METALWORKING FORMULATIONS WITH CORROSION INHIBITOR FORMULATIONS
Metalworking formulations and corrosion inhibitor formulations are provided. The metalworking fluids have excellent performance as coolants in the manufacture of thin-walled metal containers such as aluminum beverage cans.
1 . A metalworking formulation comprising:
an esterified lubricity additive;
a block copolymer;
an amine; and
a corrosion inhibitor formulation,
wherein the corrosion inhibitor formulation comprises an acyl amino acid derivative of formula Ia, Ib or Ic:
R 1 —(CO)—N(R 2 )—(CH 2 ) n —CO 2 X (Ia)
[R 1 —(CO)—N(R 2 )—(CH 2 ) n —CO 2 ] m Y (Ib)
[R 1 —(CO)—N(R 2 )—(CH 2 ) n —CO 2 ] m —Z—(OH) p (Ic)
where:
R 1 is C 6 -C 30 optionally substituted alkyl or C 6 -C 30 optionally substituted alkenyl, and
R 2 is hydrogen or C 1 -C 4 optionally substituted alkyl;
X is hydrogen, C 1 -C 30 optionally substituted alkyl, or C 2 -C 30 optionally substituted alkenyl;
Y is an alkali metal or an alkaline earth metal;
Z is a residue remaining after removal of a hydroxyl group from a polyhydric alcohol;
m is an integer of 1 or greater, which is 1 when Y is an alkali metal and 2 when Y is an alkaline earth metal;
p is an integer of zero or greater;
n is an integer of 1 to 4, and
m+p is the valency of Z.
2 . The metalworking formulation of claim 1 , wherein the corrosion inhibitor formulation further comprises a succinic acid derivative, a triazole, a C 6 -C 20 branched carboxylic acid, a sugar alcohol, an imidazoline, or a mixture thereof.
3 . The metalworking formulation of claim 2 , wherein the formulation comprises a triazole:oleyl sarcosine weight ratio of from 0:1 to 7:1.
4 . The metalworking formulation of claim 1 , wherein the corrosion inhibitor formulation comprises:
N-oleyl sarcosine;
a water soluble succinic ester;
an amidated succinic acid derivative;
a sodium salt of tolyl triazole; and
neodecanoic acid.
5 . The metalworking formulation of claim 1 , wherein the acyl amino acid derivative is from 0.1% to 5% by weight of the formulation.
6 . The metalworking formulation of claim 1 , wherein the acyl amino acid derivative is N-oleyl sarcosine.
7 . The metalworking formulation of claim 1 , wherein the formulation does not significantly stain aluminum.
8 . The metalworking formulation of claim 7 , wherein the formulation is substantially free of phosphoric acid derivatives.
9 . The metalworking formulation of claim 7 , wherein the formulation is substantially free of boric acid derivates.
10 . The metalworking formulation of claim 7 , wherein the formulation is substantially free of corrosion inhibiting components that are film-formers on metal surfaces.
11 . The metalworking formulation of claim 1 , wherein the esterified lubricity additive is a water dispersible esterified dimer or trimer acid, wherein the dimer or trimer acid is the esterification product of: (1) an acid component comprising a dimer acid, a trimer acid, or a mixture thereof; and (2) an alcohol component comprising an alkylalkoxy alcohol, optionally in combination with an alkyl alcohol.
12 . The metalworking formulation of claim 1 , wherein the esterified lubricity additive is an esterification reaction product selected from the group consisting of: (a) a polyalkanoic or polyalkenoic acid derived from hydroxyfatty acids and a block copolymer selected from the group consisting of polyoxyethylene-polyoxypropylene and a reverse block copolymer of polyoxypropylene-polyoxyethylene-polyoxypropylene; (b) the reaction product of (a) with a maleic acid or anhydride; and (c) mixtures thereof.
13 . The metalworking formulation of claim 1 , wherein the esterified lubricity additive is a partial or half-ester of a compound derived from the Diels-Alder reaction of a conjugated fatty acid and an acid precursor dienophile.
14 . The metalworking formulation of claim 1 comprising the esterified lubricity additive and the block copolymer at a ratio of from 3:1 to 1:3 w/w.
15 . The metalworking formulation of claim 1 wherein the block copolymer comprises a structure represented by formula (IIa), (IIb) or (IIc):
R 3 —(EO) x —(PO) y —R 4 (IIa)
R 3 —(EO) x —(PO) y -(EO) z —R 4 (IIb)
R 3 —(PO) x -(EO) y —(PO) z —R 4 (IIc)
where w, x, y and z are independently any integer;
R 3 and R 4 are independently selected from —H, —OH, —(CR 5 R 6 ) w H, or —(CR 5 R 6 ) w OH;
R 5 is independently selected from hydrogen and C 1 -C 4 optionally substituted alkyl, and
R 6 is independently selected from hydrogen, C 1 -C 30 optionally substituted alkyl, or C 2 -C 30 optionally substituted alkenyl.
16 . The formulation of claim 15 , wherein the block copolymer comprises a structure of formula IIc, and R 5 is H and R 6 is C 1 -C 4 optionally substituted alkyl.
17 . The metalworking formulation of claim 1 wherein the block copolymer comprises two or more block copolymers of formula IIc.
18 . The metalworking formulation of claim 1 , wherein the composition comprises:
from about 3.25% to about 13.5% of the esterified lubricity additive;
from about 4% to about 19.5% of the block copolymer;
from about 1% to about 5% of a polymeric surfactant antifoaming agent;
from about 0.1% to about 2% of N-oleyl sarcosine;
from about 0.1% to about 2% of a water soluble succinic ester;
from about 0.1% to about 2% of an amidated succinic acid derivative;
from about 0.1% to about 2% of a triazole; and
from about 2% to about 8% of carboxylic acid.
19 - 29 . (canceled)
30 . A diluted metalworking composition comprising the metalworking formulation of claim 1 in an amount effective to provide lubricity, and a diluent.
31 - 34 . (canceled)
35 . A method of making a thin-walled metal can comprising the steps of:
(a) forming a metal disk;
(b) drawing the metal disk to form a shallow cup;
(c) applying the metalworking formulation of claim 1 to the shallow cup;
(d) redrawing and wall ironing the shallow cup to form a thin-walled tubular can body having an open end and an opposing closed end; and
(e) washing the metalworking formulation off the thin-walled tubular can body.
36 - 39 . (canceled)