Lubricating and descaling agents for the hot metal forming industry

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Who are we?

TIMCAL Graphite & Carbon has a strong tradition and history in carbon manufacturing. Its rst manufacturing operation was founded in 1908. Today, TIMCAL facilities produce and market a large variety of synthetic and natural graphite powders, conductive carbon blacks and dispersions of consistent high quality. Adhering to a philosophy of Total Quality Management and continuous process improvement, the TIMCAL manufacturing plants comply with ISO 9001-2000. TIMCAL Graphite & Carbon is committed to produce highly specialized graphite and carbon materials for today and tomorrow customers needs. TIMCAL Graphite & Carbon is a member of IMERYS, a world leader in adding value to minerals.

Where are we located?

With headquarters in Switzerland, TIMCAL Graphite & Carbon has an international presence with facilities and commercial ofces located in key markets around the globe. The Groups industrial and commercial activities are managed by an experienced multi-national team of more than 450 employees, from many countries on three continents.
Bodio, Switzerland

Willebroek, Belgium

What do we offer to our customers?

Providing customerrelated solutions
NTIMCAL Graphite & Carbon produces a variety of synthetic and natural graphite powders, conductive carbon blacks, calcined petroleum cokes, aqueous 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 provide 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.

Lac-des-les, Canada

What is our vision?

TIMCALs vision is to be recognized worldwide as a leader in realizing challenging solutions for its customers by means of special carbons and related applications.

Terrebonne, Canada

Changzhou, China

Baoutou, China

Fuji, Japan

Why ROLLIT?
The idea
NTo produce a lubricant for the Hot Metal Forming industry. This product must be easy to apply by spraying or dipping, resist high temperatures, be stable as an aqueous dispersion and be environmentally friendly. NThe suitability of graphite for lubricants used in Hot Metal Forming processes can be characterized by three important physical and chemical parameters: NThe lubricants formulation is optimized to improve the following properties:

Stability Purity
NThe graphite has to be free of abrasive, polluting or hazardous impurities. Minimize sedimentation No biological fermentation

TIMCAL did it!

Film properties
Adhesion to the mandrel Water resistance Thermal stability

Crystallinity
NThe crystallinity of graphite is essential for the lubrication properties. It has a direct effect on wear, tool life and workpiece quality.

Ecology and safety

NAll ROLLIT dispersions are water based and contain only environmental friendly raw materials.

Particle size distribution

NAn optimized particle size distribution provides optimum tool protection and coverage, thus improving workpiece quality.

Cost savings
NThe cost of ROLLIT material is rapidly paid back by its great advantages of: less tool wear, better workpiece surface, less down time and an increase of production speed.

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HMF Technologies and markets

NROLLIT products were developed to meet a precise need of lubricating products. 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:

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 nal application this multiple feature allows to use one single product covering two purposes.

Briquettes/Demolding agents (ROLLIT DS and DDP products)

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

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

Mandrel Bar Lubrication Forging dispersions (ROLLIT DS and (ROLLIT DF products) DDP products)
NTo withstand the high pressure, temperature 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 powder or liquid form according to customer requirements. NROLLIT DF family (Aqueous Graphite Dispersions) is specially developed for the forging industry. Physical properties like pressure and temperature are extreme during forging processes. NTherefore the lubricating effect obtained from the forging dispersion layer is of fundamental importance to reach a perfect work-piece.

Upsetting/Extrusion agents (ROLLIT DS and DDP products)

NTIMCAL offers solutions to rationalize upsetting and extrusion processes. In close cooperation with customers we are ready to further develop products responding to the particular needs of these sectors.

Application Systems
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 the appropriate sliding valve and spray nozzles. Pressure can be freely adjusted to obtain the requested quantity of lubricant on the mandrel.

EZ unit
NThis module allow the blowing of descaling products into the hot shells. NBlowing parameters can be freely selected 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.

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ROLLIT Lubricants
NThis is an overview of some of TIMCALs most used products. Of course the selection of the right product depends on many factors (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 delivered in paper bags or big bags. NThe liquid products are available in containers or drums. Feel free to contact us at: www.timcal com.

MPM & PQF

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
Especially suitable

FM

Assel mill

Push bench

Plug mill

Briquetting

Up setter

Forging

Billet coating

Suitable

Examples of use
NROLLIT products can be supplied either in powder or liquid form. TIMCAL recommends to apply ROLLIT products thorough TIMCAL Application Systems in order to obtain the best hot metal forming results. NNevertheless the application in the mill can be made also with existing injection or spraying units. NTIMCALs 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 treatment and 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

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

Sponge iron briquettes Production

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

Quality
CTIMCAL has been certied with ISO 9001/2000 and complies with the international Standards for Quality Management. CTIMCAL is committed to supplying high quality products. TIMCAL concentrates all its efforts on assuring consistent product quality. CThis makes TIMCAL condent of its products success and market satisfaction today and in the future. CTo reach these targets TIMCAL has prepared its laboratories with the most outstanding equipment operated by specialists in the lubricating industry. CThe quality of raw materials and intermediates is constantly controlled during the whole production process.

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Analytical procedures for ROLLIT products

Friction measurement with 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 rst 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 coefcient and energy dissipated during the sliding. The test variables are the sliding speed, the load and the temperatures. Reference: - TIMCAL method

Solid content
NThe solid content is measured using a Halogen Moisture Determination thermobalance. NIn this procedure 1 to 2 g of the dispersion 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

Wetting test
NIn the wetting test the quantity of remaining graphite on steel surfaces is measured after being sprayed with dispersions. NThe test has been developed to simulate 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 heated 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 passing 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

Viscosity and ow behavior

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 ow of layers is created. NThe viscosity is obtained from measuring the internal resistance and a ow curve is obtained. 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 reading the pH is recorded. Reference: - TIMCAL method

Tribological tests for 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 adhesion behavior. NTo be sure that ROLLIT products meet the clients requirements TIMCAL has developed its own friction test equipment. NWith this equipment it is possible to measure the frictional behavior of metals and alloys at a high temperature and pressure, conditions which are very close to the actual tube-rolling process. NThese tests give the friction coefcients specic 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 solutions tailor-made to the specic application of the customers.

High temperature tribometer

Lubricant sprayed onto Mandrel at 150 Shell heated to 1050 C in induction furnace

NORMAL PRESSURE (225 kN/cm2)

l = 70 mm v = 45 mm/s

Piston Friction force Friction exerted by motor Mandrel Lubricated surface

Examination of tested surfaces

"Shell"

Computer data acquisition

Storage of data

Output of experimental data

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