Molykote 8_AFC for Training

8/9/2019 Molykote 8_AFC for Training

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Dow Corning INTERNAL

Anti-Friction Coating

14 April 2011

Dr V S Iyer


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What is AF Coating?

Substrate

Anti-Friction Coating

Solid Lubricant(Low friction, anti-wear)

Binder(Keep lubricants on the surface)

Solvent

(Evaporates after applied)

Additive

(wetting, dispersing,anti settle,etc.)


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Responsibilities of Ingredients

Binder: adhesion, corrosion protectionPigments: lubrication, (corrosion protection)

Desire Maximum lubricityand problem: Maximum corrosion protection

High amount of binder = good corrosion protection, poor lubricity

High amount of pigment = good lubricity, poor corrosion protection

Mostly a Compromise

Additives: surface tension, wetting, disperging, antisettle

Solvents: medium to apply coating


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Use

of Anti-Friction Coatings (1) advantages:

dry lubrication (not affected by dust) with defined filmthickness

service life lubrication in many cases (slidingapplications/mixed friction)

no aging, evaporation, oxidation

can often replace surface treatments (ex. galvanizing), offerinlubrication + 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


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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 (coatingfacility/coating skill)

Difficult to remove(after curing), relubricate

Flammable and/or toxic solvent


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Substrate Substrate

Industrial Paint AF-Coating

much binder - less pigment much pigment - less binder

dry film dry film

Difference between AFC and

Ind.Coating

substrate substrate

wet film = 30 micronsdry film = 15 microns

solvent

curing


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Curing of AF-Coatings

Room Temperature Heat Curing

Humidity Oxygen Physical 120C - 250C

D 321R D 96 3400A, 106, 7409, D 10,D 88, D 708,

M-8800


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Heat Curing / Air CuringAdvantages Disadvantage

Heat curing Corrosion protection

Chemical resistance

Equipment (ove

Energy costs

Handling

Air curing Process

Spray cans

Storage stabili

Curing time


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Lubricant Features

Property MoS2 Graphite PTFEColour Black Greyish black Transulcent

Load Carrying capacity

AlmenWeiland 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


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Running-in effect (1)

section of an

AF-C:

afterapplication

and

after loading

Metal surface Rt = 5/10

Phosphating layer appr. 3 m.

Anti-Friction Coatingafter application

appr. 10 m.

Anti-Friction Coatingafter running-in

appr. 2 m.


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Friction values LFW1 test osc. ASTMD2714

Typical friction values of Anti-Friction Coatings

0

0.02

0.04

0.06

0.08

0.1

0.12

service life

coeff.

offric

tion

MoS2 - 1000N/mm2

MoS2 - 500

N/mm2

PTFE - 250

N/mm2

D C i INTERNAL


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AF-Coating 6

Smell526Buthanol

Smell423Butyl

acetate

---6>21White

spirit

Harmful

Smell323.5Xylene

Skin irritant

Hygroscopic763NMP

RemarksEvaporation

ranking

Flash

point()


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Do Corning INTERNAL


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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.

Solvent

Binder

Solid lubricants

MoS2

Graphite

Density Solubility to Solvent


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Surface

AF-Coating

Solid Lubricant(Low friction, anti-wear)

Solvent

(Evaporates after applied)

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.

MixingAvoid Contamination



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Degreasingwith solvent

Any dust, oil, and grease must be removed. Ultrasonic is veryuseful 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.



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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 applicationNever touch the surface with your hands.

Neutral detergent degreasingEnvironmentally friendly, but Efficiency of degreasing is not

so high.

No recommendable neutral detergent, depend on application and

requirement.

See SOP FC-315



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Sand blastingWet type and Dry type.

Treat carefully when wet type is used because of corrosion

problem.

Must remove sand by air blow or other methods.

Sand blat is effective to remove dust and corrosion.

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

of AF-coating increases.

Anchor effect

. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . .. . .



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Chapter 3 : Coating method

Chemical treatment

Coating method

Curing



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g

See SOP PALFOS M5

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 referenceZn3(PO4)2 recommendable thickness 2-6m

Mn3(PO4)2 recommendable thickness 3-5m



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g

Lubrication performanceImprovement 1

blank

sand-

blasted

sandblasted and

phosphated

MoS2 basedcoatings:

p = 1000 N/mm2

= 0.03

p = 500 N/mm2

= 0.07/0.08

PTFE based

coatings: p = 250 N/mm2

= 0.07/0.10Geometrical mean roughness



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Coating methodSpray

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



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Coating methodDip-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



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Coating methodScreen printing

parameters:

mesh size/film thickness

high viscosity coating

low evaporation solvents

adv.:

exact pattern/defined area economical



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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



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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)



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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



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Typical Molykote AFCSolid lub. binder P/B Cure

system

D 321R MoS2 +Graphite

Inorganicbinder

Very high Roomtemp. cure

106 MoS2 +Graphite

Epoxy resin high Heat cure

7409 MoS2 +Graphite Polyamide-imide resin average Heat cure

D 10 Graphite Polyamide-imide resin

average Heat cure

D-708 PTFE Phenolicresin

low Heat cure

D 96 PTFE Water baseresin

low Roomtemp. cure



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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



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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


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Molykote D 321R AFC

Tire vulcanizing machine



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Molykote 106 AFC

Advantage

High load carrying capacity

Long term lubrication

Good adhesion

Easy to apply (compare with 7409 AFC)

Disadvantage Corrosion resistance



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Molykote 106 AFC

Grommet of cylinder head gasket

Compressor shaft of refrigerator

Sliding parts in circuit breaker

Solenoid plunger


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Molykote 106 AFC

Compressor ofrefrigerator

Circuit breaker



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Molykote 106 AFC

Solenoid plunger



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Molykote 7409 AFC

Advantage

High load carrying capacity

Long term lubrication

Good adhesion

Resistance to lubricating oil

High temp resistance

Corrosion resistance

Disadvantage Curing temperature (220)

Drying condition (Forced dry)

Preheating



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Molykote 7409 AFC Engine piston skirt

Piston ring

Screw compressor

Gas valve



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Piston

Requirement Low friction

Anti scuffing

Reducing noise

Productivity ( Screen print ) Product

D 10

PA-744

Key customer

Mahle

Federal Mogul

Aisin



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Piston Rings

Requirement

Reduce wear

Reduce adhesive

Product

D-321R

7409

Key customers

Riken

Dana

Federal Mogul



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Engine Metal

Requirement

Anti wear

Low friction

Heavy metal free (Lead)

Product 7409

Key customer

Daido Metal

Dana

Kolbenschmidt

Federal Mogul



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Molykote 7409 AFC

Screw compressor

Male rotor

female rotor



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Application Example: Camshaft and Tappets

Coatings provide

increased performance

and reduced wearduring engine run-in

and cold starts.



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Seat belts

Requirement No stack

No influence withtemperature

Long life

Product 3484

7409

Key customer Autoliv

TRW

Tokai Rika

Takata



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Molykote D 10 AFC

Advantage

High viscosity (screen printing applicable)

Good adhesion

Resistance to lubricating oil

High temp resistance

Disadvantage

Humidity sensitive (


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Application Example: Piston and Piston

Rings

Coatings minimize

noise, provide

scuffing resistance

and improve gas

mileage. Also help

to minimize

emissions.



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Molykote D-708 AFC

Advantage

Very good appearance

Low coefficient of friction

No chalking

Corrosion resistance

Disadvantage

Load carrying capacity



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Molykote D-708 AFC Sliding parts in seat belt buckle

Bonnet lock parts

Bolt / fastener


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A li i l


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Molykote D-708 AFC

Bolt / fastener


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Wi d R l t


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Window Regulator

Requirement Wide temperature service

Low noise even in Dust

Product

SK-623

AI-6159

AF coating

Key customer Aisin

Shiroki

ArvinMeritor

Brose


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Application Example: Anti Squeak Coating


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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


Application Example: Anti Squeak Coating


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Application Example: Anti-Squeak Coating

on Door Panels (2)

Extreme precision:

Molykote D-96 Anti-

Friction Coating mustbe sprayed precisely

onto those sections of

the door panel which

rub against door metal.


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Applications of MOLYKOTE AF Coatings on Engines


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Camshafts/bearings

Cup tappets

Piston rings

Piston skirt

Starter

solenoid

Starter

motor shaft

Cylinder-head studs

Carburetor

Cylinder-head gasket

Crankshaft/bearings

Studs of main

bearing cap

Flywheel

mounting hub

Applications of MOLYKOTEAF Coatings on Engines



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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



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Viscosity


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Non-Volatile Content

AFC

heat

Weight loss %

100 (%)weight loss (%) = Non-volatile content (%)



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Film thickness

steelNon-ferrous metal

film

coil coil

Eddy current

Electro-magnetic type Eddy current type



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Adhesion1

Cross cut test

cut

filmAdhesive tape

substrate

Peeling direction



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Adhesion2

Mandrel test (bending test)



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Hardness

Pencil hardness test

substrate film

pencil



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Surface Roughness

Surface roughness meter

Roughness chart



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Cured level

Wipe with solvent cloth

Observe the surface (solved or not)


Performance test of AFC


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Performance test of AFC

LFW-1 test

FALEX test

Light load oscillation test


LFW 1


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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


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Specimen ----- Ring and block Speed ------- 600-1000rpm,60-100cpm

Contact ----- Line Load ------- 30-630lbs.

Measurement --- Coefficient of friction,wear,life

Lubricant ----- Grease,Paste,oil,AF coating Temperature ----- Room temp.


F l


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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.




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Specimen ----- Pin and V-block Speed ------- 290rpm.

Contact ----- Line Load ------- 500-4500lbs.

Measurement --- Coefficient of friction,Load carrying capacity,wear life

Lubricant ----- Paste,Powder,AF coating,oil Temperature ----- Room temp.


L L d O ill ti T t


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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.




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Specimen ----- Steel-Steel,Steel-plastics,plastic-plastic

Contact ----- Point,Line Speed ------- 0-215cm/sec

Measurement --- Coefficient of friction Load ------- 0-3Kg

Lubricant ----- Grease,Paste,AF coating,oil Temperature ----- Room temp.

coating

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Molykote 8_AFC for Training