 to 10 carbon atoms; and R.sub.1 is
selected from hydrogen, an alkyl group having from 1 to 10 carbon atoms,
carboxy,
##EQU5##
2. 2'-dithiobisthiazole and derivatives thereof having the following
formula:
##SPC6##
wherein R.sub.2, R.sub.3, R.sub.4 and R.sub.5 are selected from the group
consisting of hydrogen and an alkyl group having from 1 to 10 carbon
atoms; 2,2'-dithiobis(benzothiazole) and 5,5', 6,6', and 7,7' substituted
derivatives thereof wherein the substituent is taken from a group
consisting of dichloro, dibromo, disulfonic acid, diamido, dimethyl,
dicarboxylic acid, and diethoxy; 2-mercaptonaphthiazole;
2,2'-dithiobis(naphthothiazole); diphenyl sulfide; diphenyl disulfide and
di-tert-butyl sulfone, the weight ratio of said phosphate ester to said
sulphur-containing compound being in a range of from about 25:1 to about
1:1 based on the weight of sulphur in said sulphur-containing comoound,
said additive composition containing at least about 0.005% sulphur by
weight, based on the total weight of said additive composition. 2. The
additive composition of claim 1 wherein the ratio of phosphate ester to
sulphur-containing compound is from 10:1 to 1:1 by weight based on the
sulphur content of the sulphur-containing compound and wherein R of the
formula of (a) is selected from the group consisting of a linear alkyl
group having from 6 to 20 carbon atoms, an alkyl phenyl group, the alkyl
group having from 1 to 14 carbon atoms, and phenyl; n is a number from 1
to 10; and X is selected from hydrogen, ammonium, diethanolamine, and
triethanolamine.
3. The composition of claim 2 in which said sulphur-containing compound
comprises 2-mercaptobenzothiazole.
4. The composition of claim 2 in which the sulphur-containing compound
comprises 5-substituted, 6-substituted and 7-substituted
2-mercaptobenzothiazole wherein the substituent is selected from the group
consisting of chloro, bromo, sulfonic acid, amido, methyl, carboxylic
acid, and ethoxy.
5. The composition of claim 2 in which the sulphur-containing compound
comprises 2-mercaptobenzothiazole derivatives having the following
formula:
##SPC7##
wherein X is selected from hydrogen, hydroxymethyl and metals of groups
I-A, I-B, II-A and II-B of the periodic table.
6. The composition of claim 2 in which the sulphur-containing compound
comprises 2,2'-dithiobisthiazole and derivatives thereof having the
following formula:
##SPC8##
wherein R.sub.2, R.sub.3, R.sub.4 and R.sub.5 are selected from the group
consisting of hydrogen and an alkyl group having from 1 to 10 carbon
atoms.
7. The composition of claim 2 in which the sulphur-containing compound
comprises 2,2'-dithiobis(benzothiazole) and 5,5', 6,6', and 7,7'
substituted derivatives thereof wherein the substituent is taken from a
group consisting of dichloro, dibromo, disulfonic acid, diamido, dimethyl,
dicarboxylic acid, and diethoxy.
8. The composition of claim 2 in which the sulphur-containing compound
comprises diphenyl sulfide.
9. The composition of claim 2 in which the sulphur-containing compound
comprises elemental sulphur.
10. The composition of claim 2 in which the sulphur-containing compound
comprises sulphurized mineral oils.
11. An improved metalworking composition comprising:
a. a phosphate ester having the following formula:
##EQU6##
wherein EO is ethylene oxide; R is selected from the group consisting of
linear or branched chain alkyl groups having from 6 to 30 carbon atoms,
phenyl, alkylphenyl, wherein the alkyl groups have a total of from 2 to 20
carbon atoms; X is selected from hydrogen, ammonium, amines and metals
from groups I-A, I-B, II-A and II-B of the periodic table; n is a number
from 0 - 50; a is 1, 2 or 3, and b is 0, 1 or 2 with the proviso that said
a plus said b equals 3;
b. a sulphur-containing compound selected from the group consisting of
elemental sulphur; sulphurized mineral oils; 2-mercaptobenzothiazole;
5-substituted, 6-substituted and 7-substituted 2-mercaptobenzothiazole
wherein the substituent is selected from the group consisting of chloro,
bromo, sulfonic acid, amido, methyl, carboxylic acid, and ethoxy;
2-mercaptobenzothiazole derivatives having the following formula:
##SPC9##
wherein X is selected from hydrogen, hydroxymethyl and metals of groups
I-A, I-B, II-A and II-B of the periodic table; derivatives of
2-mercaptothiazole having the formula:
##SPC10##
wherein X is selected from hydrogen, hydroxymethyl and metals from groups
I-A, I-B, II-A and II-B of the periodic table; R is selected from hydrogen
and an alkyl group having from 1 to 10 carbon atoms; and R.sub.1 is
selected from hydrogen, an alkyl group having from 1 to 10 carbon atoms,
carboxy,
##EQU7##
2. 2'-dithiobisthiazole and derivatives thereof having the following
formula:
##SPC11##
wherein R.sub.2, R.sub.3 R.sub.4 and R.sub.5 are selected from the group
consisting of hydrogen and an alkyl group having from 1 to 10 carbon
atoms, 2,2'-dithiobis(benzothiazole) and 5,5', 6,6', and 7,7' substituted
derivatives thereof wherein the substituent is taken from a group
consisting of dichloro, dibromo, disulfonic acid, diamido, dimethyl,
dicarboxylic acid, and diethoxy; 2-mercaptonaphthothiazole;
2,2'-dithiobis(naphthothiazole); diphenyl sulfide; diphenyl disulfide and
di-tert-butyl sulfone; and
c. an oil based lubricating vehicle, the weight ratio of said phosphate
ester to said sulphur-containing compound being in the range of from about
25:1 to about 1:1 based on the weight of sulphur in said
sulphur-containing compound and said composition containing at least about
0.0015% sulphur by weight, based on the total weight of said metalworking
composition, whereby the metalworking composition has a desirable
combination of extreme pressure, antiwear and corrosion-inhibiting
properties.
12. The metalworking composition of claim 11 wherein the ratio of phosphate
ester to sulphur-containing compound is from 10:1 to 1:1 by weight based
on the sulphur content of the sulphur-containing compound, wherein R is
selected from the group consisting of a linear alkyl group having from 6
to 20 carbon atoms, an alkyl phenyl group, the alkyl group having from 1
to 14 carbon atoms, and phenyl; n is a number from 1 to 10; and X is
selected from hydrogen, ammonium, diethanolamine, and triethanolamine and
in which said composition contains at least about 0.10% sulphur by weight,
based on the total weight of said metalworking composition.
13. The metalworking composition of claim 12 wherein said vehicle is
selected from the group consisting of a mineral oil, a glycol, a mineral
oil-water mixture and a glycol-water mixture.
14. The metalworking composition of claim 13 wherein the vehicle is a
hexylene glycol-water mixture.
15. The metalworking composition of claim 12 in which said
sulphur-containing compound comprises 2-mercaptobenzothiazole.
16. The metalworking composition of claim 13 in which the
sulphur-containing compound comprises 5-substituted, 6-substituted and
7-substituted 2-mercaptobenzothiazole wherein the substituent is selected
from the group consisting of chloro, bromo, sulfonic acid, amido, methyl,
carboxylic acid, and ethoxy.
17. The metalworking composition of claim 13 in which the
sulphur-containing compound comprises 2-mercaptobenzothiazole derivatives
having the following formula:
##SPC12##
wherein X is selected from hydrogen, hydroxymethyl and metals of groups
I-A, I-B, II-A and II-B of the periodic table.
18. The metalworking composition of claim 13 in which the
sulphur-containing compound comprises 2,2'-dithiobisthiazole and
derivatives thereof having the following formula:
##SPC13##
wherein R.sub.2, R.sub.3, R.sub.4 and R.sub.5 are selected from the group
consisting of hydrogen and an alkyl group having from 1 to 10 carbon
atoms.
19. The metalworking composition of claim 13 in which the
sulphur-containing compound comprises 2,2'-dithiobis(benzothiazole) and
5,5', 6,6', and 7,7' substituted derivatives thereof wherein the
substituent is taken from a group consisting of dichloro, dibromo,
disulfonic acid, diamido, dimethyl, dicarboxylic acid, and diethoxy.
20. The metalworking composition of claim 13 in which the
sulphur-containing compound comprises diphenyl sulfide.
21. The metalworking composition of claim 13 in which the
sulphur-containing compound comprises elemental sulphur.
22. The metalworking composition of claim 13 in which the
sulphur-containing compound comprises sulphurized mineral oil.
23. A metalworking process which comprises working metal in the presence of
the metalworking composition of claim 13. |
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Claims |
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Description |
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This invention relates to metalworking compositions and an additive for
such oil-base metalworking and cooling compositions. More particularly,
this invention relates to a metalworking additive comprising a phosphate
ester having the following formula:
##EQU1##
WHEREIN EO is ethylene oxide; R is selected from the group consisting of
linear or branched chain alkyl groups having from 6 to 30 carbon atoms,
phenyl, alkylphenyl, wherein the alkyl group has from 1 to 10 carbon
atoms, and dialkyl phenyl, wherein the alkyl groups have a total of from 2
to 20 carbon atoms; X is selected from hydrogen, ammonium, amines and
metals from groups I-A, I-B, II-A or II-B of the periodic table; n is a
number from 0 to 50; a is a number from 1 to 3, b is a number from 0 to 2,
and a plus b = 3; and a sulphur-containing compound. This invention also
provides a metalworking composition comprising the above additive in a
suitable oil-based vehicle. This invention provides an additive which is
used in compositions for cooling and lubricating surfaces which are in
frictional contact such as those employed in metalworking operations, such
as turning, cutting, drilling, grinding and the like.
Lubricants which have been previously employed in metalworking operations
are of two main types, the mineral oils and the so-called soluble oils,
which are oil and water emulsions prepared from hydrocarbon oils, water
and an emulsifying agent. These prior art lubricants have had many
drawbacks, such as inflammability, operability only at certain cutting
speeds, rusting, poor extreme pressure properties, etc. Although certain
of these prior art lubricant compositions do not have one or more of these
undesirable properties, there are no known lubricant compositions which
have all the desirable properties of the various prior art lubricating
compositions without their corresponding disadvantages and drawbacks.
Briefly, it is found that metalworking lubricant compositions containing
the additive of the present invention have excellent extreme pressure
antiwear and corrosion-inhibiting properties. Metalworking emulsions
containing the additive of this invention also are not inflammable and are
extremely stable.
It is therefore a primary object of this invention to provide an additive
for lubricant cooling compositions which imparts excellent extreme
pressure, antiwear, corrosion-inhibiting and non-inflammable properties to
the metalworking composition.
It is a further object of this invention to provide a metalworking additive
which gives the metalworking composition a low foam profile.
It is a still further object of this invention to provide a metalworking
additive comprising a phosphate ester and a sulphur-containing compound.
It is a still further object of this invention to provide an extreme
pressure and antiwear metalworking composition which is non-inflammable,
low foaming and corrosion resistant.
Still further objects and advantages of the composition of the present
invention will become more apparent from the following more detailed
description thereof.
In accordance with this invention, it has been found that a metalworking
additive comprising a phosphate ester and a sulphur-containing compound
unexpectedly gives metalworking compositions excellent extreme pressure,
antiwear and rust-inhibiting properties. This result was especially
unexpected since the phosphate esters and sulphur-containing compound have
been used singly in prior metalworking lubricating compositions. These
metalworking lubricating compositions had either good extreme pressure
properties or antiwear properties, but not both. Compositions containing
the phosphate esters or sulphur-containing compounds also required the
addition of an anti-rust agent. It is therefore quite unexpected that the
combination of a phosphate ester and a sulphur-containing compound in a
metalworking composition would produce an extreme pressure, antiwear and
corrosion-resistant lubricating composition. As stated above, the
composition of this invention contains a phosphate ester having the
following formula:
##EQU2##
wherein EO, X, n, a and b have the same meanings as above, and a
sulphur-containing compound. Although any of the above phosphate esters
are suitable for use in the composition of this invention, those phosphate
esters are especially preferred wherein R is selected from linear alkyl
having from 6 to 20 carbon atoms, alkylphenyl, wherein the alkyl group has
from 1 to 14 carbon atoms, and phenyl; n is a number from 0 to 10; X is
selected from hydrogen, ammonium, diethanolamine and triethanolamine; and
EO, a and b have the same meanings as above. These compounds may be
produced by methods disclosed in U.S. Pat. Nos. 3,004,056 and 3,004,057.
The sulphur-containing compounds used in the composition of this invention
include elemental sulphur; sulphurized oils, such as lard oil, sperm oil,
cod oil, mineral oil, etc.; 2-mercaptobenzothiazole and derivatives
thereof having the following formula:
##SPC1##
wherein X is selected from hydrogen, hydroxymethyl and metals from Groups
I-A, I-B, II-A or II-B of the periodic table; R is selected from hydrogen
and an alkyl group having from 1 to 10 carbon atoms; R.sub.1 is selected
from hydrogen and an alkyl group having from 1 to 10 carbon atoms,
carboxy,
##EQU3##
2-mercaptobenzothiazole and derivatives having the following formula:
##SPC2##
wherein X has the same meaning as above; substituted 2-mercaptothiazole
compounds, such as:
5-chloro-2-mercpatobenzothiazole,
5-bromo-2-mercaptobenzothiazole,
5-sulfonic acid (sodium salt)-2-mercaptobenzothiazole,
5-amido-2-mercaptobenzothiazole,
5-methyl-2-mercaptobenzothiazole,
7-methyl-2-mercaptobenzothiazole,
5-carboxylic acid-2-mercaptobenzothiazole,
5-ethoxy-2-mercaptobenzothiazole,
6-ethoxy-2-mercaptobenzothiazole,
6-chloro-2-mercaptobenzothiazole, etc.;
2,2'-dithiobis (thiazole) and derivatives thereof having the following
formula:
##SPC3##
wherein R.sub.2, R.sub.3, R.sub.4 and R.sub.5 are selected from hydrogen
and an alkyl group having from 1 to 10 carbon atoms; 2,2'-dithiobis
(benzothiazole) and derivatives thereof such as
5,5'-dichloro-2,2'-dithiobis (benzothiazole), 5,5'-dibromo-2,2'-dithiobis
(benzothiazole), 5,5'-disulfonic acid (sodium salt)-2,2'-dithiobis
(benzothiazole), 5,5'-diamido-2,2'-dithiobis (benzothiazole),
5,5'-dimethyl-2,2'-dithiobis (benzothiazole), 7,7'-dimethyl-2,2'-dithiobis
(benzothiazole), 5,5'-dicarboxylic acid-2,2'-dithiobis (benzothiazole),
5,5'-diethoxy-2,2'-dithiobis (benzothiazole), 6,6'-diethoxy-2,2'dithiobis
(benzothiazole), etc.; polysulfides of the 2-mercaptobenzothiazole
compounds listed above; 2-mercaptonapthothiazole; 2,2'-dithiobis
(naphthothiazole) and polysulfides of 2-mercaptonaphthothiazole and
derivatives of these compounds analogous to the 2-mercaptobenzothiazole
derivatives listed above; diphenyl sulfide and analogues such as
di-n-butyl sulphide, di-sec-butyl sulphide, di-tert-butyl sulphide,
dibenzyl sulphide, etc.; diphenyl disulfide with analogues such as
di-n-butyl disulphide, di-sec-butyl disulphide, di-tert-butyl disulphide,
dibenzyl disulphide, di-octyl disulphide, di-allyl disulphide,
di-n-dodecyl disulphide, etc.; and various sulfones such as di-tert-butyl
sulfone.
Although any of the above sulphur-containing compounds may be used in the
composition of this invention, 2-mercaptobenzothiazole and its
derivatives, elemental sulphur, and the sulphur-containing oils are
preferred.
In general, the additive of this invention contains the phosphate ester and
sulphur-containing compound in a weight ratio of from 23:1 to 1:1 based on
the weight of sulphur in the sulphur-containing compound. The additive of
this invention generally comprises less than 10% by weight of the final
metalworking composition with the only limitation being the final sulphur
content of the composition. The sulphur must comprise at least 0.0015% by
weight of the total weight of the metalworking composition. The upper
limit is dictated primarily by economics, since a large percentage of the
composition of this invention does not appreciably improve the
characteristics of the composition. In general, the preferred additive
contains a weight ratio of from 10:1 to 1:1 with the sulphur content being
at least 0.10% based on the total weight of the composition.
The additive composition of this invention is prepared in the form of an
emulsifiable concentrate by mixing the phosphate ester compounds with a
portion of a suitable vehicle, such as mineral oils, vegetable oils,
animal oils, esters of fatty acids, manufactured oils, cracked
hydrocarbons, etc., with stirring to dissolve the phosphate ester. If the
phosphate ester is to be neutralized, a neutralizing agent is added at
this point. The sulphur-containing compound is dissolved in a suitable
non-ionic surfactant, such as the condensation product of a polyglycol
ether, or an alkylene oxide such as propylene oxide, butylene oxide or
ethylene oxide with an organic compound containing at least 6 carbon atoms
and a reactive hydrogen atom, such as alcohols, phenols, thiols, primary
and secondary amines, carboxylic and sulfonic acids and their amides, and
is added to the phosphate ester-oil mixture. This mixture is then diluted
with a suitable oil-based vehicle to provide a metalworking emulsion
containing from 1 to 30% of the additive mixture.
If the vehicle used is a sulphur-containing oil such as lard oil, sperm
oil, cod oil, etc., a further sulphur-containing compound is not required.
In this instance, the metalworking composition would comprise a mixture of
the phosphate ester and the sulphur-containing oil.
Since the metalworking compositions of this invention are low foaming and
rust-inhibiting, other foam and rust inhibitors are not needed.
The following examples more fully illustrate the additive compositions of
this invention and metalworking fluids containing these additives. These
examples are for the purpose of illustration only and are not intended to
be limiting in any way. In the following examples, all parts and
percentages are by weight.
EXAMPLE 1
An emulsifiable metalworking concentrate was prepared by adding 3.00 g of
the phosphate ester based on oleyl alcohol plus 4 EO and 17.0 g of a 100
SUS solvent refined naphthenic pale oil into a wide mouth jar. This
mixture was stirred at room temperature to dissolve the phosphate ester.
0.70 g of diethanolamine was then added to this mixture, followed by the
addition of 14.0 g of a mixture of 1.0 g of 2-mercaptobenzothiazole
previously dissolved in 13.0 g of a nonionic surfactant (Igepal CO-430).
65.3 g of 100 SUS solvent refined naphthenic pale oil was then added and
this mixture was warmed on a hot plate for 3 to 5 minutes and stirred to
effect complete solution of all components. The concentrate was fluid and
clear on standing at room temperature.
EXAMPLES 2 TO 6
Using the procedure of Example 1, emulsifiable concentrates having the
compositions listed in Table I were prepared.
COMPARATIVE EXAMPLE 1
Following the procedure of Example 1, a concentrate containing no
2-mercaptobenzothiazole was prepared. This concentrate had the following
composition:
3.0 g phosphate ester based on oleyl alcohol
plus 4 EO
13.0 g nonionic (Igepal CO-430)
0.70 g diethanolamine
83.3 g 100 SUS solvent refined naphthenic
pale oil
TABLE I
__________________________________________________________________________
PRODUCT EXAMPLE NO.
2 3 4 5 6
Grams Added
__________________________________________________________________________
Phosphate Ester .sup.(1)
3.0 3.5 3.5 3.0 3.0
Nonionic .sup.(2) 13.0 13.0 13.0 13.0 13.0
Diethanolamine 0.70 0.75 0.75 0.70 0.70
2-mercaptobenzothiazole
1.25 1.0 1.25 0.75 0.50
100 SUS oil 82.1 82.8 82.5 82.6 82.8
__________________________________________________________________________
.sup.(1) The phosphate ester based on oleyl alcohol plus 4 EO
.sup.(2) Igepal CO-430
COMPARATIVE EXAMPLE 2
Using the procedure of Example 1, an attempt was made to prepare a
concentrate containing no phosphate ester. However, the
2-mercaptobenzothiazole was not soluble in a formulation containing 13.0 g
of nonionic (Igepal CO-430) and 86.0 g of 100 SUS oil.
EXAMPLE 7
Seven metalworking emulsions were prepared containing 5% of the
concentrates described in Examples 1 through 6 and Comparative Example 1.
These emulsions were labelled Emulsions 1 through 6 and CE-1 respectively
and had excellent stability, not showing creaming or bottom separation
after standing for 24 hours at room temperature. The pH of these emulsions
varied from 7.0 to 7.45. These emulsions were then subjected to a
rust-inhibiting test, a Shell 4-ball extreme pressure test and a Falex
wear test. The results of these tests, which will be more fully described
below, are shown in Table II.
The rust-inhibiting properties of these metalworking emulsions were tested
by immersing about 10 g of clean cast iron chips in the emulsion for 5 to
10 minutes, after which time the emulsion was drained off and the chips
were placed on a clean 1020 carbon steel panel and allowed to stand for 24
hours in the laboratory atmosphere. The results listed in Table II show
the percentage rust which formed on the chips immersed in each emulsion.
As can be readily seen from the results listed in Table II, those
formulations which were prepared from concentrates containing more than
0.50% of 2-mercaptobenzothiazole were effective in inhibiting rust, while
those containing either less than 0.50% 2-mercaptobenzothiazole or no
2-mercaptobenzothiazole showed significant amounts of rust forming on
these chips. This test clearly shows that the rust-inhibiting properties
of these metalworking emulsions are vastly improved by the addition of
2-mercaptobenzothiazole to the phosphate ester containing composition.
The extreme pressure properties of these emulsions were tested by using the
Shell 4-ball tester, which is the standard testing device for lubricants.
These tests were run at a 100 kg load, 1500 rpm, and room temperature,
using 52100 steel balls. The results of the Shell 4-ball test show that by
adding the 2-mercaptobenzothiazole to the phosphate ester, the extreme
pressure properties of the metalworking emulsion are vastly improved. Even
Emulsion 6, which only contained 0.50% of 2-mercaptobenzothiazole, showed
vastly improved properties over Comparative Example 1, which contained no
2-mercaptobenzothiazole. These tests clearly showed that metalworking
emulsions containing both a phosphate ester and a sulfur-containing
compound, in this case 2-mercaptobenzothiazole, have improved extreme
pressure properties over compositions containing the phosphate ester
alone.
The Falex load tests were run using SAE 3135 steel pins, Rockwell hardness
B-87, 8-10 RMS finish and AISI C-1137 steel V blocks, Rockwell C-20
hardness, 6-8 RMS finish. The load was increased in 250-pound increments,
running 2 minutes at each 250-pound level until failure occurred either by
pin breakage or by failure to maintain torque. The results of this test
show that those metalworking emulsions containing both the phosphate ester
and the sulphur-containing compound were able to withstand far greater
loads than the metalworking emulsion containing only the phosphate ester.
In fact, in some cases the load passed using emulsions containing the
phosphate ester and the sulphur-containing compound were nearly twice as
great as the load passed in Comparative Example 1.
The Falex wear tests were run using the same types of pins and blocks at a
load of 1500 pounds. These tests were run on a 1:3 dilution of the 5%
emulsions and the results listed are the number of teeth required to
maintain the 1500 pound load for fifteen minutes. The fewer teeth required
to maintain a load, the less wear is indicated. As is evident from the
results in Table II, the emulsions containing the combination of the
phosphate ester and more than 0.50% of 2-mercaptobenzothiazole exhibited
performance far greater than those emulsions which had 0.50%
2-mercaptobenzothiazole or less. This test shows the importance of
maintaining the proper ratio of 2-mercaptobenzothiazole to phosphate
ester, since although Emulsion Number 6 contained 2-mercaptobenzothiazole,
it did not contain enough to impart excellent wear resistant properties,
as evidenced by Emulsions Number 1 and 5.
TABLE II
__________________________________________________________________________
Antiwear and Extreme Pressure Testing
__________________________________________________________________________
RUNNING TIME,
Emulsions 1 through 6, Concentrate
CE-1
MINUTES 1 2 3 4 5 6
Shell 4-Ball Scar Diameters, mm, 5% Emulsion
10 0.600
0.650
0.650
0.650
0.575
0.640
1.00
30 0.750
0.775
0.808
0.825
0.750
0.850
Weld
Falex Load Test, 5% Emulsion
LOAD PASSED,
LBS. 4250 4500 3750 4250 3500 3500 2250
Falex Wear Test, 1:3 Dilution of 5% Emulsion
WEAR, NO.
OF TEETH 0 5 12 0 43 Pin Pin
Broke
Broke
__________________________________________________________________________
EXAMPLE 8
Four metalworking concentrates as described below in Table III were diluted
to form a 5% solution with 1:1 hexylene glycol/water mixture. Shell 4-ball
tests were run on these dilute solutions using a 100 kg load, 1500 rpm,
52100 steel balls, at room temperature, and attempts were made to measure
the scar diameters after 10 and 30 minutes running time. In Table III, MBT
stands for 2-mercaptobenzothiazole, DEA stands for diethanolamine, and
phosphate ester stands for the phosphate ester based on oleyl alcohol plus
4 EO. As is evident from the results of Table III, wherein only
concentrate 4 containing the 2-mercaptobenzothiazole and the phosphate
ester yielded scar diameters, since the other three concentrates welded
after from 2 to 9 minutes, a metalworking composition containing both a
sulphur derivative and a phosphate ester exhibits vastly improved extreme
pressure properties.
EXAMPLE 9
Metalworking concentrates containing the various phosphate esters described
in Table IV prepared in a 1:1 mixture of hexylene glycol/water. These
concentrates contained 3.0% of the phosphate ester and 1.0% of
triethanolamine and were diluted to a 5% solution with 19 parts of a 1:1
mixture of hexylene glycol/water.
TABLE III
__________________________________________________________________________
CONCENTRATE
% MBT
% DEA
% Phosphate
Scar Diameter, mm.
NUMBER Ester 10 min.
30 min.
__________________________________________________________________________
1 0.50 Weld
2 0.50 0.70 Weld
3 0.70 3.0 Weld
4 0.50 0.70 3.0 0.625
0.710
__________________________________________________________________________
For each phosphate ester, a concentrate was prepared with
2-mercaptobenzothiazole present in a concentration of 0.50% and without
2-mercaptobenzothiazole (MBT). Shell 4-ball tests were run on these
dilutions and scar diameters were measured after 10 and 30 minutes running
time at a load of 100 kg, 1500 rpm, and room temperature, using 52100
steel balls. Also one run was made in a hexylene glycol/water solution
containing only 0.50% of 2-mercaptobenzothiazole (MBT). The results are
listed in Table IV.
EXAMPLE 10
An emulsifiable metalworking concentrate was prepared by adding 30 g of
phosphate ester based on oleyl alcohol plus 4 EO, 130 g of nonionic
surfactant (Igepal CO-430), 6.8 g of diethanolamine, and 10.0 g of the
zinc salt of 2-mercaptobenzothiazole. This mixture was heated with
stirring to 120.degree.C until a clear solution was obtained. Then 8232 g
of 100 SUS solvent refined naphthenic pale oil was added and the mixture
was stirred until uniform and allowed to cool to room temperature, giving
a clear, stable, emulsifiable concentrate. A 5% emulsion of this
concentrate showed no creaming or bottom separation after standing for 24
hours at room temperature. Shell 4-ball tests and Falex load tests were
run on the 5% emulsion of this concentrate and a similar concentrate
containing no zinc salt of 2-mercaptobenzothiazole. The Falex wear tests
were run on a 1:3 dilution of the 5% emulsion. The resulting data are
listed in Table V.
TABLE IV
__________________________________________________________________________
Antiwear Performance of Various Phosphate Esters
with MBT (2-mercaptobenzothiazole)
Phosphate Ester Shell 4-Ball Performance Scar Diameter, mm
Moles EO per
WITH MBT WITHOUT MBT
Base Mole of Base
10 min.
30 min.
10 min.
30 min.
__________________________________________________________________________
Dodecylphenol
1.8 0.645 0.825 0.613 Weld
Dinonylphenol
7.0 0.846 1.00 0.754 Weld
Dinonylphenol
9.6 0.833 0.900 0.733 Weld
Phenol 6.0 0.908 0.971 Weld
Tridecyl alcohol
3.0 0.679 0.896 Weld
No phosphate ester
Weld
__________________________________________________________________________
TABLE V
______________________________________
Antiwear-EP Performance of a Phosphate Ester
Plus the Zinc Salt of 2-Mercaptobenzothiazole
Test Performance Results
Test With Zn-MBT Without Zn-MBT
______________________________________
Shell 4-Ball, Scar Dia., mm
With Zn-MBT Without Zm-MBT
______________________________________
10 min. 0.600 0.950
30 min. 0.800 Weld
Falex Load, lbs. 3250 2000
Falex Wear, No. of Teeth
0 Pin Broke
______________________________________
As illustrated by the results shown in Table V, the combination of a
phosphate ester and a zinc salt of a sulphur compound produced
satisfactory results. The concentration containing both the phosphate
ester and the zinc salt was also tested for rust inhibition as described
in Example 7. After 24 hours, no rust was observed on chips treated with
the metalworking fluid containing both the phosphate ester and the zinc
salt of 2-mercaptobenzothiazole, while rusting was observed on the chips
immersed in the fluid containing no sulphur-containing compound.
EXAMPLE 11
Concentrates containing no oil were prepared by blending 16.9 g of
phosphate ester, 73.4 g of a nonionic surfactant (Igepal CO-430), 4.07 g
of diethanolamine, and 5.64 g of either 2-mercaptobenzothiazole or its
zinc salt and heating to about 100.degree.- 120.degree.C with stirring. A
clear, stable concentrate was formed which was readily dilutable with oil
to form an emulsifiable concentrate and yielded metalworking emulsions
having properties identical with those previously described.
EXAMPLE 12
An oil-base metalworking fluid was prepared by adding to the base oil 0.50%
of the phosphate ester based on oleyl alcohol plus 4 EO and 0.10%
elemental sulphur. This fluid was tested as above and gave a Falex load of
4250 pounds, and Shell 4-ball scar diameters of 0.596 mm for at least 10
minutes and 0.693 mm for at least 30 minutes.
A similar fluid was prepared containing only 0.50% of the phosphate ester.
This fluid yielded a Falex load of only 1750 pounds and scar diameters of
0.588 mm (10 minutes) and 0.696 mm (30 minutes) were measured. A similar
fluid was also prepared containing only 0.10% elemental sulphur. This
fluid yielded a Falex load of only 1000 pounds and a scar diameter of
greater than 1.0 mm after 10 minutes running time. From these results, it
is apparent that the combination of the phosphate ester with the elemental
sulphur gave a great improvement in the Falex load carrying capacity of
the metalworking fluid.
EXAMPLE 13
An oil-base metalworking fluid was prepared by adding to the oil base 0.50%
of the phosphate ester based on oleyl alcohol plus 4 EO and 0.10% dibenzyl
disulfide. This oil passed a Falex load of 2250 pounds while the fluid
containing only 0.10% dibenzyl disulfide passed a Falex load of only 500
pounds, showing again that improvement was obtained when a combination of
a phosphate ester and a sulphur-containing compound was used.
EXAMPLE 14
An emulsifiable metalworking concentrate was prepared by adding 60 g of 100
SUS solvent refined pale oil, 6.7 g of the phosphate ester based on oleyl
alcohol plus 4 EO, 10 g of sulphurized sperm oil containing 11.5% sulphur,
10 g of nonionic surfactant (Igepal CO-430) and 13.3 g of nonionic
surfactant (Triester of oleyl plus 7 EO).
A similar concentrate was prepared in which the sulphurized sperm oil was
omitted and in its place, an additional 10 g of 100 SUS solvent refined
pale oil was used. Both these concentrates were clear and stable and 5%
emulsions prepared from these concentrates were also stable, showing no
creaming or bottom separation in 24 hours standing at room temperature.
Shell 4-ball tests and Falex load tests were run on these 5% emulsions and
Falex wear tests were run on 1:10 dilutions of the 5% emulsion. The tests
were run under the same conditions as those described previously and the
results are shown in Table VI below.
EXAMPLE 15
An emulsifiable metalworking concentrate was prepared by adding 7.0 g of
100 SUS solvent refined naphthenic pale oil, 1.0 g of the phosphate ester
prepared from oleyl alcohol plus 4 EO, 1.0 g of annonionic emulsifier
(Igepal CO-430), and 1.0 g of a sulphurized sperm oil containing 11.5%
sulphur to a bottle, warming for 3 to 5 minutes with shaking to give a
clear, stable concentrate. A 5% emulsion was prepared by diluting this
concentrate with tap water. This emulsion was stable, showing no
separation after 24 hours at room temperature. Falex wear tests were run
on a 1:10 dilution of this 5% emulsion at a jaw load of 1500 pounds and
gave zero teeth wear.
TABLE VI
______________________________________
Performance of Phosphate Ester with Sulphurized Sperm Oil
Performance
With Without
Sulphurized Sulphurized
Test Sperm Oil Sperm Oil
______________________________________
Shell 4-Ball
Scar Diameter, mm
10 min. 0.617 0.650
30 min. 0.775 0.825
Falex Load
Load passed, lbs.
4250 4000
Falex Wear
No. of Teeth
18 200
______________________________________
when a similar formulation was prepared omitting the sulphurized sperm oil,
the pin broke after 6 minutes at 1500 pounds in the Falex wear test,
demonstrating the superior performance of the combination of products.
EXAMPLE 16
An emulsifiable metalworking concentrate was prepared by adding 6.4 g of a
100 SUS solvent refined naphthenic pale oil, 2.0 g of the phosphate ester
based on dinonylphenol plus 9.6 EO, and 1.6 g of a sulphurized sperm oil
containing 11.5% sulphur to a bottle. The mixture was warmed slightly and
stirred to effect complete solution. A clear, stable concentrate was
obtained and a 5% emulsion of this concentrate in tap water was very
stable, showing no separation after 24 hours. A Falex wear test was run on
a 1:10 dilution of the 5% emulsion. Zero teeth wear was obtained during 15
minutes at a 1500 pound jaw load. A similar formulation, prepared without
the sulphurized sperm oil, broke the pin in a Falex wear test after 11
minutes at 1500 pounds.
EXAMPLE 17
An emulsifiable metalworking concentrate was prepared without a phosphate
ester present by adding 3.0 g of sulphurized sperm oil, 3.0 g of a
petroleum sulfonate (Petromix No. 9), 3.0 g of a nonionic emulsifier
(Igepal CO-430) and 21.0 g of a 100 SUS solvent refined naphthenic pale
oil to a bottle. The concentrate formed an excellent, stable 5% emulsion.
However, in a Falex wear test on a 1:10 dilution of the 5% emulsion, 116
teeth wear were observed in 15 minutes at a jaw load of 1500 pounds.
Comparison of the results of this example with those of Examples 15 and 16
demonstrates that both the phosphate ester and sulphur-containing product
must be present in the metalworking formulation to obtain excellent
antiwear properties.
EXAMPLE 18
A commercially available sulphurized cutting oil containing 3/4 to 1%
sulphur was evaluated on the Shell 4-ball tester and Falex machine. The
balls welded after about 2 minutes at a load of 160 kg, 1500 rpm, using
52100 steel balls in the Shell 4-ball tester. A Falex load of 4250 pounds
was attained; the wear was 264 teeth in a Falex wear test at 1000 pounds
jaw load. When 0.5% of the phosphate ester prepared from oleyl alcohol
plus 4 EO was added to the oil, the Shell 4-ball scar diameters were 0.709
mm after 10 minutes running at 160 kg load and 0.850 mm after 30 minutes.
When 1.0% of the same phosphate ester was added, the Falex wear at 1000
pounds was zero teeth; the pin showed no discoloration and was very
smooth. Both tests showed, therefore, great improvement in wear
performance upon addition of the phosphate ester to the sulphurized oil.
Also, when 1.0 % of the phosphate ester and 1.0% of a t-C.sub.18 H.sub.37
NH.sub.2 to t-C.sub.22 H.sub.45 NH.sub.2 amine (Primene JMT) were added,
the Falex load increased to 4500 pounds and the Falex wear was zero teeth.
EXAMPLE 19
A metalworking oil was formulated by adding 1.0 g of the ammonium salt of
the phosphate ester based on oleyl alcohol plus 4 EO to 99.0 g of a
sulphurized mineral oil containing 3/4 to 1% sulphur. The oil passed 4500
pounds jaw load without failure in the Falex load test, while the oil
without the ammonium salt of a phosphate ester failed at 4250 pounds.
EXAMPLE 20
A metalworking oil was formulated by adding 1.0 g of the monoethanolamine
salt of the phosphate ester of oleyl alcohol plus 4.0 EO to 99.0 g of a
sulphurized mineral oil. The formulated oil passed 4500 pounds jaw load
without failure while the oil without the amine salt of the phosphate
ester failed at 4250 pounds and developed 10 pounds higher torque.
EXAMPLE 21
Three emulsifiable concentrates were prepared containing the components at
the concentrations shown in Table VII.
Emulsions were prepared containing 5% concentrate in 60 ppm tap water and
tested for frothing according to Federal Specification VV-C-846a, Method | | |
