Lubricant for metal cold forming processes and methods of use of the same

A method of coating a metal with a lubricant prior to cold forming the metal comprising the steps of:

• a) providing a lubricant consisting essentially of one or more lubricating compounds selected from the group consisting of a soap that is a metal salt of a C6 to C22 fatty acid, a soap that is a metal salt of a C6 to C22 fatty acid containing one or more hydroxyl function groups, boric acid, a metal salt of boric acid, boron nitride, zinc oxide, calcium oxide, molybdenum disulfide, an emulsion of polyethylene, an emulsion of high density polyethylene, an emulsion of polypropylene, an emulsion of maleated polypropylene, an emulsion of a urethane, an emulsion of an oxidized polyethylene, an emulsion of an oxidized high density polyethylene, an emulsion of an oxidized polypropylene, an emulsion of an oxidized maleated polypropylene, an emulsion of an oxidized urethane, and mixtures thereof and one or more starches, wherein a weight:weight ratio of a total amount of the one or more lubricating compounds to a total amount of the one or more starches in the lubricant is in a range of from 1:1 to 8:1, the lubricant, optionally, including at least one additional component selected from the group consisting of a surfactant, a corrosion inhibitor, a processing aid, a bactericidal agent, a bacteriostatic agent, a fungistatic agent, a fungicidal agent, a defoaming agent, a viscosity modifier, a pH buffering agent, or mixtures thereof, wherein a total amount of the at least one additional component does not exceed 5% by weight based on a total weight of the lubricant and wherein the lubricant is a solid at 75° F.;
• and
• b) applying the lubricant to a surface of a metal substrate wherein the metal substrate does not have a coating of zinc phosphate prior to application of the lubricant.

An article of manufacture comprising:

• a metal substrate having a surface;
• and
• a lubricant coated onto said surface of said metal substrate, said lubricant consisting essentially of one or more lubricating compounds selected from the group consisting of a soap that is a metal salt of a C6 to C22 fatty acid, a soap that is a metal salt of a C6 to C22 fatty acid containing one or more hydroxyl function groups, boric acid, a metal salt of boric acid, boron nitride, zinc oxide, calcium oxide, molybdenum disulfide, an emulsion of polyethylene, an emulsion of high density polyethylene, an emulsion of polypropylene, an emulsion of maleated polypropylene, an emulsion of a urethane, an emulsion of an oxidized polyethylene, an emulsion of an oxidized high density polyethylene, an emulsion of an oxidized polypropylene, an emulsion of an oxidized maleated polypropylene, an emulsion of an oxidized urethane, and mixtures thereof and one or more starches, wherein a weight:weight ratio of a total amount of said one or more lubricating compounds to a total amount of said one or more starches in said lubricant is in a range of from 1:1 to 8:1, said lubricant, optionally, including at least one additional component selected from the group consisting of a surfactant, a corrosion inhibitor, a processing aid, a bactericidal agent, a bacteriostatic agent, a fungistatic agent, a fungicidal agent, a defoaming agent, a viscosity modifier, a pH buffering agent, or mixtures thereof, wherein a total amount of said at least one additional component does not exceed 5% by weight based on a total weight of said lubricant and wherein said lubricant is applied at a dry coating weight level of from 250 to 2000 mg/square foot onto said surface.