Molykote 8 - AFC For Training

Dow Corning INTERNAL
Anti-Friction Coating
14 April 2011
Dr V S Iyer
What is AF Coating?
Solvent
(Evaporates after applied)
Solid Lubricant
(Low friction, anti-wear)
Substrate
Binder
(Keep lubricants on the surface)
Additive
(wetting, dispersing,anti settle,etc.)
Responsibilities of Ingredients
Binder:
Pigments:
Additives:
Solvents:
adhesion, corrosion protection

lubrication, (corrosion protection)
surface tension, wetting, disperging, antisettle
medium to apply coating
Desire
and problem:
Maximum lubricity
Maximum corrosion protection
High amount of binder = good corrosion protection, poor lubricity

High amount of pigment = good lubricity, poor corrosion protection
Mostly a Compromise
Use of Anti-Friction Coatings (1)

advantages:
dry lubrication (not affected by dust) with defined film

thickness
service life lubrication in many cases (sliding
applications/mixed friction)
no aging, evaporation, oxidation
can often replace surface treatments (ex. galvanizing), offerin
lubrication + corrosion protection
fully effective even after prolonged shut down
vacuum & radation resistance
Keeps factory, plant clean without any leakage of oil.
Useful for optical instrument
Use of Anti-Friction Coatings (2)

limitations:
not recommended for high speed & rolling applications
under hydrodynamic conditions used only with

greases/oils (offer running-in and emergency
lubrication)
application process (cost, curing)
Difficulties in application procedure (coating
facility/coating skill)
Difficult to remove(after curing), relubricate
Flammable and/or toxic solvent
Difference between AFC and

Ind.Coating
dry film
dry film
Substrate
Industrial Paint
much binder - less pigment
Substrate
AF-Coating
much pigment - less binder
solvent
wet film = 30 microns
curing
substrate
dry film = 15 microns
substrate
Curing of AF-Coatings
Room Temperature
Humidity Oxygen
D 321R
M-8800
Physical
D 96
Heat Curing
120C - 250C
3400A, 106, 7409, D 10,

D 88, D 708,
Heat Curing / Air Curing

Advantages
Disadvantages
Heat curing
Corrosion protection
Chemical resistance
Equipment (ove
Energy costs
Handling
Air curing
Process
Spray cans
Storage stabilit
Curing time
Lubricant Features
Property
MoS2
Graphite
PTFE
Colour
Black
Greyish black
Transulcent
Load Carrying capacity

Almen Weiland M/C
N/mm2
> 3000
300
20
Thermal stability
-180/450C
+600
+250
Coeff of friction (100%

RH)
0% RH
In vacuum
0.2
.04
0.03
0.12
1.0
2.0
0.12
.04
.03
Adhesion on metals
best
Poor
Poorest
Electrical conductivity
low
high
Low
Coeff of friction
Lowest on high loads
medium
Lowest on low loads
Running-in effect (1)

after application
after running-in
appr. 10 m.
appr. 2 m.
section of an
AF-C:
after
application
and
after loading
Metal surface Rt = 5/10

Phosphating layer appr. 3 m.
Friction values LFW1 test osc. ASTM

D2714
Typical friction values of Anti-Friction Coatings
coeff. of friction
0.12
0.1
MoS2 - 1000
N/mm2
MoS2 - 500
N/mm2
PTFE - 250
N/mm2
0.08
0.06
0.04
0.02
0
service life
AF-Coating 6
Evaporation
ranking
Remarks
Skin irritant
Hygroscopic
23.5
Harmful
Smell
>21
---
23
Smell
26
Smell
Flash
point()
NMP
Xylene
White
spirit
Butyl
acetate
Buthanol
63
Chapter 2 : How to use AF coating

Mixing
Degreasing
Sand blast
Chemical treatment
Mixing
Density
Solvent
<1.0
Binder
<2.0
Solid lubricants
MoS2
Graphite
4.8
2.3
Solubility to Solvent
Soluble
Insoluble
Insoluble
AF-Coating must be mixed well before use. Density of solid

Lubricants are higher than the one of solvent.
Ratio of Solid lubricants to binder is extremely important for
the performance of AF Coating.
Mixing
Avoid Contamination
AF-Coating
Solvent
(Evaporates after applied)
Surface
Solid Lubricant
(Low friction, anti-wear)
Binder
(Keep lubricant on the surface)
Dust : Enhance abrasive wear
Contamination of dust enhances abrasive wear.

Contamination of oil decreases adhesion and cohesion.
Solvent evaporation while the can is open increases
viscosity of AF-Coating. Hard to apply.
Degreasing
with solvent
Any dust, oil, and grease must be removed. Ultrasonic is very
useful on this process.
After Degreasing process, you mustnt touch with your hands.
Usually three or more degreasing batches are used. Purity of

solvent on the last batch must be controlled.
Alkaline degreasing
(Mainly for aluminum)
Follow instruction.
Control temperature and time.
Control purity of the detergent batch.
Wash with water to remove alkaline detergent from the surface.
Dry surface before application
Never touch the surface with your hands.
See SOP FC-315
Neutral detergent degreasing

Environmentally friendly, but Efficiency of degreasing is not
so high.
No recommendable neutral detergent, depend on application and
requirement.
Sand blasting
Wet type and Dry type.
Sand blat is done to obtain rough surface, so that adhesion

of AF-coating increases.
Sand blat is effective to remove dust and corrosion.
. .. .. .. .. .. .. .. .. .. .. .. .. .. .
. .. .. .. .. .. .. .. .. .. .. .. .. .. .
. .. . .. . . . ..
Anchor effect
Treat carefully when wet type is used because of corrosion

problem.
Must remove sand by air blow or other methods.
Chapter 3 : Coating method

Chemical treatment
Coating method
Curing
Chemical treatment
(Phosphating)
Follow instruction.
Control temperature and time.
Control purity and PH of the bath.
Wash with water to remove excess phosphate from the surface.
Dry surface before application
Never touch the surface with your hands.
For reference
Zn3(PO4)2 recommendable thickness 2-6m
Mn3(PO4)2 recommendable thickness 3-5m
See SOP PALFOS M5
Lubrication performance
Improvement 1
sandblasted and
phosphated
MoS2 based
coatings:
p = 1000 N/mm2
= 0.03
p = 500 N/mm2
= 0.07/0.08
sandblasted
blank
PTFE based
coatings:
p = 250 N/mm2
Geometrical mean roughness
= 0.07/0.10
Coating method
Spray
parameters:
speed
quantity of material
distance
air pressure
viscosity of coating
1. spray pattern regulation
2. material quantity
regulation
3. air pressure micrometer
4. coating material inlet
adv.:
good appearance
even film thickness
disadv.:
not so economic (investment)
overspray
Coating method
Dip-spinning (centrifuging)
parameters:
form/quantity of parts
rotational speed
viscosity of the coating
adv.:
for bulk goods
economical
disadv.:
two layers min.
bath control
film thickness tolerance
Coating method
Screen printing
parameters:
mesh size/film thickness
high viscosity coating
low evaporation solvents
adv.:
exact pattern/defined area
economical
Curing
circulation oven (hot air stream)
recommended for bulk-goods
object temperature
infrared rays
absorption of the rays in the coating
reduction of the curing & cooling down time
plane surfaces
induction system
the workpiece is heated in a very short period
Selecting an AFC
Please refer to the Antifriction coating selection guidein addn u
should Know
Equipment / MachinePart to be coated ( like
Gear/Pins/Gasket/Screw/Others)
Material of the Part ( SS/MS/Plastic/Aluminium)
Treatment on Part( sandblasting/Phosphating Mn or Zinc etc)
Surface finish (machined/smooth/very smooth)
Dimension of Part ( Dia/length/Width/Height)
Selection of AFC
Movement of part ( to and Fro/ Oscillating/Other)

Speed ( Very slow/slow/Medium/Fast)
Pl mention RPM
Contact with
(steam/dust/water/oil/fuels/referigerant/other)
Operating Temperature :
AFC Recommended :Similar application in global
Business potential
Typical Molykote AFC

Solid lub.
binder
P/B
Cure
system
D 321R
MoS2 +
Graphite
Inorganic
binder
Very high
Room
temp. cure
106
MoS2 +
Graphite
Epoxy resin
high
Heat cure
7409
MoS2 +
Graphite
Polyamideimide resin
average
Heat cure
D 10
Graphite
Polyamideimide resin
average
Heat cure
D-708
PTFE
Phenolic
resin
low
Heat cure
D 96
PTFE
Water base
resin
low
Room
temp. cure
Molykote D 321 R AFC
Advantage
Temperature resistance
Low coefficient of friction
Easy to apply (aerosol can)
No heat curing is required
Running-in
malleability
Disadvantage
Corrosion resistance
Chalking
Application examples
Molykote D 321R AFC
Running-in of gear wheel

Metal (cold) forging
Hydro-forming (stainless steel)
Mechanical element in air plane (maintenance)
Die slider at tire manufacturer
Molykote D 321R AFC
Hydro-forming
Metal (cold) forging
Molykote D 321R AFC
Tire vulcanizing machine
Molykote 106 AFC

Advantage
High load carrying capacity

Long term lubrication
Good adhesion
Easy to apply (compare with 7409 AFC)
Disadvantage
Molykote 106 AFC
Grommet of cylinder head gasket

Compressor shaft of refrigerator
Sliding parts in circuit breaker
Solenoid plunger
Molykote 106 AFC
Grommet
Application Example: Exhaust Manifold

Gaskets
Coated gaskets are

used to eliminate
the ping in most
all Ford exhaust
systems.
Molykote 106 AFC
Compressor of
refrigerator
Circuit breaker
Molykote 106 AFC
Solenoid plunger
Molykote 7409 AFC
Advantage
High load carrying capacity

Long term lubrication
Good adhesion
Resistance to lubricating oil
High temp resistance
Disadvantage
Curing temperature (220)
Drying condition (Forced dry)
Preheating
Molykote 7409 AFC
Engine piston skirt

Piston ring
Screw compressor
Gas valve
Piston
Requirement
Low friction
Anti scuffing
Reducing noise
Productivity ( Screen print )
Product
D 10
PA-744
Key customer
Mahle
Federal Mogul
Aisin
Piston Rings
Requirement
Reduce wear
Reduce adhesive
Product
D-321R
7409
Key customers
Riken
Dana
Federal Mogul
Engine Metal
Requirement
Anti wear
Low friction
Heavy metal free (Lead)
Product
7409
Key customer
Daido Metal
Dana
Kolbenschmidt
Federal Mogul
Molykote 7409 AFC
female rotor
Male rotor
Screw compressor
Application Example: Camshaft and Tappets
Coatings provide
increased performance
and reduced wear
during engine run-in
and cold starts.
Seat belts
Requirement
No stack
No influence with
temperature
Long life
Product
3484
7409
Key customer
Autoliv
TRW
Tokai Rika
Takata
Molykote D 10 AFC
Advantage
High viscosity (screen printing applicable)

Good adhesion
Resistance to lubricating oil
High temp resistance
Disadvantage
Humidity sensitive (<40%RH, 25 required)
Drying condition (Forced dry)
Application Example: Piston and Piston

Rings
Coatings minimize
noise, provide
scuffing resistance
and improve gas
mileage. Also help
to minimize
emissions.
Molykote D-708 AFC

Advantage
Very good appearance

Low coefficient of friction
No chalking
Disadvantage
Load carrying capacity
Molykote D-708 AFC
Sliding parts in seat belt buckle

Bonnet lock parts
Bolt / fastener
Molykote D-708 AFC
Bonnet lock
Seat belt
Molykote D-708 AFC
Bolt / fastener
Application Example: Wiper Blade Coating
Special coating
formulated to be
used with water
repellent glass,
both abrasionresistant and
judder free. D708
Window Regulator
Requirement
Wide temperature service
Low noise even in Dust
Product
SK-623
AI-6159
AF coating
Key customer
Aisin
Shiroki
ArvinMeritor
Brose
Molykote D 96 AFC
Advantage
Water base
Good adhesion plastic
Transparent
Elimination of stick-slip
Air-curing
Disadvantage
Load carrying capacity
Application Example: Anti-Squeak Coating

on Door Panels
Invisible to the eye:
The innovative
coating eliminates
the squeak caused
by friction between
the car door and its
interior trim panel.
Application Example: Anti-Squeak Coating

on Door Panels (2)
Extreme precision:
Molykote D-96 AntiFriction Coating must
be sprayed precisely
onto those sections of
the door panel which
rub against door metal.
Throttle Valve
Requirement
Sealing
Lubricity
Fuel resistance
Product
6050
7400
Key customer
Bosch
Denso
Valeo
Hitachi
Applications of MOLYKOTE AF Coatings on Engines

Camshafts/bearings
Cup tappets
Cylinder-head studs
Carburetor
Cylinder-head gasket
Piston rings
Piston skirt
Starter
solenoid
Starter
motor shaft
Crankshaft/bearings
Studs of main
bearing cap
Flywheel
mounting hub
General Test method of AFC
For the paint (as supplied)
Appearance
Viscosity
Non-volatile content
Density
For the film (when cured)
Appearance
Film thickness
Adhesion
Hardness
Surface roughness
Cured level
Viscosity
Density
Weight (gram)
Volume (cm3)
Specific gravity cup
= density (g/cm3)
Non-Volatile Content
AFC
heat
Weight loss %
100 (%) weight loss (%) = Non-volatile content (%)
Film thickness
coil
coil
film
Eddy current
steel
Electro-magnetic type
Non-ferrous metal
Eddy current type
Adhesion1
Peeling direction
Adhesive tape
substrate
film
cut
Cross cut test
Adhesion2
Mandrel test (bending test)
Hardness
pencil
substrate
film
Pencil hardness test
Surface Roughness
Surface roughness meter
Roughness chart
Cured level
Wipe with solvent cloth
Observe the surface (solved or not)
Performance test of AFC

LFW-1 test
FALEX test
Light load oscillation test
LFW-1
(ASTM D-2714)
What is LFW-1 test?

LFW-1 test measures the coefficient of friction as well as wear ratio
(life time) by rotating or oscillating movements.
The coefficient of friction is tested by the contact of ring on block.
Why the test for?

LFW-1 evaluates the lubricity of lubricants by the coefficient of friction
and wear ratio under different loads and speeds conditions.
Structure of test machine
Specimen ----Contact
----Measurement --Lubricant -----
Ring and block

Line
Coefficient of friction,wear,life
Grease,Paste,oil,AF coating
Speed
Load
------- 600-1000rpm,60-100cpm
------- 30-630lbs.
Temperature ----- Room temp.
Falex
(ASTM D-2670)
What is Falex test?

Falex test measures the coefficient of friction, load carrying capacity
and wear life of lubricants.
The structure of the system is composed of 2-V-shaped blocks and steel
shaft.
Why the test for?

Falex test evaluates lubricating characteristic of lubricants showed in
a coefficient of friction, O.K. load and wear life.
Specimen ----Contact
Pin and V-block

Speed
------290rpm.
Line
Load
------500-4500lbs.
Coefficient of friction,Load carrying capacity,wear life
Paste,Powder,AF coating,oil
Temperature ----Room temp.
Low Load Oscillating Tester

What is Low load oscillating test?
Low load oscillating test determines the coefficient of friction under
relatively low load condition.
Why the test?

Low load oscillating test can evaluate lubricity between different materials.
This test is especially useful for the evaluation of plastic lubrication.
coating
Specimen
-----
Contact
Steel-Steel,Steel-plastics,plastic-plastic
Point,Line
Coefficient of friction
Grease,Paste,AF coating,oil
Speed
------Load
------Temperature -----
0-215cm/sec
0-3Kg
Room temp.

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Dow Corning INTERNAL

Dow Corning INTERNAL

Dow Corning INTERNAL

adhesion, corrosion protection

High amount of binder = good corrosion protection, poor lubricity

Dow Corning INTERNAL

Use of Anti-Friction Coatings (1)

dry lubrication (not affected by dust) with defined film

Dow Corning INTERNAL

Use of Anti-Friction Coatings (2)

under hydrodynamic conditions used only with

Dow Corning INTERNAL

Difference between AFC and

wet film = 30 microns

dry film = 15 microns

Dow Corning INTERNAL

3400A, 106, 7409, D 10,

Dow Corning INTERNAL

Heat Curing / Air Curing

Dow Corning INTERNAL

Load Carrying capacity

Coeff of friction (100%

Lowest on high loads

Lowest on low loads

Dow Corning INTERNAL

Running-in effect (1)

Metal surface Rt = 5/10

Dow Corning INTERNAL

Friction values LFW1 test osc. ASTM

Dow Corning INTERNAL

Dow Corning INTERNAL

Chapter 2 : How to use AF coating

Dow Corning INTERNAL

AF-Coating must be mixed well before use. Density of solid

Dow Corning INTERNAL

Contamination of dust enhances abrasive wear.

Dow Corning INTERNAL

Usually three or more degreasing batches are used. Purity of

Dow Corning INTERNAL

Neutral detergent degreasing

Dow Corning INTERNAL

Sand blat is done to obtain rough surface, so that adhesion

Treat carefully when wet type is used because of corrosion

Dow Corning INTERNAL

Chapter 3 : Coating method

Dow Corning INTERNAL

Dow Corning INTERNAL

Geometrical mean roughness

Dow Corning INTERNAL

Dow Corning INTERNAL

Dow Corning INTERNAL

Dow Corning INTERNAL

Dow Corning INTERNAL

Dow Corning INTERNAL

Movement of part ( to and Fro/ Oscillating/Other)

Dow Corning INTERNAL

Typical Molykote AFC

Dow Corning INTERNAL

Molykote D 321 R AFC

Dow Corning INTERNAL

Running-in of gear wheel

Dow Corning INTERNAL

Metal (cold) forging