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US 7,125,435 B2Granted
Powder metallurgy lubricants, compositions, and methods for using the same
AssigneeHoeganaes Corporation
InventorsGeorge Poszmik, Sydney Luk
Life of this patent
Estimating the term…
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. The solid lubricants contain functionalized polyalkylene lubricants substituted with functional groups selected from the group consisting of a phosphate group, phosphite group, hypophosphate, hypophosphite, polyphosphate, thiophosphate, dithiophosphate, thiocarbamate, dithiocarbamate, borate, thiosulfate, sulfate group, or sulfonate group.
Claims31
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 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 containing from about 8 to about 1000 carbon atoms, 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.
5 more elements
A metallurgical powder composition comprising:
- (a) at least about 80 percent by weight of a metal-based powder;
- and
- (b) at least about 10 percent by weight of a functionalized polyalkylene 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 containing from about 8 to about 1000 carbon atoms, 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 lubricant.
5 more elements
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 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 containing from about 8 to about 1000 carbon atoms, 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.
5 more elements
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 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 containing from about 8 to about 1000 carbon atoms, 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.
7 more elements
Dependencies are inferred from the claim text.