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Metalworking Additives

The metalworking industry is undergoing significant changes brought about by a heightened awareness of health and hygiene issues, an increased demand on fluid functionality, and a move toward safer, more environmentally acceptable ingredients. Lonza is well poised to provide cost-effective solutions to these and other issues facing formulators of metalworking fluids and corrosion inhibitors. Drawing on global resources in biocides as well as its broad knowledge of custom oleochemical synthesis, Lonza is dedicated to providing innovative technologies that address both current and future metalworking industry needs.

Microbial Control Agents


Lonza is a global leader in microbial control agents with dozens of products used for disinfection, preservation, and hygiene applications. Utilizing experience gained from over 40 years of research and development, Lonza manufactures a diverse line of active ingredients for controlling pathogens. Let our biocide specialists recommend a preservative to keep your formulations free from microorganisms during both in-can storage and in-use applications.

Corrosion Inhibitors
CarboShield 1000, dialkyldimethyl ammonium bicarbonate/ carbonate, is an innovative alternative to traditional corrosion inhibitors. It has been shown in repeated lab-scale tests and in commercial applications that it can protect steel, aluminum, copper, brass, zinc, tin and other metal surfaces from corrosion. It provides additional benefits as a cationic surface-active agent to help with parts cleaning, grease removal, and increased formulation stability. CarboShield 1000 also provides remarkable fluid clarity through stable microemulsions. CarboShield 1000 should be included in any program targeted toward reducing metal corrosion.

Functional Additives
Lonza offers a comprehensive range of emulsifiers such as polyethylene glycol esters, glycerol esters, and polyglycerol esters. Many of these are also manufactured as food grade ingredients so in addition to their unique functionality, they are among the safest of chemical additives. Recent research has shown that they can also provide metalworking marketspecific benefits such as tramp oil rejection and foam control. Contact your nearest Lonza sales representative to learn more about functional additives and the entire metalworking additive line.

Microbial Control Agents


Control of microorganisms in metalworking fluids is critical in todays working environment. Contaminated fluids can separate into phases, increase corrosion, and emit unpleasant odors. Controlling the microorganism population in metalworking fluids creates a more hygienic workplace for employees. Lonzas expertise in disinfection and preservation provides formulators with assurance for safe and effective biocontrol.
Regulatory Status % US EU Product Chemical Description Form Activity FIFRA* BPD** Carboquat MW50 Specialty Quat Liquid 50 a No Dantogard DMDMH (dimethyloldimethyl hydantoin) Liquid 40 NA a Dantogard XL-1000 DMDMH (dimethyloldimethyl hydantoin) Powder 100 NA a Dantoserve SG DMDMH and benzisothiazolinone Liquid 50 a a Lonzabac 12.100 Tertiary alkyl amine Liquid 100 a a Lonzabac 12.30 Tertiary alkyl amine Liquid 30 No a Lonzaserve SG DMDMH/CMIT/MIT Liquid 50 NA a Glycacil L IPBC Liquid 10 NA a Glycacil S IPBC Solid 10 NA a Isocil MW-14 CMIT/MIT Liquid 14 NA a Isocil WT n-OIT Liquid 45 a No * FIFRA Federal Insecticide, Fungicide, Rodenticide Act ** BPD Biocidal Products Directive N/A Not Applicable

Graph 1: Free HCHO in Dantogard and Dantoserve SG vs. Triazine Level of free HCHO*(ppm)/10% Active at 25C
40000 35000 30000 25000 20000 15000 10000 5000 0

Day 0 Day 7 Day 30 Day 7 654 4831 36119 Day 30 1423 4834 36749

Day 0 Dantoserve SG 726 Dantogard 4578 Triazine 35383 *HPLC assay of free formaldehyde

Samples of synthetic metalworking fluid containing 1000 ppm actives were taken from a study similar to the one above and analyzed for free formaldehyde. The results are shown in Graph 2.

As shown in Table 1, Dantoserve SG provides effective control Graph 2: Free HCHO in Dantogard and Dantoserve SG vs. Triazine at typical use levels of mixed bacteria in a synthetic metalworking fluid under test conditions set forth in ASTM method D 3946. It is superior to Level of free HCHO*(ppm)/1000 ppm Active at 25C the performance of Triazine (Tris (2-hydroxyethyl) hexahydro-striazine) in the test. Additionally, a blend of Dantoserve SG and 400 Carboquat MW50 shows excellent performance at only 550 ppm 350 actives, with the blend significantly outperforming Triazine at 300 either 500 or 1000 ppm actives. 250 Table 1 ASTM D 3946 Aerobic Bacteria Counts in 5% Synthetic MWF; log reduction
Dantoserve SG Sample 1000 ppm Time 0 Day 5 7 Day 8 6 Day 8 (*) Day 12 7 *after re-inoculation Dantoserve SG 500 ppm 2 2 3 Dantoserve SG/CQ Triazine 500/50 500 ppm 7 6 7 5 7 2 Triazine 1000 ppm 6 6 6 200 150 100 50 0 Day 0 Day 7 Day 30 Day 7 127 201 388 Day 30 141 221 391

Day 0 Dantoserve SG 102 Dantogard 134 Triazine 358 *HPLC assay of free formaldehyde

In Graph 1, Dantogard shows significant advantages by providing lower free formaldehyde levels in both concentrate and at use dilution levels. Dantogard and Dantoserve SG both show significantly less free formaldehyde when compared to Triazine in both 10% solutions and at use-dilution levels (1000 ppm). 3

Corrosion Inhibitors

Product CarboShield 1000 Unamine O Chemical Description Dialkyldimethyl ammonium bicarbonate/carbonate (DDABC) Oleyl hydroxyethyl imidazoline Form % Activity Applications Liquid Liquid 50 85 Flash rust prevention. Corrosion inhibition on steel, aluminum, copper, brass, zinc, tin and other metals. Corrosion inhibitor. Can work synergis- tically with other components.

Aluminum Corrosion/Anti-Staining Results:CarboShield 1000 effectively inhibits staining and corrosion on aluminum at elevated pH (>10). Testing Conditions: Aluminum panels (3003H14, mill finish) were subjected to deionized water pH adjusted to values of 10.5 or 11.5 via ammonium hydroxide. Neat CarboShield 1000 was used at 0.2% rate (0.1% active). The panels were observed periodically for visual staining. As expected, the higher pH sample showed the greatest rate of staining. Unlike a dodecanedioic acid/ MEA blend, CarboShield 1000 significantly reduces staining on aluminum.
Aluminum Samples at pH = 11.5 after 2 hours

Aluminum Samples at pH = 10.5 after 1 week

CarboShield 1000 is an exciting new corrosion control technology based on dialkyldimethyl ammonium bicarbonate/carbonate (DDABC). It is non-volatile, chemically stable in neutral to alkaline pH, thermally stable to over 130C, water miscible, and compatible with oxidants such as hydrogen peroxide and bleach. DDABC is hard water tolerant thereby reducing or eliminating the need for sequestering agents such as EDTA or NTA. Corrosion test results indicate that CarboShield 1000 is extremely effective on a wide range of metals including steel, aluminum, copper, brass, zinc, tin, and galvanized steel. CarboShield 1000 is an exciting new corrosion control technology, and is now registered with the following regulatory agencies as a metalworking/ metal cleaning fluid additive: TSCA (US), DSL (Canada), and ELINCS (Europe). Concise summaries of toxicological and biodegradability data are available upon request. For further information please visit our website www.lonzacarboshield.com.

In both pictures, DI water control (left), 0.1% active CarboShield 1000 (right)

Copper Corrosion Results: CarboShield 1000 effectively prevents copper corrosion even under very harsh conditions. Standard 1/2 inch copper tubes were subjected to solutions containing either 25 ppm bleach (sodium hypochlorite) or 3.5% salt water (sodium chloride). Tubes protected with neat CarboShield 1000 at 0.2% rate (0.1% active) appeared like new after 24 hours.

Composition
The following composition is typical for CarboShield 1000.
Component DDABC Free Amine (didecylmethyl amine) Methanol Propylene Glycol Water Total *CarboShield 1000E contains <3.0% Methanol. Typical Level 50.0% 1.2% 3.3%* 7.2% 38.3% 100%

Copper in 25 ppm bleach water after 24 hours

Copper in 3.5% saltwater after 24 hours

In both pictures, uninhibited control (left), 0.1% active CarboShield 1000 (right)

Functional Additives
Lonzas expertise in ester technology can provide technologists with safe, renewable resource options for their formulating needs. From products such as glyceryl monooleate to ethoxylated sorbitan esters (Polysorbates) to PEG esters, Lonzas broad range of emulsifiers and functional agents provide a wide range of HLB and surface-active characteristics. By proper selection of additives based on their physico-chemical properties, it is possible to optimize their performance attributes. Our knowledgeable formulation experts can assist in the selection of the proper emulsifier to enhance formulation stability as well as recommend an additive to control foam. Whether your goal is to control foam, tramp oil, or increase fluid functionality, Lonzas broad line of oleochemical-based ingredients and our technical support staff can assist in solving the most complex problems facing the metalworking fluid formulator today. Call our toll-free technical support hotline at 1-800-365-8324 and see what Lonza can offer. PEG Esters Product
Pegosperse 400 ML Pegosperse 400 DL Pegosperse 400 DO Pegosperse 400 MC Pegosperse 400 MO Pegosperse 400 MOT Pegosperse 600 MO Pegosperse 600 DO Pegosperse 400 DOT Pegosperse 600 DOT

Ethoxylated Monoglycerides and Polysorbates Acid Sap Product Chemical Description Form Value Value HLB Application
Lonzest SMO-5 Lonzest SMO-20 Lonzest STO-20 Lonzest SML-20 POE (5) Sorbitan Monooleate Liquid POE (20) Sorbitan Monooleate Liquid POE (20) Sorbitan Trioleate Liquid POE (20) Sorbitan Monolaurate Liquid 1 1 7 1 10 Emulsifier 15 Emulsifier 11 Emulsifier 17 Emulsifier

Foam Control Agents


Acid Sap Product Chemical Description Form Value Value HLB Application Polyaldo DGDO-KFG Decaglyceryl decaoleate Liquid 8 170 3 Foam Control Polyaldo 10-4-O Decaglyceryl tetraoleate Liquid 8 125 7 Foam Control

Foam Control Agents Graph 1


60 50 45 40 35 30 25 20 15 10 5 0

Tests were run on synthetic MWFS using Lonza foam control agents. Foam reduction for Polyaldo DGDO-KFG is shown in Graph 1. Results are for Shake Test.

(50) Control (0) 0.2% Polyaldo DGDO-KFG

Chemical Description PEG 400 Monolaurate PEG 400 Dilaurate PEG 400 Dioleate PEG 400 Mono Caprylate/Caprate PEG 400 Monooleate PEG 400 Monotallate PEG 600 Monooleate PEG 600 Dioleate PEG 400 Ditallate PEG 600 Ditallate

Acid Form Value Liquid 3 Liquid 5 Liquid 5 Liquid 2 Liquid Liquid Liquid Liquid Liquid Liquid 2 8 6 5 10 10

Sap Value HLB Application 95 14 Emulsifier 135 10 Emulsifier 120 8 Emulsifier 102 15 Emulsifier 84 86 67 98 115 95 11 11 13 9 8 11 Emulsifier Emulsifier/ Lubricant Emulsifier Lubricant Emulsifier Emulsifier

Foam Height, ml.

Tramp Oil Rejection Aid


Product

Chemical Description

Form Liquid

APHA Color 50

PH 7

Lonza 1125 PHMG* *Developmental product.

Monoglycerides and Sorbitan Esters Product Chemical Description Form


Lonzest GMO Lonzest GDL Lonzest GMT Lonzest SMO Lonzest SML Lonzest TAO Glyceryl Monooleate Glyceryl Dilaurate Glyceryl Monotallate Sorbitan Monooleate Sorbitan Monolaurate Sorbitan Monotallate Liquid Liquid Liquid Liquid Liquid Liquid

Acid Value 2 5 2 8 7 8

Sap Value HLBApplication 170 3 Emulsifier 225 7 Emulsifier 160 3 Emulsifier 155 4 Emulsifier 165 8 Emulsifier 155 4 Emulsifier

Lonza Ltd Muenchensteinerstrasse 38 CH-4002 Basel, Switzerland Tel +41 61 316 81 11 Fax +41 61 316 91 11 contact@lonza.com

Lonza Inc 90 Boroline Road Allendale, NJ 07401, USA Tel +1 201 316 9200 Fax +1 201 785 9973 contact.allendale@lonza.com

The information contained herein is believed to be correct and corresponds to the latest state of scientific and technical knowledge. However, no warranty is made, either express or implied, regarding its accuracy or the results to be obtained from the use of such information. No statement is intended or should be construed as a recommendation to infringe any existing patent. Lonza, Inc. May, 2007 Printed in the USA.

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