About Metal Working Lubricants, Coolants and Fluids

Metal working lubricants, coolants and fluids are specialized coatings and carriers for metal forming,
metal cutting, lapping, polishing, and grinding applications. Metal forming oils, greases and fluids are
designed to enhance lubrication during extrusion, wire drawing, stamping, bending, swaging, rolling,
embossing, and other deformation processes. Metal cutting fluids are used in metal machining for
improving tool life (reducing wear), increasing lubrication, reducing workpiece thermal deformation,
improving surface finish and flushing away chips from the cutting zone. In lapping or polishing
compounds, fluids or oils are used to carry abrasive powders. In grinding applications, the main
function of metal working lubricants, coolants and fluids is to perform workpiece cooling. These
products are also used to prevent rust and corrosion, and to serve as release agents that prevent
materials from sticking or adhering to an underlying surface.
There are three basic types of metal working lubricants, coolants and fluids: fluids, greases, and solid
lubricants or dry film. Fluids are a broad category of products that includes lubricants, coolants, metal
working fluids, refrigerants, dielectric greases, transformer oils, base oils, and fuel or oil additives.
Greases, gels and lubricating pastes are thick, high viscosity products that do not run or flow off
surfaces. Greases often consist of oil thickened with a sodium or calcium soap complex or non-soap
thickener. Solid lubricants or dry film lubricants are compounds such as hexagonal flake graphite,
boron nitride (BN), molybdenum disulfide, or polytetrafluoroethylene (PTFE) powders designed to
reduce friction, binding or wear; exclude water; or provide other specialized characteristics.
Metal working lubricants, coolants and fluids vary widely in terms of chemical composition. Some
products contain petroleum or mineral oils, glycol or polyglycol, ester or diester, or silicone-based
fluids with outstanding thermal and dielectric properties. Other products contain high water content
fluids (HWCF); natural oils; soap, lithium, and aluminum complexes; or waxes such as paraffin and
stearate. Industrial lubricants that are based on halogenated hydrocarbons include chlorofluorcarbon
(CFC), halogenated fluorocarbon (HFC), halogenated chlorofluorocarbon (HCFC), and
perfluorocarbon (PFC). Fluoropolymer-based solid lubricants include polytetrafluoroethylene (PTFE)
and are available in various forms. Synthetic fluids do not contain a petroleum or mineral oil base, but
provide exceptional fire resistance and cooling performance. The characteristics, cost and heat
transfer performance of semi-synthetic fluids fall between those of synthetic and soluble oil fluids.
Important properties for metal working lubricants, coolants and fluids include concentration, flash
point, autogenous ignition (AIT), and special features. Concentration is measured after dilution of
the fluid solution on a volumetric basis. Flash point is the lowest temperature at which a liquid can
give off sufficient vapors to form an ignitable mixture in air near the surface of the liquid. Autogenous
ignition (AIT) is the temperature at which ignition occurs spontaneously. Some metal working
lubricants, coolants, and fluids are fire resistant, biodegradable, low foaming, or oxidation inhibiting.
Others metal working lubricants, coolants and fluids are designed specifically for automotive,
transportation, aerospace, or military applications.
Lubricants, fluids and coolants regularly used in the metal working industry are highly
specialised and designed to perform specific tasks. In addition to metal forming, metal
working includes a fairly broad range of tasks - including polishing, cutting, embossing and
grinding.

Metal working lubricants are used for several reasons. While one of the primary functions is
to increase lubrication, they can also reduce thermal deformation, improve the overall finish
of a metal surface and help to effectively remove loose metal chips from the cutting area.

Lubricants can be used to carry abrasive powders, when used for polishing or lapping of
metals. They are effective in acting as a cooling agent when used in grinding applications and
they also prevent certain materials from sticking to surfaces. Lubricants can help reduce the
effects of corrosion and rust.

And perhaps most importantly, the correct use of metal working lubricants will help to reduce
wear and tear, prolong the life of tools and other moving parts, reduce the time spent on
maintenance - and of course ultimately ensure a company's profitability over the long term.

Different lubricants possess different properties and features. Features that might be
important when choosing a lubricant include resistance to heat, oxidation inhibiting ability
and biodegradable ability. Flash point is also an important consideration - the flash point is
the lowest temperature at which liquid can emit enough vapours to cause an ignition.

Metal working lubricants come in three types: greases, fluids and solid lubricants. Each has
different properties and can be used most effectively in different industrial applications.
Which lubricant to use will depend on several factors - the characteristics of any die used, the
temperature and the overall processing conditions.

Solid lubricants are chemical compounds such as boron nitride and often have such qualities
as being able to keep out moisture, reduce friction and generally reduce wear and tear.

Some industries need specialised lubricants - the transportation, aerospace and automotive
industries are some of the biggest users. The steel forging industry commonly uses graphite
based lubricants which is often graphite immersed in oil or water. This type of lubricant also
has the advantage of having no fumes and is able to keep the steel forge and surrounding area
clean.

Lubricants used in metalwork vary widely in their chemical composition as well as their uses.
Lubricants may contain such varied ingredients as mineral or petroleum oils, natural oils,
waxes or paraffin.

Some lubricants contain a high percentage of water and are generally known in the industry
as HWCF - high water content fluids. Synthetic fluids generally provide an effective
resistance to heat as well as excellent cooling abilities; they don't contain a petroleum or
mineral oil base.

They may not be the most glamorous part of the metal working industry - but without a
doubt, the indispensable lubricant is certainly one of the most important.

James Martindale writes for Rocol. Rocol specialise in anti graffiti products, traffic
management and industrial metal working lubricants. Rocol take pride in producing advanced
products for industry needs.