US2172533A - Material amd process of using the - Google Patents

Description

Patented Sept. 12, 1939 PATENT OFFICE MATERIAL AND PROCESS OF USING THE SAME IN THE LIETAL WORKING ART Michael W. Freeman, Detroit, Mich.

No Drawing. Application May 27, 1935,

Serial No. 23,705

10 Claims.

The present invention relates to a material and to the process of using the same in the metal working arts for forming, processing, handling, and finishing of metal.

In the metal working arts, it is quite customary to take a piece of metal, for example, a fiat sheet, bar, or wire, and to subject it to one or more successive rolling, stamping, drawing, or cold forging operations to transform the metal blank into an article of predetermined configuration and dimensions. To perform these operations satisfactorily and economically, it is necessary to give consideration to the effect on the metal being worked upon and the dies or other instrumentalities used in working-the metal.

Often the final article produced is formed by welding or otherwise uniting two or more parts together. Usually the shaped article is finished by the application of a coat or coats of paint,

0 metal platings, rubber, or the like. Heretofore,

it has been the custom to employ a lubricant during the shaping or working operations; a flux when welding; special preparations when plating or painting, and so on; and frequently, if not always, the treatment'for one stage of operation is antagonistic to subsequent stages, necessitating cleaning or washing of the metal object between stages.

By way of example, it is mentioned that in the drawing of metal, so-called drawing compounds, which are in reality lubricants, are applied to produce a film between the metal and the die for protecting the die from excessive wear, thus preserving its .design and life of utility. Not only is it important to protect the die, but it is likewise important to work the metal in a way that its structure is not adversely disturbed and not requiring excessive cleaning or other work thereon as a direct result of the rolling, drawing,

stamping, or other operations.

Dies in most instances are quite expensive, requiring skilled labor in their production, and are necessarily of accurate dimensions. In selecting a lubricant for use between a die and metal to be 46 shaped, the lubricant or drawing compound should have excellent covering properties, particularly capable of resisting the squeezing out action promoted when the die and work are pressed together and to also resist segregation.

50 Further, the ideal properties of a lubricant or drawing compound are such as not. to interfere with subsequent operations on or treatment of the metal.

Ordinarily, a drawing compound is used for its effectiveness only during the drawing operation,

and by reason of necessity it is the practice to remove the remains of the drawing compound after the metal working steps. An important advantage gained by the use of my material resides in the fact that the same material, and in 5 many cases a single application thereof, will serve in various capacities. That is, the material in some cases can be applied initially as a drawing lubricant by way ofexample, and left on the work so that after drawing it may serve 10 as a base for welding and/or as a means to facilitate adhesion of a protective or decorative coating such as rubber, paint, or other finishes to the metal surface.

One of the primary objects of the invention is 15 to provide a material or composition and method of using the same wherein it will serve as a drawing lubricant more efficiently than present conventional lubricants for the same purpose and will at the same time in some cases serve other 20 purposes and eliminate some stages of operations. This will be explained more in detail hereinafter.

The expressions drawing compound, composition, and material as used throughout the application will beunderstood to include a lubri- 25 cant for rolling, drawing, shearing, piercing, stamping, cold forging, and other operations in the metal working arts for forming, processing, handling, and finishing metals, and to also serve as a base for welding or as a means to facilitate adhesion of protective .coatings such as rubber, paints, metal platings, and the like.

The main object of the invention is to produce a material or composition of this character in the broad sense as stated above made from or 35 including organic sulphonic acids or mixtures thereof, their salts, or their derivatives, and is in no way limited to any particular method of obtaining these compounds.

Broadly speaking, the organic sulphonic acids and their salts can be roughly divided into two groups, namely: (1) the aromatic hydrocarbons; and (2) the aliphatic hydrocarbons. This invention contemplates the use of both the sulphonic acids and their salts of both the aliphatic and aromatic hydrocarbons and also the derivatives of the organic sulphonic acids and their salts of both the aromatic and aliphatic series of hydrocarbons.

Taking into consideration the matter of cost of materials on the market today, it is desirable to use sulphonic acids or salts or derivatives thereof of the aromatic hydrocarbon series, although sulphonic acids, their salts, or derivatives from 55 the aliphatic series can and have been used by me with very satisfactory results.

As examples of organic sulphonic acids or derivatives thereof, the following may be mentioned:

Hexane sulphonic acid,

Amyl sulphonic acid,

Mono chloro amyl sulphonic acid, Benzene sulphonic acid,

Phenol sulphonic acid, Naphthalene sulphonic acid, Heptane sulphonic acid,

Acetone disulphonic acid, Dichloro amylene sulphonic acid, Myristic sulphonic acid,

Stearic sulphonic acid, Anthracene sulphonic acid,

The sulphonic chlorides, Disulphonic dinaphthyl methane, Tristearin sulphonic acid, Amylum sulphonic acid, Spermaceti sulphonic acid.

As a further example to show one method of producing a satisfactory material, commercial benzol, which may contain toluene, xylol, phenol, and other compounds, can be treated in the following manner:

The commercial benzol is sulphonated with fuming or concentrated sulphuric acid, the mixture being subjected to elevated temperatures. Starting with a definite weight of concentrated or fuming sulphuric acid, say 100 mole weight, heated gradually, commercial benzol is added either in the liquid or vapor state to the extent of about 50 to '75 mole weight until approximately from one-half-to three-fourths of sulphuric acid is reacted with the benzene to form benzene sulphonic acid and-a mixture ofother sulphonic acids. To the sulphuric acid benzene sulphonic acid mixture commercial naphthalene is added until about 50% of the remaining free sulphuric acid reacts with it to form naphthalene sulphonic acid.

In one production factory test run, the crude naphthalene employed in the above mixture was approximately 50% naphthalene, 20% phenanthrene, 10% carbazole, and 20% anthracene. To this was added about 4 mole weight of phosphorus pentaoxide to take up the water of reaction, and with continued heating the resultant composition of sulphonic acids was substantially free from sulphuric acid.

Inpassing, it may be stated that the chloro benzene, chloro naphthalene, stearin, spermaceti, stearic acid, and the like were used in a manner similar to that just described with extremely satisfactory results for wire drawing operations.

The necessity for providing a drawing compound free from sulphuric acid will vary depending upon the application. In some cases, relatively large amounts of free sulphuric acid may be tolerated without detrimental effect, while in other cases the content of free sulphuric acid should be reduced to a minimum. I prefer to keep the drawing compound free from sulphuric acid to avoid any risk of undesirable attack upon either the metal being worked upon or the work- 4 ing instrumentalities.

The composition produced in accordance with the above instructions was then dissolved in water to produce a solution which was applied to the metal and preferably the temperature of the bath is elevated during treatment of the metal.

To test the efficacy of the material for various applications and processes, many factory prothe rods treated in the sulphonic acid mixture solution were welded with the area of weld being smooth and generally much more satisfactory in appearance than was the case with those rods welded without the treatment. The comparison was carried further than that of appearance by separating the rods where welded and polishing them for .micro inspection. This inspection showed that the rods treated with the sulphonic acid material appear to receive the weld uniformly, while the untreated rods had spots separating the weld from the surface of the metal, indicating that the sulphonic acid mixture improved the weld between the rod sections as well as the appearance of the welded pieces.

Instead of subjecting the metal piece to be welded to treatment, the welding wire may be treated either with a sulphonic acid only or with a composition binding material containing the sulphonic acid as its active constituent. In other words, the tests show that all that is necessary for satisfactory welding is to have the sulphonic acid, mixtures thereof, salts, or derivatives thereof, present during the welding operation. Sheet steel and heavy steel plates have been welded in the same way with equally satisfactory results.

(2) To show the effect of my material on the adhesion of paint and rubber to metal treated therewith, some metal pieces were first subjected applied. This was evidenced by the humidity and salt spray test.

For a period of about one year, production tests were carried out in a large enameling plant, and it was conclusively found that the metal surfaces treated with my composition were enameled in a manner much superior to those pieces enameled without this treatment. Further tests' on the impact machine also proved that it surpassed conventional enameling.

(3) To show the effects of the sulphonic acid material on plating, a production test was conducted with metal parts prepared in the conventionalmanner by first treating the metal parts with a solution including a sulphonic acid and the pieces were then plated with a cadmium plating, and it was observed that the cadmium coating was much more uniform and adherent than without the use of the sulphonic acid film when subjected to the salt spray test. It may be noted that in some cases it is possible that the metallic salts, such as chromium, nickel, and the like, of the sulphonic acids may be used as plating material should it be more convenient to do so in lieu of applying the film on the finished articles. (4) As to the properties of a sulphonic acid material when using the same in drawing, rolling, stamping, shearing, and similar operations, production tests were conducted in several difsurrounding'atmosphere on the film as well as ferent large steel, automobile, and other plants. These tests are of course only representative, applications, as those versed in the art will readily appreciate the applicability of the. material to. many other uses not specifically hereinset forth. For example, in one of many runs, inner flanges,

to be made from 11 gauge hotroll steel from strips about l2"x84"x /;;",,were placed in a bath composed of about 90% water and 10% of the time for treatmentis suflicient whenthe metal attains the temperature of the bath, which ordinarily is in the neighborhood of 200 degrees the effect on the metal which in this case hapsubjected to four difierent operations.

of burring could be'eliminated. The above op erations are referred to as dry stamping, and.

after stamping about thirty-five tons of the 11 gauge steel, it was'discovered that the dies were actually in better condition than before they were used for shaping the metal coated with film of mymaterial.

This would suggest that the steel may be treated at the steel mill with material in accordance with my invention, and then sent out ready for drawing and stamping to the fabricator. Similarly, such a film can be left on drawn wire for shipping. to the cold forging or welding plants without further treatment required.

(5) In another application, sheets are rolled from one-half inch bars, which are cut to proper length depending on finished sheet to be produced. The bars are heated until they become red hot and are then rolled a number of times until their thickness is about twice the thickness of the ultimate thickness desired. It is then customary to pickle the metal, after which it is again heated to red heat and to then roll the breakdown sheets in pairs that is, one upon the other. oftentimes this results in a sticking or rolling together of the sheets.

I overcome this difliculty by coating the breaka down sheets to be rolled together with my sul phonic acid material which may, if desired, include, in addition to the iron salts of sulphonic acid, such salts as aluminum, magnesium, lead,

etc. of the sulphonic acid. Then when the coated metal pieces are made "red hot for rolling in pairs, the coating material is converted into a carbonaceous residue or soot, giving a powdery coating or layer capable of resisting welding or undue sticking of the sheets together.

One of the decided advantages gained when using my material or composition is that when the metal is treated with it, it can ordinarily be passed through successive metal working stages without the necessity of applying other drawing compounds or conventional lubricants between different operations. In drawing wire, for example, thec oils may be treated in a bath of my material. This material may include high molecular weight fatty acids, their salts, such as stearic, palmitic, etc., their glycerides and esters ,and'their sulphonic acids or'salts. No further washing or liming, or application, of. other draw- :ing compound, is necessary. The coils of wire .treatedinthismanner were further drawn and subsequentlysubjected'to cold forging without further}. treatment. This of .course depends somewhat upon the specific operations through the sulphonic acid mixture for a period of severa] minutes; When ;it is not necessary to remove mill or oxide scale from the metal surfaces,

which jthefwire is passed and in some cases-it may be advisable'to-recoat. the wire with additional material. I

As examples of other work done, but which in K101591156 constitutes a complete statement of the uses'towhich this compositionhas and can be put; -7 gauge metal was passed through three successive operations to produce brake drums. ,11 gauge metal for spare wheel carrier bolt flanges] was blanked and drawn, restruck and sized, and pierced. Fender supports of 11 gauge -'.material were blanked, formed, and pierced, with imilar operations beingused for producing running board supports made of 11 gauge steel.

Emergency brake drums were made from 9' gauge {steel with two and one-half inch surface in a single draw, blanked, drawn, restripped, trimmed,

"rid pierced. 's The art of metal working is so diversified that t is not feasible to attempt to prescribe specific ,combinations of sulphonic compounds and instructions for any and all conditions. Therefore, representative. examples are herein set forth which will clearly disclose to the art various uses and then store the treated metal fora .ong period of time, or to ship it over a long distance before final deformation or shaping of the metal. Under these circumstances, it is suggested that a sulphonic acid, substantially water insoluble at normal temperatures, be incorporated, such as, for example, hexadecyl sulphonic acid and the like which are very sparingly soluble in water below 50 degrees centigrade.

Where continuous drawing is employed, such as in wire drawing, the dies get heated up often to temperatures of about 90 degrees, centigrade, and sometimes in excess of this temperature. In such cases, it is usually found to be advantageous to incorporate a sulphonic acid or derivative thereof of higher boiling point and capable of solidifying more readily. The salts of such sulphonic acids have a high melting point and permit a more efiicient and uniform draw. In such cases, I have incorporated a mixture of sulphonic acids as above described and stearic sulphonic acid, its salts, or the like.

In other cases and particularly in some forms of stamping and drawing where the impact and distribution of stresses are not uniform, it is desirable to incorporate other materials that are capable of maintaining the salts of the sulphonic acids in a plastic state after the water has evaporated. In such cases, I have added chlorinated materials and preferably those chlorinated mate: rials that do not decompose easily at elevated temperatures, or other plasticizers and liquids, such as trichlorphenol oxide, dibutyl phthalate, and the like, with possible additions of pyridine, quinoline, or isoquinoline, as well as other active amines of the aliphatic series. The amines have 7 the property of reducing the effect of mobility of the chlorine radical and the like, thereby increasing materially its rust-proof properties. In some instances, I have found it possible to add conventicnal lubricants and drawing compounds.

'Other advantages to be gained by the use of my material are that the dies have a longer life than with prior art lubricants, notwithstanding the fact that in some cases they may become heated more easily with this dry drawing process. Ordinarily, the heat thus generated is not obj ectionabe but in those cases where it is, a small amount of suitable fluid may be periodically placed upon those areas of the die showing a tendency to overheating. My material spreads more uniformly, thus allowing the use of a batch system and centralized control particularly in the larger plants. A further important advantage is that the material possesses the. property of cleaning the surfaces of the metal at the same time the drawing material is applied; that is, during the time the metal is in the solution, it is cleaned, the extent of cleaning depending upon the concentration of the bath, the temperature thereof, the length of time the metal is left in the bath, the type of metal, and other variables.

It will be understood that the sulphonic acid, saits, or derivatives thereof, need not be used in solution form, although ordinarily this is preferable, because in drawing wire, for example, which has previously had scale removed so that it is clean, the wire may be drawn through dry sulphonic acids or salts thereof. In other words, the wire passing to the die may be moved through a body of powder or crystals of the sulphonic acid.

Bright stock may be produced by passing the wire through a "liquid sulphonic acid, its salts or derivatives, or a solution thereof.

I claim:

1. In the metal working art, the method of preparing metal for fabrication including the step of subjecting the surface of said metal to 'a solution having as its principal active constituent an organic sulphonic acid substantially devoid of mineral acid content.

2. In the metal working art, the method of preparing metal for fabrication including the step of subjecting the surface of said metal to a solution having as its principal active constituent salts of the principal active constituent of which is an organic sulphonic acid substantially devoid of mineral acid content.

4. In the metal working art, a method including the step of fabricating metal in the presence of a material the principal active constituent of which is an organic sulphonic acid substantially devoid of mineral acid content.

5. In the metal working art, the method of working a plurality of pieces of metal simultaneously in contact with one another including the step of interposing a material the principal active constituent of which is an organic sulphonic acid substantially devoid of mineral acid content.

6. In the metal working art, the method of joining pieces of metal together including the step of subjecting the contacting surfaces of said metal pieces to a material the principal active constituent of which is an organic sulphonic acid substantially devoid of mineral acid content.

7. In the metal working art, the method of drawing metal including the step of coating the surface of the metal to be drawn with a material the principal active constituent of which is an organic sulphonic acid substantially devoid of mineral acid content.

8. In the metal working art, the method of drawing metal including the step of coating the surface of the metal to be drawn with a material the principal active constituent of which is an organic sulphonic acid substantially devoid of mineral acid content, said material including an alkaloid.

9. In the metal working art, the method of preparing a metal surface for operations thereupon including the step of coating the same with an organic sulphonic acid substantially devoid of other active constituents.

10. In the metal working art, a material for treating metal surfaces comprising a sulphonic acid substantially devoid of other active constituents.

MICHAEL W. FREEMAN.