SOLID FILM LUBRICANTS

THE DRY LUBRICATION

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CONTENTS
INTRODUCTION...................................................................................................................... 3 STRUCTURE AND FUNCTION OF SOLID FILM LUBRICANTS...................................................... 4 PERFORMANCE RANGE OF SOLID FILM LUBRICANTS.............................................................. 6 PRE-TREATMENT AND APPLICATION....................................................................................... 7 TYPICAL TEST METHODS FOR SOLID FILM LUBRICANTS.........................................................10 SELECTION AND USE OF SOLID FILM LUBRICANTS.................................................................12 USING SOLID FILM LUBRICANTS ON VARIOUS AUTOMOTIVE APPLICATIONS......................... 13 FUCHS LUBRITECH'S SOLID FILM LUBRICANT CONCEPT.........................................................14

APPENDIX APPLICATIONS.......................................................................................................................16 CHARACTERISTIC DATA........................................................................................................ 17 CHECK-LIST SOLID FILM LUBRICANT COATING...................................................................18

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INTRODUCTION

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INTRODUCTION INTRODUCTION
In many instances, if it's a question of dry film lubrication, solid film lubricants are the optimum choice. Solid lubricant coating has proved its worth many times over and today provides a reliable and indispensable design element. Increases in automated production and assembly makes solid film lubricants ever more important. They make it possible to provide many structural components with dry, efficient lubrication and, compared with conventional lubricants, permit designs to be simpler. They improve the running-in of highly-stressed machinery components, in many simplify installation guarantee processes and, instances, maintenance-free

lifetime lubrication. Solid film lubricants manufactured by FUCHS LUBRITECH are "state-of-the-art" and meet the increasing technical demands made by diverse sectors such as industrial and plant technology, metal-processing industry, machinery construction and the commodity goods and automotive industries. In addition to their outstanding technical properties, the solid film lubricants made by FUCHS LUBRITECH also comply with the ever-increasing demands to address environmental issues.

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STRUCTURE AND FUNCTION OF SOLID FILM LUBRICANTS

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STRUCTURE STRUCTURE AND FUNCTION OF AND SOLID FILM LUBRICANTS FUNCTION

Solid film lubricants are carefully selected solid lubricants combined with organic or inorganic binders dispersed in solvents. The fundamental difference compared with normal industrial varnishes is that they contain solid lubricants instead of colour pigments. Apart from the main components binders, solid lubricants and solvents solid film lubricants may also contain functional additives such as corrosion inhibitors or UV active components.

COMPOSITION OF SOLID FILM LUBRICANTS

Solid Lubricants MoS2, graphite, PTFE ... Binders Epoxy-, polyurethane-, amide-imide-, silicone resin Solvents Organic solvents, water Additives Corrosion protection, wetting, preservatives, UV additive ...

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STRUCTURE AND FUNCTION OF SOLID FILM LUBRICANTS

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INDUSTRIAL VARNISH
30 m

After drying and curing, solid film lubricants form a strong dry coating several microns thick, by adhering firmly to the substrate. The film reduces both wear and friction as well as acting as a parting agent and provides lubrication between the opposing surfaces.

SOLID FILM LUBRICANT

10 m
10m

SOLID FILM LUBRICANT ON PHOSPHATED METAL

10-15 m

Solid lubricant deposited on surface

Solid lubricant impregnated into surface

Scanning electron micrograph of the surface of a MoS2 solid film lubricant layer before applying frictional load.

10m

Binder Metal

Colour pigment Solid lubricant

Phosphate layer

Scanning electron micrograph of the surface of a MoS2 solid film lubricant layer after frictional loading smoothing of the surface of the solid film lubricant.

FUNCTION OF A SOLID FILM LUBRICANT

Opposing surface Opposing surface Opposing surface

Initial smoothing of the surface of the solid film lubricant takes place as a result of the relative movement of the opposing surfaces. A partial discharge of material from the solid film lubricant layer creates a "transfer" film on the

1) Partial separation of the solid lubricant from the coating

2) Transfer of the solid lubricant onto the opposing surface

3) Formation of the transfer film

opposite surface. The build-up of lubricating film between the two surfaces leads to a reduction in the coefficient of friction.

STRIBECK DIAGRAM: MODEL OF THE FRICTION AREAS DURING FLUID LUBRICATION

Static friction Coefficient of Friction

The solid film lubricant provides the dual advantage of dry and clean lubrication and in many instances can replace the use of greases and fluid lubricants, particularly where slow sliding movements are involved. In addition solid film lubricants can be

Boundary friction Hydrodynamic friction (Fluid lubrication) Boundary friction Mixed friction

used in combination with fluid or pastes. Solid film lubricants enhance the lubrication of components in the boundary friction region, when there is no hydrodynamic lubrication and direct contact between the surfaces occurs.

Mixed friction

Hydrodynamic friction Rotational speed n Solid film lubricant Oil

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PERFORMANCE RANGE OF SOLID FILM LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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PERFORMANCE FILM LUBRICANTS PERFORMANCE RANGE OF SOLID RANGE

Solid film lubricants enable to pre-treat and store lubricated parts ready for assembly. They are characterised by extremely high resistance to pressure and to temperatures; they neither age nor become resinous and at the same time are clean to handle. FUCHS LUBRITECH's solid film lubricants possess outstanding lubricating and protective properties: ADVANTAGES FIELDS OF APPLICATION

SOLID FILM LUBRICANTS

Q make dry and clean lubrication possible Q are resistant to contamination Q protect against corrosion Q lubricate under extreme conditions

SOLID FILM LUBRICANTS

Q make assembly and dismantling of fitted parts simpler Q optimise the running-in performance of highly-stressed components Q make maintenance-free lifetime lubrication possible Q prevent the occurrence of "stick-slip" and thus reduce noise Q attain precise coefficients of friction with low variables for fasteners Q when combined with oil and grease lubrication guarantee additional

(high and low temperatures, vacuum, radiation)

Q are suitable for the surface refinement of a number

of materials (metals, plastics, elastomers, ceramics, glass etc.)

safety through emergency lubrication.

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PRE-TREATMENT AND APPLICATION

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PRE-TREATMENT PRE-TREATMENT AND APPLICATION & APPLICATION

The application of solid film lubricants is a complex subject and should be done by specialists.

PRE-TREATMENT
Surface preparation of the parts to be coated plays an important role during solid film lubricant coating. Good adhesion and therefore long lifetime can only be achieved with a pre-treatment which is customised for the particular part and solid film lubricant. Thorough removal of all grease residues, dust, dirt, rust and scale is a fundamental part of the pre-treatment of the work piece surface.

METAL PARTS: De-greasing can usually be done by using organic solvents, such as, for example, hydrocarbon, acetone etc. A more environmentally and user-friendly result can be achieved by using alkaline or neutral aqueous cleaners. The effectiveness of the cleaners can usually be intensified when combined with ultrasound or heat. Rust and scale can be removed mechanically or chemically. Grinding or blasting are suitable mechanical pre-treatment methods. Rust and scale can be removed chemically through pickling in acids or lyes. Phosphatising can give significantly improved adhesion of the solid film lubricant onto the metal surface. Phosphating improves both the mechanical properties and corrosion protection of the parts to be coated. Normally, zinc or manganese phosphating is used.

PLASTIC PARTS: De-greasing of plastics and elastomers can be achieved with aqueous cleaners or solvents. When using solvents, however, attention should be paid to compatibility with the plastics to be cleaned. The adhesion of the solid film lubricants can be improved by roughing the surface, for example. Suitable methods are grinding or blasting with CO2 or sand. Deformation of the parts or surface damage must be activation, corona or flame treatment can be used for the pre-treatment of plastics. avoided. Alternatively, physical methods such as plasma

Relative service life of solid film lubricants is dependent upon roughness of the substratum and pre-treatment methods

sandblasted and phosphated sandblasted ground

2 4 6 8 10 12 14 16 18 Surface roughness [m]

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Relative service life

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PRE-TREATMENT AND APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Drum

Spraying

Sand blasting Continuous drum Chemical pre-treatment

Using robots

CLEANING

PRE-TREATMENT

APPL

APPLICATION
Decisive for the application of the solid film lubricant are primarily the geometric shape of the parts and the technical application properties of the selected coating. Application is principally undertaken using traditional processes found in coating technology, such as, dipping, tumbling, dip-centrifuging and spraying. SPRAY-COATING For most products it has been shown that the "non volatile part" of the solid film lubricant should be set at about 26-30% for spray application. The non-volatile part corresponds to the dry residue, i.e. the dry lubricant coating after the solvent has evaporated. Any standard spray gun may be used. HVLP spray guns, with a circular/spread jet setting and a nozzle diameter of 0.5-0.8 mm, have proved to be particularly suitable. The specific design of the HVLP spray technology allows varnish utilisation of up to 60%. In many usages pre-heating of the parts to be coated to 60-80C is an advantage. This also allows the application of layers with a thickness greater than 20m without intermediate ventilation. Spray-coating usually achieves layer thicknesses of 10-30 m. DIP-CENTRIFUGING During centrifuge coating, it is recommended to set the non-volatile part to 22-28%, in order to achieve an optimum coating result. Here, too, it can be an advantage to pre-heat the parts to be coated to 80-85 C.
very suitable conditionally suitable SUMMARY OF THE COATING METHODS AND AREAS OF APPLICATION

Higher temperatures lead to partial accumulations of varnish and rough surfaces, lower temperatures only give rise to very thin layers. The ideal degree of filling of the centrifuge depends on the plant and usually has to be determined empirically (guideline: 60-70%). Using this method of application varnish utilisation can amount to up to 90%. It is, however, difficult to achieve homogenous layers over 10m thick. With dip-centrifuging there is the danger that the parts will stick together (particularly parts with flat surfaces). The parts should, therefore, be moved continuously during dipping and also when drying or curing afterwards.

Spray coating Drum coating Dip Coating Dip/centrifugal coating Spray drum coating

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PRE-TREATMENT AND APPLICATION

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Centrifuge

Dipping

Baking

UV light

Layer thickness testing Rotary cycling table Drying

CATION

HARDENING

QUALITY CONTROL

PACKING

DRUM COATING Coating in drums is particularly suitable for bulk goods, which have simple shapes (e.g. washers, bolts, pins, O-rings). An advantage of this process is the surface smoothing that occurs due to the friction between the coated parts in the drum and so homogenous layer surfaces can be achieved. By combining it with a spray coating in so-called "spraying drums" the thickness of product deposited can be controlled precisely, thereby giving an improved coating.

Normal curing temperatures are in the region of approx. 100-200C. More detailed information about the solid film lubricants made by FUCHS LUBRITECH can be obtained from the relevant product information sheets.

QUALITY CONTROL
The general criteria used for the quality control of solid film lubricant layers are the surface finish, the coating thickness and adhesion to the surface of the component. Transparent solid film lubricants usually contain a special UV indicator which can be made visible with a UV lamp and allows "Yes/No" control. Further control parameters are determined by the shape of the component and the requirements of the coating applied. Quality control statistical analysis using appropriate test rigs is rarely required.

HARDENING
Air-drying solid film lubricants are dried at room temperature before being subjected to frictional load, while heat-cured solid film lubricants are cured after coating.

Reduced consumption of coating

Eliminate components sticking

Bulk components

Complex shapes

Greater coating thickness

Ensure coating quality

Individual components

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Costs

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TYPICAL TEST METHODS FOR SOLID FILM LUBRICANTS

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TYPICAL METHODS METHODS FO TYPICAL TEST TEST

FOR SOLID FILM LUBRICANTS
Various methods are used to test the performance of solid film lubricants. The individual characteristics of a solid film lubricant can be established by selecting the correct test method. ALMEN WIELAND TEST METHOD
Q Q

3500 3000 2500 2000 1500

350 300 250 200 150 100 50 0 Time [min] 18:00 Temperature T [C]

RLV1)

060

Rotating shaft (coated) fixed in two bearing shells Contact geometry: flat surface Test criteria: fretting load, coefficient of friction Measurement at slow sliding speeds
F n

Q Q

1000 500 0 00:00

SRV TEST METHOD

Q Q

DIN 51834-8 Oscillating counterpart on a plate (coated)

F
Coefficient of Friction,

0,250

0,200

0,150

Contact geometry: line (alternatively flat surface or point) Test criteria: coefficient of friction, wear Service life testing at high sliding speeds and varying surface pressures

0,100

Q Q

0,050

0 0 10 20 30 40 50 60 70 Time [min] 80 90 100 110 120

LFW1 TEST METHOD

Q Q Q Q Q

0,20

ASTM D 2714 (RLV1) 119) Oscillating ring on block (coated) Contact geometry: line Test criteria: coefficient of friction, wear Service life testing at slow sliding speeds
Coefficient of Friction, 0,10

-0,10

-0,20 0 00:30 01:00 01:30 Time [h:min] 02:00 02:30

1) RLV: LUBRITECH Laboratory Specifications

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METHODS FOR SOLID FILM LUBRICANTS

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OR SOLID FILM LUBRICANTS

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COEFFICIENT OF FRICTION TESTING ON ELASTOMERS

Q Q

uncoated 7 6 5 4 3 2 1 0 0
10 20 30 40

DIN 52375 (RLV1) 142) Oscillating counterpart on a coated elastomer plate Contact geometry: flat surface Test criteria: friction force Measurement at slow speeds and under low loads

coated with solid film lubricant

Q Q Q

Sliding track [mm]

SCREW TEST
Q Q

100

DIN EN ISO 16047 (DIN 946) Determination of coefficients of friction on bolted connections Contact geometry: flat surface (thread and bolt head) Test criteria: coefficient of friction, clamping force Measurement of thread friction, friction under head and total coefficient of friction
Tightening torque MA [Nm]

80

60

40

20

0 0
10.000 20.000 30.000 40.000

Clamping force Fv [Nm]

CORROSION TESTS
Q

DIN 50021 (salt spray test), DIN 50017 (condensed water test), VDA 621-415 (alternating cycles test)

Determination of the corrosion resistance of coated test plates or components

uncoated coated with solid film lubricant

1) RLV: LUBRITECH Laboratory Specifications

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SELECTION AND USE OF SOLID FILM LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SELECTION OF SOLID FILM LUBRICANTS SELECTION AND USE & USE

Coefficient of Friction,

The special demands placed on a solid film lubricant coating are as numerous as the possible applications. The selection of a suitable solid film lubricant requires a high degree of professional competence and is mainly determined by these factors: type of component, purpose of the coating, surrounding conditions and quality management requirements. Solid film lubricants manufactured by FUCHS LUBRITECH have proved themselves in many fields and represent the optimum solution for dry and clean lubrication. Thus, for example, they can provide installation-compatible lubrication for screw connections, fitted parts and O-rings, help to minimise wear on gear components essential to safety.

0,24

Running-in phase
0,21 0,18 0,15 0,12 0,09

Stationary phase
0,06 0,03

Characteristic slope of the coefficient of friction of a MoS2-based solid film lubricant depending on the test duration.

Test duration

SELECTION CRITERIA FOR COATINGS

COMPONENT COATING PURPOSE

Geometry Weight Q Material Q Surface Q Coating costs

Q Q

Running-in lubrication Q Assembly Q Lifetime lubrication Q Corrosion protection Q Wear reduction Q Decorative appearance Q Increase in value Q

Service life (relative)

and provide lifetime lubrication for components

20 min-1

TYPE OF COATING
Temperature range Q Environmental conditions Q Friction conditions Q Load Q Type of movement Q Load cycle Q
ENVIRONMENTAL CONDITIONS

60 min-1 100 min-1

20 40 60 80 Load [N/mm2]

Influence of load and speed on the service life of a MoS2-based solid film lubricant.

Coefficient of Friction,

Component testing Model testing Q Statistical process control Q Documentation

Q Q

0,15

QUALITY CONTROL REQUIREMENTS

0,10

The assessment as to whether a solid film lubricant is suitable for providing lifetime lubrication for a component must usually be proved through trials on suitable test rigs. Generally solid film lubricants have a limited service life, which will be indicated in the trial by an increase in the coefficient of friction and the appearance of wear phenomena. Thus, it should be noted that load and sliding speed of the component can have a great influence on the performance of the solid film lubricant.
200 400 600 800 Load [N/mm2] 0,05

Influence of load on the coefficient of friction of a MoS2-based solid film lubricant.

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USING SOLID FILM LUBRICANTS ON VARIOUS AUTOMOTIVE APPLICATIONS

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USING SOLID FILM USING SOLID FILM LUBRICANTS ON VARIOUSLUBRICANTS AUTOMOTIVE APPLICATIONS
11 10 1

2 3 4 9 5
So urc e: Da im ler Ch rys ler AG

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AREAS OF APPLICATION
1 2 3 4 5
Coating of profile gaskets Various plastic parts in the car interior Connecting parts in the engine compartment Elements of the fuel injection system Reduced coefficient of friction of O-rings Wear reduction of gaskets Coating of wheel bolts High temperature solid film lubricants for exhaust systems Wear reduction of seat adjustment mechanisms Closure mechanisms of the safety-belt systems Sliding components in the boot lid Sections of the door locking system Installation lubrication / running-in conditions Lifetime lubrication Noise reduction

Apart from numerous industrial applications, the versatility of solid film lubrication can be seen from the automotive applications outlined below. Solid film lubricants ease the assembly of sealing and bolting elements, contribute to interior noise reduction, provide the best possible performance under extreme conditions (e.g. engine compartment, exhaust system) and guarantee safe and reliable lubrication of components.

6 7 8 9 10 11 12

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THE SOLID FILM LUBRICANT CONCEPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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THE CUSTOMER IS PARAMOUNT THE SOLID FILM LUBRICANT CONCEPT

Our professional and experienced lubrication technology team will help you find solutions to your technical requirements. With our sample coating service we offer you the opportunity to test the efficiency of our products on your components. If necessary we will develop tailormade solutions especially for your application. In addition we will assist you with the implementation of a solid film lubricant coating system up to the production stage. In addition, through the know-how transfer of the application technology, we make it possible for implementation to take place at your own premises or at those of one of our numerous external partners. We offer you the opportunity to have coating work carried out at one of our coating centres (FLT Surface Technology).

Sample coating on a laboratory- and semi commercial scale

the of er gy nsf lo tra no w tech -ho g ow tin Kn coa

Tec on hnica lub l a ric dvi an ce ts e ng tr ati en co ng c act ati ntr co Co own r ou in

Service investigations by our development division

14 SOLID FILM LUBRICANTS - THE DRY LUBRICATION

of tai Dev lor elo -m pm ad en ep t rod uct s

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APPENDIX

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APPLICATIONS AND CHARACTERISTIC DATA CHECK-LIST SOLID FILM LUBRICANT COATING

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APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CHECK-LIST SOLID FILM LUBRICANT COATING

Please cross off as appropriate

1. GENERAL CUSTOMER INFORMATION

Company

Contact person

Department

Street

Postal Code/ Location

Phone

Fax

E-Mail

Internet

2. INFORMATION ABOUT THE COMPONENT FUNCTION / AREA OF APPLICATION (if possible enclose drawing or sketch)
Description

To what stresses is the component / the system subjected? Surface pressure Surrounding media (e.g. dust, salt water, oil, air etc.) Type of movement (e.g. rolling, sliding) Operating temperature C up to C

3. INFORMATION CONCERNING THE COMPONENT TO BE COATED

Material

Steel

(alloy/description; e.g. St. 37, 100 Chromium 6)

Stainless Steel Miscellaneous

Plastic/elastomers Surface finish blank

(e.g. PA, PP NBR, EPDM)

Roughness (e.g. Ra value)

(e.g. phosphatised, galvanised)

Surface finished

4. INFORMATION ABOUT THE UNCOATED MATING SURFACE AT 3.

Material

Steel

(alloy/description; e.g. St. 37, 100 Chromium 6)

Stainless Steel Miscellaneous

Plastic/elastomers Surface finish blank

(e.g. PA, PP NBR, EPDM)

Roughness (e.g. Ra value)

(e.g. phosphatised, galvanised)

Surface finished

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APPENDIX

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5. REQUIREMENT PROFILE
Coating specified by the customer : (including pre-treatment) Coating for assembly aid Running-in lubrication Low coefficient of friction [] Better wear performance Corrosion protection [h] Test method Miscellaneous Component testing: Load cycles (number of cycles): Sliding speed in m/s: Sliding track in mm: Water-based Durable function lubrication Solvent-based

Approx. layer thickness in m: (only give details if absolutely necessary) Partial coating (please indicate area on the drawing) Complete coating (standard process)

6. WHAT MUST BE TAKEN INTO ACCOUNT REGARDING THE COMPONENT / ITS USE?
Sand-blasting permissible Phosphating permissible Avoid temperatures below Miscellaneous Yes Yes No No C / above C

7. INFORMATION NEEDED FOR JOB COATING As part of our sample coating service we will suggest one or more coating processes. In order to be able to select a suitable process for you at the sample stage we would ask you for the following information:
Number of items per year Number of items per delivery Part weight, if applicable Other requirements

SEND IN THE CHECK-LIST Please forward this check-list and supplementary information to: FUCHS LUBRITECH GMBH Product Management, Dry Film and Coatings Werner-Heisenberg-Strae 1 67661 Kaiserslautern/Germany E-mail: gleitlacke@fuchs-lubritech.de NOTE: This and other check-lists are also available for downloading on the Internet from www.fuchs-lubritech.com.

FUCHS LUBRITECH GMBH

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Lubrication Technology

FUCHS LUBRITECH GMBH

Werner-Heisenberg-Strae 1 67661 Kaiserslautern/Germany www.fuchs-lubritech.com
Phone: +49 (0) 6301 3206-0 Fax: +49 (0) 6301 3206-940

E-Mail: info@fuchs-lubritech.de

1' PP 03/07 0601787