Dry Film Technology

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Dry Film Technology

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Project Coil
History of Steel Mill Applied Lubricants
DRY FILM LUBRICANTS BASED ON POLYMER
CORROSION PREVENTIVES
THIXOTROPIC CORROSION PREVENTIVES
1990
PRELUBES
DRY FILM LUBRICANTS BASED ON WAX DISPERSIONS
1996
2. GENERATION PRELUBES
2. GENERATION THIXOTROPIC CORR.PREVENTIVES
DRY FILM LUBRICANTS BASED ON PARAFFIN
2000
2001
SEMI DRY FILM LUBRICANTS
DRY FILM LUBRICANTS BASED ON ESTER
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RD Demands for Dry Film Lubricant Design

• Significantly improved drawing performance
  compared to pre-lubes
• Application with existing electrostatic spray
  equipment
• Compatibility with existing and future
  electro-coat systems
• Sealer and adhesive compatibility
• One product for steel and aluminium
• Environmentally friendly

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Typical Coefficients of Friction
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Castrol Dry Film Lubricant Iloform PN 950 DFR
K Tester Cup Drawing Test, Substrate ZE
highly chlorinated Spotlubricant
Dry Film Lubricant
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VDA Flat Die Test
Benchmarking of Dry Film Lubricants determines
max clamp force FN , friction coefficient µ and
appearance of stick slip FN 4 24 N/mm² Drawing
speed 50 mm/s Contact surface 10000 mm² Stroke 98
mm
FN
FZ

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Flat Die Test RigUniversity of Waterloo
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Flat Die Test RigUniversity of Waterloo
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Dry Film Lubricant Drawing Performance Flat Die
Test Station - University of Waterloo
Load limit momentarily set to 400 kN, shut-off
during trial
Prelubes

Semi-synthetic
Prelubes
Paraffinbasische Dry Film Lubricants
Conventional mineral oil based Prelubes
Experimental Products
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Dry Film Lubricant on Electrogalvanized Material
Flat Die Test Station - University of Waterloo
Load limit momentarily set to 400 kN, shut-off
during trial
Maximum normal force was only limited by the
setting of the test equipment, after adjusting
this setting we will be capable to perform tests
up to 75 N/mm². During our preliminary testing no
stick-slip was observed.
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Dry Film Lubricant on Hot-dip Galvanized Material
Flat Die Test Station - University of Waterloo
Load limit momentarily set to 400 kN, shut-off
during trial
Maximum normal force was only limited by the
setting of the test equipment, after adjusting
this setting we will be capable to perform tests
up to 75 N/mm². During our preliminary testing no
stick-slip was observed.
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Dry Film Lubricant on Galvannealed Material Flat
Die Test Station - University of Waterloo
Load limit momentarily set to 400 kN, shut-off
during trial
Maximum normal force was only limited by the
setting of the test equipment, after adjusting
this setting we will be capable to perform tests
up to 75 N/mm². During our preliminary testing no
stick-slip was observed.
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Dry Film Lubricant on Bare SteelFlat Die Test
Station - University of Waterloo
Load limit momentarily set to 400 kN, shut-off
during trial
Maximum normal force was only limited by the
setting of the test equipment, after adjusting
this setting we will be capable to perform tests
up to 75 N/mm². During our preliminary testing no
stick-slip was observed.
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Dry Film Lubricant on Aluminum Flat Die Test
Station - University of Waterloo
Load limit set to 400 kN, shut-off during trial
Maximum normal force was only limited by the
setting of the test equipment, after adjusting
this setting we will be capable to perform tests
up to 75 N/mm². During our preliminary testing no
stick-slip was observed.
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Advantages of Electrostatic Spray Application

• Application Technology for Steel Mill Applied
  Corrosion Preventives, Pre-lubes and Dry Film
  Lubricant

• Reliable and even coating
• Consistency
• Uniform and precise edge-to-edge coverage
• Wide range of possible coating weights, usually
  0.5 3.5 g/m²
• Minimized misting
• No contact to the steel surface
• No wear and tear of application rollers
• Significant savings on coating materials

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Electrostatic Spray Application Principle
Function
1 reservoir 2 filter (10 40 µ) 3 supply lines 4
spray bar 5 housing 6 return line
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Electrostatic Spray Application Types of Spray
Bars
standard spray bar
fixed spray width
segment spray bar
TOTALSTAT spray bar
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Atomization at Electrostatic Spraying in
dependence of the film weight

very fine
fine
coarse
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Electrostatic Spray Application

• Castrol steel mill applied corrosion preventives,
  pre-lubes and dry film lubricants are designed to
  be applied by common electrostatic spray
  equipment.
• Examples are
• DUMA Maschinen- und Anlagenbau GmbH
  Duisburg, Germany
• Fara Technology PLC Ripley, GB
• GFG - Sussex, Wisconsin, USA
• (Peabody Electrostatic Coating Systems)
• SMR de Haan Oberhausen, Germany
• Ravarini Castoldi C. srl
• Divisione Elettrospray Milano, Italy
• United Air Specialist INC. Cincinnati, Ohio,
  USA
• (TOTALSTAT Electrostatic Liquid Coating
  Systems)

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Spray Application withNordson Air-Assisted
Airless GunNordson, Amherst Ohio - May 2003
Iloform PN 950 DF
Product temperature 170 180 F Fluid
pressure 700 PSI Coating weights 150 and 200
mg/sqf Atomization very fine Surface
wetting good on all substrates Substrates bare
steel electrogalvanized dto.
phosphatized hot-dip galvanized galvannealed
increased temperature was necessary because
of non-heated nozzle at test spray gun
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Air-assisted Airless Applikation von Dry Film
Lubricants
2
3
Temperatures at/of the im System 1 reservoir
Smp. 20-30C 2 supply lines Smp 20C 3
spray bar Smp 20C 4 pressure air? Druckluft
RT
3
2
1
4
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Demands on Corrosion Preventive Oils and
Mill Applied Lubricants

• Corrosion protection for storage and transport
  min. 6 months
• Secure protection under severe climate conditions
• Multi-substrate compatibility
• Defined and even application with electrostatic
  spray equipment
• Stability against aging
• Compatibility with car manufacturing process
• No negative influence on welding process
• Compatibility with adhesives and sealers
• Compatibility with cathaphoretic dip paints
• Readily removable after storage (3 months) and
• temperature treatment (180C 20 min)

• Run-off retardation
• Aromatic content of base oil gt 10
• No barium or other heavy metals
• No solvents or volatile components
• Excellent lubrication for sheet metal forming
  (Pre-lubes and Dry Film Lubricants only)

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Sealer and Adhesive Compatibility
Adhesive used on coating with
Oil, compatible
Dry Film, Acrylate
Dry Film, Paraffin
Dry Film, Ester
after application
after curing
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Adhesive CompatibilityTesting according to VDA
230-201
Adhesive Iloform DF
XW 1185 Epoxy (GEX) all substrates o.k.
Terostat 3216 Rubber (Henkel) all substrates o.k.
Terokal 8552 PVC (Henkel) all substrates o.k.
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Removability Test VDA 230-201 GM 0401271 und
Renault-Norm Iloform PN 950 DF
Substrate bare steel electro-galvanized hot-dip galvanized galvannealed
VDA-Test not part of test procedure passed passed passed
GMB0401271 passed passed not part of test procedure not part of test procedure
Renault-Norm/ Sollac-Test passed passed passed passed
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Electrocoat Compatibility according to VDA
230-201 revisedIloform PN 950 DF
Type Crater
PPG Enviroprime 0
PPG Enviroprime 2000 0
Source PPG
Source PPG
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Viscosity Temperature Chart Castrol Dry Film
Lubricant Iloform PN 950 DF
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Manufacturing ProcessOverview of steps with cost
saving potential
1
4
3
2
BLANK CUTTING
COIL WASHING
BLANK WASHING
SHEET METAL FORMING
LUBRICATING
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ASSEMBLY
INTERMEDIATE WASHING
TOP COAT
CATHAPHORETIC DIP PAINT
PHOSPHATIZING
WASHING
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Dry Film Lubricant Iloform PN 950 DF Case
Studies

• Audi Stamping Plant Ingolstadt, Germany
• June 2003
• inner door panel Audi A 4,
• blank size 1525 x 550 x 0.75 mm,
• hot-dip galvanized material,
• coating weight 1.2 1.4 g/m²,
• Electrostatically applied (Fara Technology)
• Thyssen Krupp Stahl Neuwied
• 30 parts produced successfully

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Dry Film Lubricant Iloform PN 950 DFCase Studies

• Electrolux Home Products, Swainsboro, GA
• May 2002
• lawnmower deck, parts 4055IF and 404,
• blank size 807 x 1000 x 1.9 and 825 x 750 x 1.9
  mm,
• bare steel sheet metal,
• coating weight variable 1.6 6.0 g/m³,
• prepared by electrostatic spraying (Gencoat)
• 200 parts successfully produced and assembled

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Dry Film Lubricant Iloform PN 950 DF Case
Studies

• Electrolux Home Products, Swainsboro, GA
• October 2003
• hi-vac lawn mower deck,
• blank size 825 x 750 x 1.9 mm,
• bare steel sheet metal,
• coating weight variable 2.0 g/m², manually
  applied
• extremely critical drawing part, due to a
  high scrap rate
• also known as 50 50 deck

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Dry Film Lubricant Iloform PN 950 DFCase Studies

• Ford Stamping Plant Saarlouis, Germany
• June 2003
• inner body side panel, Focus 3-door
  hatchback,
• blank size 1525 x 3475 x 0.75 mm,
• hot-dip galvanized sheet metal,
• coating weight 1.2 1.4 g/m²,
• prepared by electrostatic spraying
• (ThyssenKrupp Stahl Neuwied, spray equipment
• FaraTechnology)
• 500 parts successfully produced and assembled

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Dry Film Lubricant Iloform PN 950 DFCase
Studies

• Electrolux Home Products - Swainsboro, GA
• May 2002
• Lawnmower decks, part 4055IF and 404
• blank size 807x1000x1.9 and 825x750x1.9 mm,
  bare steel sheet metal
• coating weight variable 1.6 6.0 g/m²,
  prepared by electrostatic
• spraying (Gencoat)
• 200 parts successfully produced and assembled

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Dry Film Lubricant Iloform PN 950 DF Trials
Electrolux Home Products, Swainsboro, GA
Profile of the pressing part
ca. 160 mm
ca. 750 mm
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Dry Film Lubricant Iloform PN 950 DF Trials 2

• Electrolux Home Products - Swainsboro, GA
• October 2003
• Lawnmower decks Hi-Vac
• blank size 825 x 750 x 1.9 mm, bare steel
  sheet metal
• coating weight variable appr. 2.0 g/m²,
  prepared manual
• Extreme difficult part, due to the high failure
  rate it is called internally 5050 deck

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Dry Film Lubricant Iloform PN 950 DF Trials
Electrolux Home Products, Swainsboro, GA
Profile of the pressing part
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Advantages of the Dry Film Technology

• superior lubrication
• multisubstrate compatibility including aluminum
• dry-to-the-touch film
• reduced quantities applied
• mechanical surface protection
• clean working environment
• significant cost savings

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Iloform PN 950 DF Dry Film Lubricant
Appearance white, solid Viscosity at 20
C solid Viscosity at 50 C 34
mm²/s Flash point lt 200 C Corrosion
protection Condensation climate chamber DIN 51
386-1 gt 20 Cycles Salt spray test ASTM
B-117 gt 24 h Open shed storage min.
12 month Indoor storage min. 18 month
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Possible Cost Savings Dry Film Technology

• eliminates coil and blank washing for many parts
• no cost for blank or coilwash fluids
• reduced maintenace cost
• reduced houseceeping
• less tool maintenancequantities applied
• no disposal of used product
• no cost for additional spot lubricants
• reduced tool maintenance cost
• no intermediate washing operations
• no cleaner cost
• no equipment maintenance
• no disposal of used cleaner fluid
• potential to use lower cost steel

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Dry Film Lubricant Iloform PN 950 DFCase
Studies

• Ford Stamping Plant - Saarlouis, Germany
• June 2003
• Inner-body side panel, Focus 3-door hatchback
  
• blank size 1525x3475x0.75 mm, hot-dip
  galvanized sheet metal
• coating weight 1.2 1.4 g/m², prepared by
  electrostatic
• spraying (ThyssenKrupp Stahl Neuwied, spray
  equipment
• FaraTechnology)
• 500 parts successfully produced and assembled

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Dry Film Lubricant Iloform PN 950
DFPraxisversuche

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Dry Film Lubricant Iloform PN 950 DFCase Study 1
- Result

• Metal sheets dry-to-the-touch
• No particle contamination
• No problems in the de-stacking process
• Only slight modification of the clamp force was
  necessary in the beginning
• Main trial 550 o.K. parts
• Usage of the parts without problems

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Dry Film Lubricant Iloform PN 950 DFCase Study 2

• AUDI Stamping Plant - Ingolstadt, Germany
• June 2003
• Inner-door panel, A4
• Blank size appr. 1525x1735x0.75 mm, hot-dip
  galvanized sheet metal
• Coating weight 1.2 1.4 g/m², prepared by
  electrostatic
• Spraying (ThyssenKrupp Stahl Neuwied, spray
  equipment FaraTechnology)
• 30 parts successfully produced and passed througt
  the additional processes (cleaning, phosphating
  and painting o.K.)

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Dry Film Lubricant Iloform PN 950 DFCase Study 3

• Metallwerk Hofmaninger, Austria
• Pre trial Pressing of a concete mixer part

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Drawing of the part
390 mm
190 mm
Ø 578 mm

• part concrete mixer
• Metall sheet 960 x 1 mm

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Data for pre trial

• A spayable alternative für the current product
  Castrol Iloform PS 158.
• Due to the amount of solid additives the
  application of this the product could only be
  made manually via roller or brush.
• Material 1,0 mm DC 03 of voestalpine
• The application in this pretrial was made manual
  by brush without measuring the film thickness,
  therfore we do not have any information about
  this fact.
• 1 punch
• Further actions Trials with a defined product
  amount to evaluate the minimum dry film quantity
  for a safe process.

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Dry Film Lubricant Iloform PN 950 DFCase
Studies 4

• Ford Stamping Plant - Saarlouis, Germany
• December 2004
• Inner wheel house for the back wheel, C-MAX
  galvanealed sheet metal, coating weight 0.6 1.4
  g/m² (not homogenous), prepared by air spray
  (ARCELOR Flemalle), difficult operation need for
  the conventional production with oil a amount of
  gt 5g/m²
• 1000 parts successfully produced (no fail part,
  very clean tools without any deposits)

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Dry Film Lubricant Iloform PN 950 DFCase
Studies 5

• VW Stamping Plant - Emden, Germany
• January 2005
• Inner panel for the Passat door, HDG tailored
  blank (thickness 0.7 and 1.6 mm)
• Coating weight (application manually with a spray
  gun)
• 0.9 - 1.2 g/m² - comparison with competitor
  products
• 10 parts successfully produced during the normal
  production process with the adjustments used for
  the normal oil lubrication
• Result no breaks were seen / only slight
  waviness occured (no product problem, adjustments
  of the tool forces are necessary)
• 10 parts are ready for the adjustment trials in
  the Try-Out-Press in the future