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STLE Chicago Section's 2014 Education Program on Metalworking Fluid Formulation

January 01, 2014
Ted McClure
Online Only Articles

STLE Chicago Section 2014 Education Program

Argonne National Laboratories, Argonne, IL
Thursday, January 16, 2014

Metalworking Fluid Formulation: Practical Strategies and Current Issues

With the implementation of the globally harmonized hazard communication standard (GHS), biocide re-registration, changing end-user requirements and ongoing raw material issues, MWF formulations are evolving. The Chicago Section, STLE is offering a one day seminar for anyone involved with formulation or maintenance and service of metalworking fluids, as well as end-users desiring a deeper understanding of fluids. The program will be held at Argonne National Laboratories, Argonne, IL, on Thursday, January 16, 2014. The program features industry experts presenting practical, useful, information on a range of important MWF formulation topics.

The seminar will open with Selim Erhan, Ph.D., Senior Scientist at Afton Chemical Corporation, presenting: Formulating Metalworking Fluids, Selection of Additives and Testing; The types of MWF formulas will be described, along with important considerations in formulating and selecting additives. Metalworking fluids are delicate balances. Components must stay together under harsh conditions. They also must not hinder each other’s performance. Guidelines, pitfalls, test methods and trends will be discussed. Dr. Erhan is currently a. His background includes extensive experience as a fluid formulator and developer of additives for MWF.

The most significant issue currently facing companies producing and using MWF is GHS. John K. Howell, Ph.D., Vice President, GHS Resources, Inc., specializing in preparation of GHS-compliant SDSs, will present; GHS: Impact on MWF Formulating Strategies. OSHA's new hazard communication rules which implement the Globally Harmonized System (GHS) are causing MWF formulators to rethink their formulating strategies. With hazard classification of finished MWF products based on the classifications of included ingredients, more attention must be paid to the impact of included neutralization products and biocides on classification. In this paper, Dr. Howell will quickly review GHS basics and then, with the June 1, 2015, implementation date for new Safety Data Sheets and labels in mind, review how included ingredients impact classification. Lastly, product testing may offer an opportunity to demonstrate a lowered health hazard than what the classification based on OSHA's mixture rules would otherwise indicate. Dr. Howell has over forty-three years experience in metal finishing and MWF technologies, including formulation.

Christine McInnis, Ph.D., Customer Application Specialist for Dow Microbial Control,   and Patrick Brutto, Senior Technical Service & Development Specialist for Dow Consumer & Industrial Solutions, will present; Formulating with Biocides and Amines for Longer Fluid Life and Multi-Metal Compatibility. Metalworking Fluids (MWF) have never been easy to formulate. There have always been many factors to consider including the application type (cutting, grinding, stamping, etc.), the metal being machined, biological growth, and worker exposure. As regulatory, sustainability, and performance pressures increase from both governmental organizations and end users, MWF formulating is harder than ever. This presentation will help formulators develop fluids that meet current regulations and end user performance demands. In particular, a discussion of currently available biocides and their positive and negative features will be discussed. In order to meet end user performance demands for longer lasting fluids, a discussion on how to formulate a fluid concentrate with anti-biofilm properties will also be covered. Additionally, the impact of amine choice on fluid performance and longevity, as well as multi-metal compatibility will be discussed. The authors have over 30 years combined experience in the chemical and lubricant industries.

With the demand for higher productivity; speeds and feeds are increasing in MWF applications. This necessitates fluids with excellent foam control. Michael C. Miller, Research Director for CLC Lubricants, will present; Foam Control & Formulation Techniques to Minimize Foam in Water Dilutable MWFs. This presentation will address various methods of foam testing and their applicability, including how to test for defoamer stability and selection of defoamers, but more importantly, how to select raw materials, for water dilutable metalworking coolants to reduce foam (what to include and why and what to exclude or limit and why).  The talk will also discuss the causes of foam and how to address them. Mr. Miller has worked in the metalworking fluids industry for over 30 years, including experience in the additive business, as a machinist and a formulator of finished fluids.

Emulsifiers are key ingredients in water diluted MWF, affecting most of the important performance properties of the fluids. Joseph Schultz of The Lubrizol Corporation will present; Emulsification and Emulsifiers. Emulsification strategies, including HLB, the types, and advantages and disadvantages of various emulsifiers used in MWF will be described. Strategies to adjust formulations from soluble oils to semi-synthetics will be discussed.

Corrosion control is another important function of MWF formulations. E. Jon Schnellbacher, Technical Director, Additives International – Lockhart Corp., will present; Selection and Testing of Rust Preventives for Metalworking Fluids. Metalworking fluids serve as in-process corrosion preventives for machine components and short-term protective coatings for machined parts. This includes compatibility with a variety of metals. This talk will discuss the selection of corrosion preventive ingredients, efficacy testing, and formula optimization for ferrous and non-ferrous applications. Mr. Schnellbacher has spent 24 years working with additives, coatings, rust preventives, metalworking fluids, and industrial cleaning compounds.

The fees for this one day course are $200 for STLE members and $250 for non-members, including lunch, continental breakfast and a presentation flash drive. Attendees are invited to also register for the STLE Chicago Section monthly technical meeting, immediately following the program, featuring networking, dinner and a biocide regulatory update presented by Troy Corp.  Lodging is available at the Argonne Guest House (800) 632-8990 for $75 per night plus taxes, or off-site in Willowbrook and Burr Ridge, IL.

Please visit the Chicago Section website, www.chicagostle.org, for online registration and further details, or contact Ted McClure, TribSys LLC, via email at tmcclure@tribsys.com or via phone at (219) 771-0920 or Mike Damiani, Radco Industries, via email at mdamiani@radcoind.com. Non-US Citizens need to complete ANL-593 at least 6-8 weeks before the seminar for Argonne security clearance.

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