Compositions and use thereof for metal shaping

1. An aqueous composition comprising:

(i) about 5 to 32% by weight of a film-forming lubricant comprising a polyethylene emulsion capable of being solubilized into water in dispersible or emulsifiable form and which softens at a temperature of about 80 to about 200° C. and having an average particle size of 0.001 to 1.5 μm;

(ii) about 5 to 15% by weight of a film forming acrylic-based polymeric binder capable of being solubilized into water in dispersible or emulsifiable form;

(iii) about 10 to 50% by weight of a solid lubricant comprising a metal stearate capable of being solubilized into water in dispersible or emulsifiable form; and

(iv) about 0.5 to about 10% by weight of a corrosion inhibitor; and

(v) the balance water;

wherein said components are at least 90% emulsified when combined in a liquid medium and wherein said composition functions to maintain a thin lubricating film under metal shaping process conditions.

2. The composition according to claim 1 , further comprising one or more of

(a) a coalescing/drying agent; and

(b) a rheology modifier.

3. The composition according to claim 2 , wherein said coalescing/drying agent has an evaporation rate of about 1 to about 30.

4. The composition according to claim 2 , wherein said coalescing/drying agent is a glycol ether, a propylene glycol n-propyl ether, a dipropylene glycol methyl ether, or a propylene glycol butyl ether.

5. The composition according to claim 2 , comprising about 0.001 to about 5% by weight of said coalescing/drying agent.

6. The composition according to claim 1 , wherein said solid lubricant is calcium stearate.

7. The composition according to claim 1 , wherein said solid lubricant or said film-forming polymeric binder may independently further comprise one or more of water, a surfactant, or emulsifying agent.

8. The composition according to claim 1 comprising about 10 to about 40% by weight of said solid lubricant.

9. The composition according to claim 1 , wherein said corrosion inhibitor comprises an alkanolamine salt or an alkanolamine carboxylic acid salt.

10. A method comprising:

(i) applying a composition of claim 1 to a metal substrate; and

(ii) shaping said metal substrate,

wherein said composition functions to maintain a thin lubricating film under metal shaping process conditions.

11. The method according to claim 10 , wherein said shaping comprises one or more of:

(a) drawing said metal substrate;

(b) stamping said metal substrate;

(c) expansion or reduction; and

(d) bending.

12. The method according to claim 10 , wherein said shaping comprises heading.

13. The method according to claim 10 , wherein said shaping comprises hydroforming.

14. The method according to claim 10 , further comprising one or a combination of:

applying said composition to said metal substrate by spraying, dipping, flooding, contact rolling, squeegeeing, brushing or a combination thereof;

drying said composition on said metal substrate prior to shaping said metal substrate; and

drying said composition to a thickness on said metal substrate of about 0.2 to 5 mil.

15. The method according to claim 10 , wherein said metal substrate contains one metal or metal alloy or wherein said metal substrate is in the form of a pipe, sheet, block, bar, rod or wire.

16. The method according to claim 10 , which prevents metal corrosion, galling or seizing of said metal substrate before, while, or after shaping said metal substrate.