hot metal forming

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Lubricating and descaling agents for the hot metal forming industry

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Hot Metal Forming

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Page 1: Hot Metal Forming

Lubricating and descaling agents for the hot metal forming industry

Page 2: Hot Metal Forming

www.timcal.com

Where are we located? With headquarters in Switzerland, TIMCAL Graphite & Carbon has an international presence with facilities and commercial offices located in key markets around the globe.

The Group’s industrial and commercial activities are managed by an experienced multi-national team of more than 450 employees, from many countries on three continents.

What do we offer to our customers?“Providing customer-related solutions”

NTIMCAL Graphite & Carbon pro-duces a variety of synthetic and natural graphite powders, conductive carbon blacks, calcined petroleum cokes, aque-ous dispersions and silicon carbide with a common keyword: consistency.

NThey are manufactured under stringent process control conditions from the raw material stage through to the end product.

NAdditionally “our team of marketing and R&D” cooperates very closely with customers and research institutes to pro-vide the very best advice and assists clients with today and tomorrows solutions.

NFor further information please contact our team or visit our website:www.timcal.com.

Bodio, Switzerland

Willebroek, Belgium

Lac-des-Îles, Canada

Terrebonne, Canada

Changzhou, China

Baoutou, China

Fuji, Japan

Who are we? TIMCAL Graphite & Carbon has a strong tradition and history in carbon manufacturing. Its first manufacturing op-eration was founded in 1908.

Today, TIMCAL facilities produce and market a large variety of synthetic and nat-ural graphite powders, conductive carbon blacks and dispersions of consistent high quality. Adhering to a philosophy of Total Qual-ity Management and continuous process improvement, the TIMCAL manufactur-ing plants comply with ISO 9001-2000.

TIMCAL Graphite & Carbon is commit-ted to produce highly specialized graphite and carbon materials for today and tomor-row customers’ needs. TIMCAL Graphite & Carbon is a mem-ber of IMERYS, a world leader in adding value to minerals.

What is our vision?TIMCAL’s vision is to be recog-nized worldwide as a leader in realizing challenging solutions for its customers by means of special carbons and related ap-

plications.

Page 3: Hot Metal Forming

The ideaNTo produce a lubricant for the Hot Metal Forming industry. This product must be easy to apply by spraying or dip-ping, resist high temperatures, be stable as an aqueous dispersion and be environ-mentally friendly.

TIMCAL did it!

Why ROLLIT®?

NThe suitability of graphite for lubricants used in Hot Metal Forming processes can be characterized by three important physical and chemical parameters:

PurityNThe graphite has to be free of abrasive,polluting or hazardous impurities.

CrystallinityNThe crystallinity of graphite is essential for the lubrication properties. It has a direct effect on wear, tool life and work-piece quality.

Particle size distributionNAn optimized particle size distribu-tion provides optimum tool protection and coverage, thus improving workpiece quality.

NThe lubricant’s formulation is opti-mized to improve the following proper-ties:

Stability• Minimize sedimentation• No biological fermentation

Film properties• Adhesion to the mandrel• Water resistance• Thermal stability

Ecology and safetyNAll ROLLIT® dispersions are water based and contain only environmental friendly raw materials.

Cost savingsNThe cost of ROLLIT® material is rap-idly paid back by its great advantages of: less tool wear, better workpiece surface, less down time and an increase of pro-duction speed.

Page 4: Hot Metal Forming

www.timcal.com

HMF Technologies and markets

NROLLIT® products were developed to meet a precise need of lubricating prod-ucts. Today the ROLLIT® products are wellknown by the major tube mills of the world.NThe main families of products that TIMCAL provides to the Hot Metal Forming industry are:

• Lubricating agents• Descaling agents• Forging dispersions• Briquetting/Demolding agents• Upsetting/Extrusion agents• Application systems

Mandrel Bar Lubrication (ROLLIT® DS and DDP products)

NTo withstand the high pressure, tem-perature and friction during the rolling process, as well as for ecological reasons, mandrel bar lubricants are based on high quality graphite, selected additives and water. They are supplied in either pow-der or liquid form according to customer requirements.

Scale treatment(ROLLIT® EZ products)

NThese products for treating scale in shell interiors are supplied in powder form, based on a mixture of graphite and special salts.NAdditionally, TIMCAL developed products showing with both descaling and lubricant properties. Depending on the needs of the final application this multiple feature allows to use one single product covering two purposes.

Forging dispersions(ROLLIT® DF products)

NROLLIT® DF family (Aqueous Graph-ite Dispersions) is specially developed for the forging industry. Physical properties like pressure and temperature are extreme during forging processes. NTherefore the lubricating effect ob-tained from the forging dispersion layer is of fundamental importance to reach a perfect work-piece.

Briquettes/Demolding agents (ROLLIT® DS and DDP products)

NBriquettes of sponge iron is a special process used in metallurgy. During bri-quetting a granular material (e.g. iron) is compacted under pressure between rolls. NThe forming of briquettes is often sup-ported by binding agents. ROLLIT® briquetting and demolding agents are the ideal and environmentally friendly solu-tion to prevent sticking of the briquettes to the rolls and increase the overall yield.

Upsetting/Extrusion agents (ROLLIT® DS and DDP products)

NTIMCAL offers solutions to rational-ize upsetting and extrusion processes. In close cooperation with customers we are ready to further develop products re-sponding to the particular needs of these sectors.

Page 5: Hot Metal Forming

The best hot metal forming results are achieved by applying ROLLIT® products through TIMCAL Application Systems

HP unit

NThis module was created to optimally coat the mandrel with lubricant.NThe best results are achieved using theappropriate sliding valve and spray noz-zles. Pressure can be freely adjusted to ob-tain the requested quantity of lubricant on the mandrel.

EZ unit

NThis module allow the blowing of des-caling products into the hot shells.NBlowing parameters can be freely se-lected in order to obtain the best possible distribution of the product. The unit is controlled by PLC.NA special application nozzle comes with the unit.

Application Systems

Page 6: Hot Metal Forming

www.timcal.com

ROLLIT® Lubricants

MPM & PQF

FM Asselmill

Pushbench

BriquettingUp

setterForging

Billetcoating

Plugmill

DDP family

DS 1010

DS 1150 MT

DS 1151 MT

DS 1152 MT

DS 1190 MT

DS 1231

DS 5040 MT

DS 200 MT

DS 8832 MT

WT 8690

EZ 235 C

EZ 505

EZ 510

EZ 1000

EZ 1010

EZ 3041

DF 100 MT

DF 200 MT

DF 800 MT

SuitableEspecially suitable

NThis is an overview of some of TIMCAL’s most used products. Of course the selection of the right product depends on many fac-tors (process, temperature, materials, etc.).

NOur specialists will be glad to help you in selecting the most suitable product for your application. Depending on customer requirements our powder products are de-livered in paper bags or big bags. NThe liquid products are available in con-tainers or drums. Feel free to contact us at: www.timcal com.

Page 7: Hot Metal Forming

Examples of use

NROLLIT® products can be supplied ei-ther in powder or liquid form. TIMCAL recommends to apply ROLLIT® products thorough TIMCAL Application Systems in order to obtain the best hot metal form-ing results.NNevertheless the application in the mill can be made also with existing injection or spraying units. NTIMCAL’s specialists can help customers all around the world to select and set up the appropriate application system.

Mandrel bar lubrication• Saves on production costs • Reduces mandrel wear• Improves internal surface of tubes• Improves thickness consistency• Increases production capacity• Decreases roll forces• Increases mandrel life• Prevents soil pollution• Decreases number of rejects

Scale treatmentand shell lubrication• Saves on production costs• Reduces mandrel or plug wear• Improves internal surface• Improves thickness consistency• Avoids scaling• Increases mandrel life• Prevents soil pollution• Decreases number of rejects

Tube upsetting• Saves on production costs• Reduces tool wear• Improves workpiece surface• Increases production capacity• Decreases number of rejects

Page 8: Hot Metal Forming

www.timcal.com

Forging• Saves on production costs• Reduces tool wear• Improves workpiece surface• Increases production rate• Decreases number of rejects

Sponge iron briquettesProduction• Saves on production costs• Extends die life• Improves briquette surface• Increases production rate• Increases roll life• Saves energy• Reduces waste

Examples of use

Page 9: Hot Metal Forming

Quality

CTIMCAL has been certified with ISO 9001/2000 and complies with the inter-national Standards for Quality Manage-ment.

CTIMCAL is committed to supplying high quality products. TIMCAL concen-trates all its efforts on assuring consistent product quality.

CThis makes TIMCAL confident of its product’s success and market satisfaction today and in the future.

CTo reach these targets TIMCAL has pre-pared its laboratories with the most out-standing equipment operated by special-ists in the lubricating industry.

CThe quality of raw materials and inter-mediates is constantly controlled during the whole production process.

Page 10: Hot Metal Forming

www.timcal.com

Analytical proceduresfor ROLLIT® products

Friction measurementwith Tribo-Meter

NThe friction is measured between two steel specimens chosen to represent the pierced shell (the upper specimen) and the mandrel (the lower specimen) during the rolling of seamless tubes. The test is automated and consists of several steps. NThe first step consists of coating the lower specimen with the lubricant. The upper specimen is heated in-situ to 1050 °C and positioned automatically over the lubricated piece that holds a temperature of 100 °C.NThe upper specimen (the shell) is thereafter released and a load is applied hydraulically while the lower specimen (the mandrel) is being pushed forward with a motor.NThe friction force is measured during the displacement. A computer calculates the friction coefficient and energy dissi-pated during the sliding. The test vari-ables are the sliding speed, the load and the temperatures.

Reference:- TIMCAL method

Solid content

NThe solid content is measured using a Halogen Moisture Determination ther-mobalance. NIn this procedure 1 to 2 g of the disper-sion are placed on the sample holder and dried at 120 °C until a constant weight is achieved.NThe remaining weight is recorded and expressed as a percentage.

Reference:- TIMCAL method

Viscosity and flowbehavior

NViscosity is measured in the steady state as a function of the shear rate as well as in oscillating mode as a function of the amplitude with a constant frequency. NThixotropic behavior is measured by observing the viscosity in an oscillating test as a function of the time. A rotational rheometer with a coneplate setup is used and the measurements are performed at room temperature.N1-2 grams of liquid sample are put in the gap between a stationary plane and a rotating cone. A laminar flow of layers is created. NThe viscosity is obtained from mea-suring the internal resistance and a flow curve is obtained.

Reference:- TIMCAL method

Wetting test

NIn the wetting test the quantity of re-maining graphite on steel surfaces is measured after being sprayed with dis-persions.NThe test has been developed to simu-late the behaviour of the dispersion when sprayed as a lubricant on a hot mandrel in the seamless tube production.NSteel plates are being weighed and heat-ed to the desired temperature in an oven and thereafter put on a sliding support. NThe dispersion is sprayed with a typical pressure of 50 bar on the steel plates pass-ing under the spraying unit with a speed of 1.5 m/s. NThe steel plates are dried and weighed to obtain the deposited graphite quantity as well as its thickness.

Reference:- TIMCAL method

pH

NThe pH is measured using a Digital pH Meter with a calibrated pH electrode.NThe clean electrode is immersed into the liquid. After stabilization of the read-ing the pH is recorded.

Reference:- TIMCAL method

Page 11: Hot Metal Forming

Tribological testsfor ROLLIT® products

NTribological phenomena in Hot Metal Forming processes are quite complex and depend on a wide range of parameters.NAll ROLLIT® products are thoroughly tested by TIMCAL to determine the ad-hesion behavior. NTo be sure that ROLLIT® products meet the clients requirements TIMCAL has developed its own friction test equip-ment.NWith this equipment it is possible to measure the frictional behavior of met-als and alloys at a high temperature and pressure, conditions which are very close to the actual tube-rolling process.NThese tests give the friction coefficients specific for the lubricant in combination with the tools and workpieces.NAll TIMCAL products are developed in close cooperation with the customers.NTherefore, TIMCAL can offer solu-tions tailor-made to the specific applica-tion of the customers.

Lubricantsprayed ontoMandrelat 150°

Computerdata acquisition Storage of data

Output ofexperimental data

Shell heatedto 1050° Cin induction furnace

NORMAL PRESSURE (225 kN/cm2)

l = 70 mmv = 45 mm/s

"Shell"

Lubricated surfaceMandrel

Piston

Friction force

Friction exertedby motor

Examination oftested surfaces

High temperature tribometer

Page 12: Hot Metal Forming

www.timcal.com