1、The BMW PartnershipDry Film Lubricants08.03.2005Presentation of the Castrol “Dry Film project atBMW, Oxford (UK)History of Steel Mill Applied LubricantsCORROSION PREVENTIVES DRY FILMLUBRICANTS BASEDON POLYMER2. GENERATIONPRELUBESSEMIDRY FILMLUBRICANTSTHIXOTROPICCORROSIONPREVENTIVESPRELUBES2. GENERAT

2、IONTHIXOTROPICCORR.PREVENTIVESDRY FILMLUBRICANTS BASED ON PARAFFINDRY FILMLUBRICANTS BASED ON WAX DISPERSIONDRY FILMLUBRICANTS BASED ON ESTER1990199620002001Advantages of the Dry Film Technology Superior lubrication Multisubstrate compatibility including aluminum Dry-to-the-touch film Reduced quanti

3、ties applied Mechanical surface protection Clean working environmentTypes of Dry Film LubricantsEsterMineral oil basedHot meltPolymerOrganic solvendbasedWater basedVOCEnergyTypes of Dry Film Lubricants Semi Dry Film Lubricants- Greasy- Konus Penetration appr. 20 mm Dry Film Lubricants- Lacqueur or w

4、axy- Needle Penetration 300 CComputerised calculation of the friction coefficient Quick change of material, lubricant and coating weight possible Flat Die RigDrawing IFlat Die RigDrawing IITest Facility at the University of Waterloo (CAN)“Flat Die Rigg modified 80 t pressDry Film Lubricant on differ

5、ent materials Flat Die Test Station - University of WaterlooResults of Iloform PN 950 DF acc. VDA 230-201Force limit set to 400 kNThe maximum force was limites during the tests due to safety reasons (40 N/mm). In general an maximum forde of 75 N/mm is possible by respecting the VDA parameters.During

6、 the test, no stick-slip were seen for Castrol Iloform PN 950 DF. V = const.Mineral oil based Dry Film LubricantsPrelubes*Conventional Prelubes (mineral oil based)Dry Film Lubricant on Bare SteelTest Results Iloform PN 950 DF analog VDA 230-201Maximum normal force was only limited by the setting of

7、the test equipment, after adjusting this setting we will be capable to perform tests up to 75 N/mm.During our preliminary testing no stick-slip was observed. Dry Film Lubricant on Electrogalvanized Material Test Results Iloform PN 950 DF analog VDA 230-201Maximum normal force was only limited by the

8、 setting of the test equipment, after adjusting this setting we will be capable to perform tests up to 75 N/mm.During our preliminary testing no stick-slip was observed. Dry Film Lubricant on Hot-dip Galvanized Material Test Results Iloform PN 950 DF analog VDA 230-20Maximum normal force was only li

9、mited by the setting of the test equipment, after adjusting this setting we will be capable to perform tests up to 75 N/mm.During our preliminary testing no stick-slip was observed. Dry Film Lubricant on Galvanealed Material Test Results Iloform PN 950 DF analog VDA 230-20Maximum normal force was on

10、ly limited by the setting of the test equipment, after adjusting this setting we will be capable to perform tests up to 75 N/mm.During our preliminary testing no stick-slip was observed. Dry Film Lubricant on Aluminum Test Results Iloform PN 950 DF analog VDA 230-20Maximum normal force was only limi

11、ted by the setting of the test equipment, after adjusting this setting we will be capable to perform tests up to 75 N/mm.During our preliminary testing no stick-slip was observed. Influence of Die Temperature on Friction CoefficientIloform PN 950 DF on Electrogalvanized MaterialFriction coefficient

12、determined at 400 mm/s drawing speedRemovability Test Iloform PN 950 DFacc. to VDA 230-201 and Renault SpecificationSubstratebare steelelectrogalv. hot-dip galv.galvannealedRenault Spec./Sollac-TestpassedpassedpassedpassedSubstrate bare steelelectrogalv. hot-dip galv.galvannealedVDA-Testpassedpassed

13、passedpassedAdhesive CompatibilityTesting according to VDA 230-201AdhesiveIloform DFXW 1185Epoxy (GEX)all substrates o.k.Terostat 3216Rubber (Henkel)all substrates o.k.Terokal 8552PVC (Henkel)all substrates o.k.Cataphoretic Dip Paint Compatibility according to VDA 230-202 - Iloform PN 950 DFTypeCrat

14、erPPGEnviroprime0PPGEnviroprime 20000Source: PPGIloform PN 950 DF Dry Film LubricantAppearance white, solidViscosity at 20 C solidViscosity at 50 C 34 mm/sFlash point 20 CyclesSalt spray test ASTM B-117 24 hOpen shed storage min. 12 monthIndoor storage min. 18 monthViscosity Temperature Chart Castro

15、l Dry Film Lubricant: Iloform PN 950 DFTrialsDry Film Lubricant Iloform PN 950 DFCase Studies 1/1 Electrolux Home Products - Swainsboro, GA May 2002Lawnmower decks, part # 4055IF and 404blank size 807x1000 x1.9 and 825x750 x1.9 mm, bare steel sheet metalcoating weight variable 1.6 6.0 g/m, prepared

16、by electrostatic spraying (Gencoat) 200 parts successfully produced and assembledca. 750 mmca. 160 mmProfile of the pressing partElectrolux Home Products, Swainsboro, GADry Film Lubricant Iloform PN 950 DFCase Studies 1/2 Electrolux Home Products - Swainsboro, GAOctober 2003Lawnmower decks Hi-Vac“bl

17、ank size 825 x 750 x 1.9 mm, bare steel sheet metalcoating weight variable appr. 2.0 g/m, prepared manual Extreme difficult part, due to the high failure rate it is called internally 50:50 deckResult: Fail rate with Castrol Dry Film technology reduced to 0“Dry Film Lubricant Iloform PN 950 DFCase St

18、udies 2/1ca. 600 mmca. 300 mm Profile of the pressing partElectrolux Home Products, Swainsboro, GADry Film Lubricant Iloform PN 950 DFCase Studies 2/2Dry Film Lubricant Iloform PN 950 DFCase Studies 2/3 Picture Ford Stamping Plant - Saarlouis, Germany June 2003Inner-body side panel, Focus 3-door hat

19、chback blank size 1525x3475x0.75 mm, hot-dip galvanized sheet metalcoating weight 1.2 1.4 g/m, prepared by electrostatic spraying (ThyssenKrupp Stahl Neuwied, spray equipment FaraTechnology) 500 parts successfully produced and assembledDry Film Lubricant Iloform PN 950 DFCase Studies 3/1Dry Film Lub

20、ricant Iloform PN 950 DFCase Studies 3/2 - PictureMetal sheets dry-to-the-touchNo particle contaminationNo problems in the de-stacking processOnly slight modification of the clamp force was necessary in the beginningMain trial 550 o.K. partsUsage of the parts without problemsDry Film Lubricant Ilofo

21、rm PN 950 DFCase Studies 3/3AUDI Stamping Plant - Ingolstadt, GermanyJune 2003Inner-door panel, A4 Blank size appr. 1525x1735x0.75 mm, hot-dip galvanized sheet metalCoating weight 1.2 1.4 g/m, prepared by electrostatic Spraying (ThyssenKrupp Stahl Neuwied, spray equipment FaraTechnology)30 parts suc

22、cessfully produced and passed througt the additional processes (cleaning, phosphating and painting o.K.)Dry Film Lubricant Iloform PN 950 DFCase Studies 4/1Metallwerk Hofmaninger, Austria“Pre trial: Pressing of a concete mixer partDry Film Lubricant Iloform PN 950 DFCase Studies 5/1Dry Film Lubrican

23、t Iloform PN 950 DFCase Studies 5/2 - Picture190 mm390 mm 578 mmpart: concrete mixerMetall sheet: 960 x 1 mmDry Film Lubricant Iloform PN 950 DFCase Studies 5/3 - DrawingA spayable alternative for the current product Castrol Iloform PS 158“.Due to the amount of solid additives the application of thi

24、s 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 punchFurther actions: Trials with a defined pr

25、oduct amount to evaluate the minimum dry film quantity for a safe process.Dry Film Lubricant Iloform PN 950 DFCase Studies 5/4 Ford Stamping Plant - Saarlouis, Germany December 2004Inner wheel house for the back wheel, C-MAX galvanealed sheet metal, coating weight 0.6 1.4 g/m (not homogenous), prepared by air spray (ARCELOR Flemalle), difficult operation need for the conventional production with oil a amount of 5g/m1000 parts successfully produced (no fail part, very clean tools without any deposits)Dry Fil