Dover Chemical Corporation
New Sulphurised Additive Offers High
Performance and Greener EP Technology
By John Nussbaumer, Technical Service Manager, Metalworking, Dover Chemical Corporation
M
achining operations depend on additives in cutting fluids that prevent the metal chips generated from being
welded to tool faces by the extreme temperatures and pressures at the tool-workpiece interface. If buildup
of welded chips occurs to a degree that alters the effective tool rake, all phases of the operation are seriously
affected – resulting in downtime, scrap parts and unhappy customers.
Extreme pressure (EP) additives based on phosphorus, chlorine and/or sulphur are incorporated into cutting fluids
to prevent this. Sulphur is typically used for temperatures above 400˚C, and there has been an ongoing trend to use light
color, low-odor sulphur-containing additives to provide better machining visibility and improved workplace environments.
Lighter and Greener
Dover Chemical used its deep understanding of sulphurised technology as
a major supplier to the metalworking
fluids industry to develop a new-generation additive to better meet customers’ needs. Dover’s exclusive, novel
technology required a new CAS Number and a Pre-manufacturing Notice to
be submitted and granted before starting commercial production in the
spring of 2014.
Table 1.
Patent-pending Doverlube®LCS-10
is a high performance light-colored
sulphurised vegetable ester that has
very low sulphur odor and is readily
biodegradable. The product is nonstaining with no added corrosion
inhibitors, produces no H2S and is a
Super Compliant material for VOC
emissions per the United States Environmental Protection Agency (EPA)
Rule 1144. Characteristics are shown
below.
Doverlube LCS-10 Characteristics
Sulphur Content
10.5%
ASTM D-1500
2.5 Typical on Neat Additive
Pour Point
10˚C
Viscosity
50cS @ 40˚C / 230 SUS @ 100˚F
Flashpoint, COC
288˚C / 550˚F
4-Ball Weld Load (3% in ISO 32 Oil)
500Kg
ASTM D-130, 10% @ 100˚C 3 Hours
1B
H2S Generated
None Detectable
VOC (ASTM E1868-10)
2.5121 g/L
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T R I B O L O G Y & L U B R I C AT I O N T E C H N O L O G Y • C M F P l u s
W W W. S T L E . O R G
Doverlube LCS-10 Performance
Evaluation
Performance of Doverlube LCS-10 was
evaluated by the following methods:
Vertical Drawbead Testing; 4-Ball Wear
Analysis; Micro-tap Lubricity and EP
Determination; Bridgeport CNC Machining Center Drilling Operation on
1018 Cold Rolled Steel. The standard
formula was typical for a metalworking
product:
Viscosity: 175 SUS @ 100˚F
Sulphur: 1.5% (from included S-additive)
Chlorine: 1.5% (from Paroil®152)
Lubricity: 13% (from Methyl Ester 165)
In two cases, the chlorinated alkane
was replaced by Mayfree®133 or
Doverlube® NCEP, on an equal percentage basis.
Vertical Drawbead Testing
This testing was conducted using a die
load of 500 psi on carbon steel at
ambient temperature with an additive
loading of 5% in 20cS oil. Higher efficiency numbers equate to better performance; results within +/- 5% are
considered equal.
Doverlube LCS-10
100%
10% BASE 10SE
- 3%
15% Sulphurised Ester
- 4%
15% Sulphurised Ester
- 7%
40% Polysulfide
- 8%
40% Polysulfide
- 9%
4-Ball Wear Testing
Testing speed was 1,200 rpm, load was
40 Kg at ambient temperature for 60
minutes. Smaller scar diameter dem onstrates better performance.
Doverlube LCS-10 outperforms other
sulphurised additive options in wear
tests. Formulations combining it with
Doverlube NCEP or Mayfree 133 offer
added EP performance and are chlorine-free.
W W W. S T L E . O R G
C M F P l u s • T R I B O L O G Y & L U B R I C AT I O N T E C H N O L O G Y
NOVEMBER 2014 • 3
Dover Chemical Corporation (continued)
Tap Torque Testing
Testing speed was 550 rpm to a depth
of 15mm on carbon steel. Higher efficiency shows better performance. Efficiency at +/- 3% is considered equal.
Doverlube LCS-10 provides equivalent or superior tap performance compared to alternative sulphurised products and is non-staining.
CNC Testing
HSS 0 1495” drill speed was 2,000 rpm
with a feed rate of 25.4cm/min, drilling
a plate of 1018 cold rolled steel measuring 10.2cm x 15.2cm x 0.13cm. A difference of more than 5.0 microns is
considered significant; lower micron
numbers indicate better performance.
Overall performances were considered equal at the conclusion of the
test; however, Doverlube LCS-10 demonstrated smooth wear progression,
which is desirable. The staggered wear
progression of BASE 10SE indicates
repeated welding of metal to the tool
that breaks free and then reforms and
breaks again. This shocking to the drill
will eventually lead to tool failure.
Conclusion
Doverlube LCS-10 offers equivalent or
superior EP performance for metalworking fluids with a light color that
improves visibility during machining.
Its very low odor, low VOCs and lack of
H2S generation enable formulations
that are environmentally- and operatorfriendly. It is suitable for use in many
types of base oils and vegetable esters
for many metalworking applications.
Doverlube LCS-10 entered the market in May 2014 and is commercially
available in the United States and selected Asia-Pacific countries.
For formulary assistance contact:
Lou Bona, Global Business Manager, Metalworking: [email protected], or:
John Nussbaumer, Technical Service Manager, Metalworking: [email protected]
4 • NOVEMBER 2014
T R I B O L O G Y & L U B R I C AT I O N T E C H N O L O G Y • C M F P l u s
W W W. S T L E . O R G
A New Day In
Sulphurised Technology
Additives to
Transform Lubricant
Technologies
Doverlube® LCS-10
Learn More
STLE Booth #215 &
Commercial Marketing Forum
Tuesday, 20 May at 11:00 a.m.
Call 1.800.321.8805
Email [email protected] Visit www.doverchem.com
Mayfree®, Doverlube®, Doverphos®, Mayphos®, Klorfree®, Mayco Base®, and Syn-Chek®
are registered trademarks of Dover Chemical Corporation, a subsidiary of ICC Industries Inc.
Patent-pending—
Doverlube LCS-10 is a high
performance light-colored
sulphurised vegetable ester
that makes your products
more environmentally friendly.
Key Attributes
„
100% Biodegradable
„
Gives off no detectable H2S
„
Very low odor
„
Non-active, uses no inhibitors
„
Suitable for use in many
types of base oils and
vegetable esters
„
Suitable for use in many
metalworking applications
„
Manufactured in USA,
globally available