20 MINUTES WITH…
Derek Phillips
By Thomas T. Astrene / Publisher
Keep rust and corrosion from crippling
your productivity by following the advice
of this product-development specialist.
Derek Phillips
The quick file:
Education
• Associate’s of science degree from Ferris State
University, Big Rapids, Mich.
• Bachelor’s of science and Master’s in business
administration from University of Phoenix
Work experience
• The Lubrizol Corp., Wickliffe, Ohio, 1993-Present
Several roles supporting industrial additives
development globally in project product, business
development and commercial management.
• Petro-Lube Inc., Whitmore Lake, Mich., 1989-1993
Development of industrial lubricants, specifically
water-based metalworking fluids.
TLT: Please describe the arc that led to your career in
tribology and specialization in metal protection.
Phillips: Through most of my career I’ve focused on industrial
and automotive lubricants. My job responsibilities have covered additive formulating, technical service, new technology
development and sales support.
I had a great opportunity to work three years in China. I
was able to use my collective experiences with industrial
fluid technology to start an industrial technical support laboratory and to educate our sales force and customers.
Returning to the United States, my career took a logical
direction (at least I think so!) toward managing the global
commercial activities for Lubrizol’s metal-protection additives business. Today I focus on setting product-development
18
strategies based on my knowledge of end-users’ needs and
working with others on our industrial team to understand
market dynamics. This allows us to assist our customers and
to help them to be more successful. What could be more rewarding?
TLT: Many people believe corrosion and rust are
the same thing. Describe the difference.
Phillips: Rust is a term used to describe the corrosion of iron
and iron alloys. Corrosion is a term that covers the destruction of any metal. In general, corrosion is the deterioration of
a metal by oxidation or other chemical action.
Iron can take on many different oxide states, and the
most commonly observed iron oxidized state is what we of-
Did you know? STLE was founded on March 3, 1944, in Chicago as the American Society of Lubrication Engineers (ASLE).
ten describe as red rust. In some instances,
oxide layers can be considered beneficial,
forming protective films to some metal substrates like aluminum. Even passive iron oxide layers formed in the bluing or black oxide process, traditionally used to protect
military equipment, will still require some
rust preventive for protection from further
corrosion.
Iron parts that have any stain are generally regarded as defective, and corrective action must be taken. When there is a change
in color to an iron surface, you can assume
there is some level of corrosion that leads to
aesthetic issues and, in the worst possible
case, catastrophic mechanical or structural
failure.
TLT: What are the biggest dangers that
rust and corrosion present to machinery?
Corrosion inhibitors are needed throughout
the lubricant industry for both automotive and
industrial applications to protect ferrous and
nonferrous moving or freshly machined parts.
Phillips: We can safely say that hidden rust
and corrosion on or in a machine will eventually have a negative impact on an operation’s economics. This negative cost impact
can be as simple as replacing a part and resulting loss of productivity or, more seriously, to extensive downtime from a catastrophic failure if a corroded component
goes undetected.
All machines are composed of different metal substrates
that provide their individual wear, strength, ductility and
corrosion characteristics. Having multiple metals in a piece
of equipment can cause galvanic corrosion, which creates
electrochemical attack. Some metals are more prone to
chemical attack than others. These variables must be fully
understood by equipment designers and machine operators,
so the best metal substrates and appropriate protective chemistry is employed to minimize risk and meet the desired
product lifecycle for each piece of equipment.
TLT: Why can’t a rust preventive
prevent rust permanently?
Phillips: The ability of a rust preventive to protect the surface
varies based on a number of aspects including substrate type,
surface finish, surface preparation and environment. These
factors are then applied in formulating the right adhesion
and film characteristic.
Rust preventives are formulated for a specific end-use requirement and, therefore, vary in protection properties. A
manufacturer may only need to protect a part between manufacturing processes or between shipping points. In some
cases, the part may be protected from the elements found
inside a warehouse, but in others it may be exposed to harsh
outside conditions including saltwater or acid environment
exposure. Again, depending on the performance requireW W W. ST L E .O RG ments, the protectant formulation and the protectant’s film
thickness will vary.
Applying the rust preventive is a critical part of the overall performance. Parts or equipment are commonly brushed,
dipped or sprayed with the rust preventive. Dirty parts or
equipment create poor contact for the rust preventive film,
reducing effectiveness. A clean metal substrate provides better adhesion and consistency of the protective barrier. Likewise having a wet part from the MWF, cleaner or rinse water
requires the rust preventive to displace and shed the contaminant from the surface. Additionally, once the water is
displaced, the rust preventive should separate the water,
minimizing re-contamination of the metal substrate and allowing the fluid to be continually used.
The final film may be oily, waxy or greasy depending on
the protectant requirement and subsequent processing. Oilbased products generally wash off easier. This may be good if
the part is to undergo further processing, but protection is
usually reduced.
Waxy or greasy films are more tenacious, making them by
and large harder to remove, but provide a more resilient protective barrier. Overall these protective films are not permanent and are removed if a further permanent finish is applied.
Solvent degreasing, once a common practice, has been replaced with alkaline wash solutions and minimal abrasive
cleaning. This is where a full understanding of the customer’s
T R I B O LO GY & LU B R I CAT I O N T EC H N O LO GY O C T O B E R 2 0 1 1 • 1 9
‘Rust preventives are commonly
used to protect freshly prepared
metal substrates.’
other substrates. Corrosion inhibitors are formulated to protect these parts.
Additionally, many chemistries used for other
primary functions such as detergency, emulsification
and antiwear properties can prevent corrosion or rust
from forming. These multifunctional chemistries require
careful formulation balance to provide the necessary performance properties.
Rust preventives, on the other hand, are commonly used
to protect freshly prepared metal substrates. These products
are formulated to provide blemish-free surfaces from a wide
range of conditions that generally are removed later in a further process or finishing step.
Rust preventives are required in a number of end-user applications ranging from protecting freshly rolled metal in a
steel mill to protecting finely ground ball bearings manufactured domestically or internationally to be shipped and
stored around the globe. Developing a rust preventive for a
specific application requires formulating techniques that
take into account water displacement and water separation
while building in the proper physical and chemical characteristics desired for the length of protection and the anticipated corrosive environment.
TLT: What are the respective pros and cons of
solvent- and water-based rust preventives?
performance needs must be understood to provide the best
solution.
While in service, contaminants and abrasion can break
through the barrier reaching the metal substrate and potentially starting the corrosion process. To prolong the longevity
of service, formulators use a combination of film formers and
chemical passivators. Film formers help resist physical
breakdown, and chemical passivators protect from water and
acidic environments that can make it through to the surface.
One can see the challenge of formulating a rust preventive
that provides the maximum protection for a given substrate
and operational environment.
TLT: What is the difference between corrosion
inhibitors and rust preventives? What are the
appropriate applications for each?
Phillips: The classification and use of these terms are often
loosely interpreted. Generally speaking, corrosion inhibitors
protect metal surfaces while the fluid is in contact with a
surface or within a specific process. Rust preventives are
used to protect freshly processed metal surfaces.
Corrosion inhibitors are needed throughout the lubricant
industry for both automotive and industrial applications to
protect ferrous and nonferrous moving or freshly machined
parts. Corrosion inhibitors are formulated into lubricating
oils to protect metal surfaces from common contaminants
such as acidic oxidation byproducts and condensed water.
Active chemical components necessary to provide the tribological properties for some metal surfaces can be corrosive to
2 0 • O C T O B E R 2 0 1 1 Phillips: Solvent-based rust preventives make up the greatest
percentage of the rust preventive market as they have been in
use the longest and because of certain performance attributes
including fast drying times, film consistency, wetting properties, water displacing and separating capabilities.
But solvent-based protectants are facing environmental
and regulatory challenges with new VOC (volatile organic
compound) regulation requirements and safety issues surrounding shipment of materials with low flash points. Some
suppliers have looked to solvents and oils with higher flash
points, but there are tradeoffs as the film type can change and
may not be compatible with end-user requirements.
Water-based rust preventives allow end-users to have a
safer and often cleaner work environment while still providing as much protection as solvent-based rust preventives.
Water-based rust preventives can be formulated so the resulting film is dry to touch or oily.
Highly specialized product formulation is required with
careful adjustments to concentration levels. The resulting
product may exhibit slower drying times depending on temperature and humidity of the environment. Both solvent- and
water-based rust preventives can be formulated to meet the
desired corrosion performance needed by end-users around
the world.
TLT: What do end-users need to know before
changing to water-based rust preventives?
What about switching penalties?
Phillips: Water-based rust preventives may require more
T R I B O LO GY & LU B R I CAT I O N T EC H N O LO GY W W W. ST L E .O RG
training and support for end-users whose operators are more
familiar with solvent- or oil-based rust preventives. Getting
the right amount of protective film for customers’ applications may require some dialing in of the rust preventive concentration and application.
For example, if the manufacturer is looking for a dry-totouch product in just a few minutes after processing, it’s possible that forced air drying may be required. Parts that are hot
versus ambient after processing may require more or less attention to drying. Attention also must be given to concentration maintenance of the protectant due to different evaporation rates. Geographic location can present challenges with
changing atmospheric conditions and seasonal changes,
from rainy monsoon to dryer winter months.
If the end-user has had experience with monitoring and
maintaining water-based products in an industrial setting,
the switch will be less of a burden as he is familiar with the
more challenging operating aspects and will plan accordingly. Managing hard water, evaporative losses and biological
activity should be incorporated into operations and become
a regular monitoring activity.
All in all, managing water-based rust preventives is more
involved, and managing the changes can have a substantial
impact on product performance. At the end of the day, manufacturers may spend more time managing water-based rust
W W W. ST L E .O RG preventives, but the benefits of a safer work environment and
potential final cost savings should be carefully considered.
TLT: If you could offer one piece of advice to a lubrication
engineer assigned to solve a corrosion/rust problem, what
would it be?
Phillips: Consider the conditions pre- and post-process before
making a conclusion or recommendation. The type of contaminant found in the process or potentially impacting the
process or the product need to be fully considered, as they
will present specific challenges to the lubricant or rust preventive.
Taking sufficient time to ask and understand the entire
requirement, problem or opportunity can provide longer
product lifecycles and solve preventable corrosion problems
through high-valued lubricants and rust preventives. Don’t
forget to use the resources you may have from the chemical
and engineering disciplines to understand root causes and
industry best practices in determining your optimum solution.
Delivering the best possible solution requires a careful
combination of process, operational practice, materials and
carefully formulated rust preventives or lubricants.
You can reach Derek Phillips at [email protected]
T R I B O LO GY & LU B R I CAT I O N T EC H N O LO GY O C T O B E R 2 0 1 1 • 2 1