Powder metallurgy lubricants, compositions, and methods for using the same
AssigneeHoeganaes Corporation
InventorsGeorge Poszmik, Sydney Luk
Life of this patent
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Abstract
The present invention relates to improved metallurgical powder compositions that incorporate solid lubricants, methods for preparing and using the same, and methods of making compacted parts. Ejection properties, such as stripping pressure and sliding pressure, of compacted parts can be improved by using the solid lubricants. The solid lubricants contain functionalized polyalkylene glycol lubricants that contain a phosphate group, phosphite group, hypophosphate group, hypophosphite group, polyphosphate group, thiophosphate group, dithiophosphate group, thiocarbamate group, dithiocarbamate group, borate group, thiosulfate group, sulfate group, a sulfonate group or combinations thereof.
Claims34
A metallurgical powder composition comprising:
- (a) at least about 80 percent by weight of a metal-based powder;
- and
- (b) from about 0.01 to about 5 percent by weight, based on the total weight of the metallurgical powder composition, of a solid lubricant, wherein the solid lubricant comprises a functionalized polyalkylene glycol lubricant having the formula:
- Q1-(R1)x, (a),
- Q1-(R1-Q2)n-R2 (b),
- Q1-(R1-Q2)n-R2-Q3 (c),
- R1-Q1-(R2-Q2)n-R3 (d), or
- combinations thereof wherein Q1, Q2, and Q3 are each independently a linear or branched polyalkylene glycol, and R1, R2 and R3 are each independently a phosphate group, phosphite group, hypophosphate, hypophosphite, polyphosphate, thiophosphate, dithiophosphate, thiocarbamate, dithiocarbamate, borate, thiosulfate, sulfate group, or sulfonate group, n is from 0 to about 10, and x is from about 1 to about 30.
A metallurgical powder composition comprising:
- (a) at least about 80 percent by weight of a metal-based powder;
- and
- (b) from about 0.01 to about 5 percent by weight of a functionalized polyalkylene glycol lubricant having the formula:
- Q1-(R1)x, (a),
- Q1-(R1-Q2)n-R2 (b),
- Q1-(R1-Q2)n-R2-Q3 (c),
- R1-Q1-(R2-Q2)n-R3 (d), or
- combinations thereof wherein Q1, Q2, and Q3 are each independently a linear or branched, polyalkylene glycol, and R1, R2 and R3 are each independently a phosphate group, phosphite group, hypophosphate, hypophosphite, polyphosphate, thiophosphate, dithiophosphate, thiocarbamate, dithiocarbamate, borate, thiosulfate, sulfate group, or sulfonate group, n is from 0 to about 10, and x is from about 1 to about 30, wherein the metal-based powder has an outer coating of functionalized polyalkylene glycol lubricant.
A method of making a metallurgical powder composition comprising:
- (a) providing a solid lubricant, wherein the solid lubricant comprises at least about 10 percent by weight of a functionalized polyalkylene glycol lubricant having the formula:
- Q1-(R1)x, (a),
- Q1-(R1-Q2)n-R2 (b),
- Q1-(R1-Q2)n-R2-Q3 (c),
- R1-Q1-(R2-Q2)n-R3 (d), or
- combinations thereof wherein Q1, Q2, and Q3 are each independently a linear or branched, polyalkylene glycol, and R1, R2 and R3 are each independently a phosphate group, phosphite group, hypophosphate, hypophosphite, polyphosphate, thiophosphate, dithiophosphate, thiocarbamate, dithiocarbamate, borate, thiosulfate, sulfate group, or sulfonate group, n is from 0 to about 10, and x is from about 1 to about 30;
- and
- (b) mixing the solid lubricant with a metal-based powder to form the metallurgical powder composition, wherein the metal-based powder is present in an amount of at least about 80 percent by weight and the solid lubricant is present in an amount of from 0.01 to about 5 percent by weight, based on the total weight of the metallurgical powder composition.
A method of making a metal part comprising:
- (a) providing a metallurgical powder composition comprising:
- (i) at least about 80 percent by weight of a metal-based powder;
- and
- (ii) from about 0.01 to about 5 percent by weight, based on the total weight of the metallurgical powder composition, of a solid lubricant, wherein the solid lubricant comprises at least about 10 weight percent of a functionalized polyalkylene glycol lubricant having the formula:
- Q1-(R1)x, (a),
- Q1-(R1-Q2)n-R2 (b),
- Q1-(R1-Q2)n-R2-Q3 (c),
- R1-Q1-(R2-Q2)n-R3 (d), or
- combinations thereof wherein Q1, Q2, and Q3 are each independently a linear or branched, polyalkylene glycol, and R1, R2 and R3 are each independently a phosphate group, phosphite group, hypophosphate, hypophosphite, polyphosphate, thiophosphate, dithiophosphate, thiocarbamate, dithiocarbamate, borate, thiosulfate, sulfate group, or sulfonate group, n is from 0 to about 10, and x is from about 1 to about 30;
- (b) compacting the metallurgical powder composition at a pressure of at least about 5 tsi to form a metal part.
A method for preparing a solid lubricant composition for use in metallurgical powder compositions, comprising the steps of:
- reacting from about 90% to about 99% by weight of a polyalkylene glycol with from about 10% to about 1% by weight of a functionalized reactant for from about 0.5 to about 15 hours at from about 65 to about 130 degrees Centigrade to form a reaction product;
- wherein the polyalkylene glycol is polyethylene glycol having a molecular weight from about 1,000 to about 20,000, and the functionalized reactant is phosphorus pentoxide;
- and
- cooling the reaction product to a solid.
A method for preparing a solid lubricant composition for use in metallurgical powder compositions, comprising the steps of:
- reacting from about 90% to about 99% by weight of a polyalkylene glycol with from about 10% to about 1% by weight of a functionalized reactant for from about 0.5 to about 15 hours at from about 65 to about 130 degrees Centigrade to form a reaction product;
- wherein from about 97% to about 98% by weight of a polyethylene glycol is reacted with from about 3% to about 2% by weight of phosphorus pentoxide for from about 2 to about 4 hours at from about 70 to about 85 degrees Centigrade;
- and
- cooling the reaction product to a solid.
Dependencies are inferred from the claim text.