Aluminium Industry Solutions for Reliability.pptx

Reliability for Alumnium Industry

1. Explore, Discover Solutions for more reliable operations Molykote ® Specialty Lubrication Solutions for the Dubal

2. Content Dow Corning overview Requirements of Aluminium Industry Dow Corning solutions Typical properties of Molykote ® brand specialty lubricants Products for the Aluminum Key example of application Threaded Connections (Paste / AFCs) Threaded Connections (HDG / COF & size of bolts) Threaded Connections (Test equipment) More typical applications Application of pipeline fittings

3. Dow Corning is ….. A global leader in silicones and high purity silicon More than 7,000 products/services Approx 25,000 customers Approx 10,000 employees Strong and healthy financially: $6.12 billion sales 2012 Investing in our future and our customers’ futures: geographic, manufacturing, innovation Transforming our business to deliver: Efficiency, Innovation and Sustainability Focused on sustainability and Responsible Care ®

4. Automotive, Appliance, Assembly & Maintenance Sustainability Safety, Comfort and Convenience • Worldwide quality and technologies • Local supply and expertise • Accident, fault and failure protection assistance • Resource development and preservation Environmentally Sensitive • Fuel/energy efficiency • Low VOCs, emissions • Reduced noise and wear • Less waste, more value Lower Costs, Higher Productivity Energy efficiency and alternatives Equipment reliability and durability Process and product enhancements Improved design, assembly and service

5. Industrial Assembly & Maintenance Markets Served Heavy Industries Automotive Manufacturing Appliances Maintenance, Repair & Overhaul Oil & Gas Chemical & Petrochemical Energy Facilities Engineering Food & Beverage Water Management

6. Industrial Assembly & Maintenance On the Job Challenges Reduce Unplanned Maintenance Increase Uptime Protect Worker Safety Shield Equipment from Harsh Environments Improve Energy Efficiency Extend Lifetime of Parts Improve Performance & Reliability Reduce Overall Cost of Ownership

7. Industrial Assembly & Maintenance Products & Brands High-performance lubricants Greases, anti-seize pastes, anti-friction coatings, compounds and oils Heat-resistant adhesive/sealants Silicone and fluorosilicone Silicone foams Self-expanding formulations Engineered elastomers LSR, FSR, F-LSR, HCR Silastic ®

8. Extraordinary requirements due to extreme Industry conditions Aggressive environments Salt Water and Steam High & low Temperatures Corrosive Influences Tough technical parameters Fast Movements (Centrifuges) High Loads (Mixers, Mills, Cranes) Compatibility with Special Materials and Surfaces (Seals, Cr-Ni-Steels, Special Alloys, ...)

9. Properties of Molykote ® brand Lubricants Chemical stability High oxidation resistance Corrosion protection Long-term lubrication Wide service temperature range Excellent high load carrying capacity Suitability for vacuum and high-vacuum Fast movements

10. Threaded Connections Lubrication concepts

11. Threaded Connections The most important criteria for the effectiveness of threaded connections is the achieved pre-tensioning force, this determines how firmly the parts are clamped together 60-90% of applied tightening torque is lost in the friction of the thread and under the bolt head and/or seating surface of the nut Proper lubrication is needed to install the right friction and stabilize the friction scattering

12. Threaded Connections - Torque A threaded connection transforms a tightening torque into a pre-tensioning force The tribological contact surfaces are the thread flanks and surfaces such as the seats of the screw head or the nut. There is a linear relationship between the tightening torque, M A and the pre-tensioning force F V The target is to achieve the specified clamping force of the threaded connection by applying the right torque M A = F V x (0.159 x P + 0.578 x d 2 x µ G + 0.5 x d Km x µ K )

13. Calculating the Torque Where • D= nominal bolt shank diameter • α = thread angle = 60 º • β = thread half-angle = 60 º /2 = 30 º • λ = thread helix angle = tan-1 (p/ π dp) • dp = bolt pitch diameter • μ t = Coefficient of thread friction, • μ c = Coefficient of collar (head) friction

14. Threaded Connections If the frictional values assumed (when tightening the bolts), are underestimated, the calculated pre-tensioning force is not attained and the threaded connection can become loose If the frictional values are significantly lower than expected, the calculated pre-tensioning force is exceeded and as a result the bolts may fracture during operation. With further dynamic loading, elasticity is lost and the yield point of the bolts can be exceeded

15. Threaded Connections Threaded connection lubricants need to fulfill various requirements: deliver the precise coefficient of friction level and range ensure the specified clamping force even after several tightening and loosening operations proper sealing against corrosive influence from the environment low scatter of coefficient of friction values compensate the influence of the surface treatments or bolt materials (e.g. hot dip galvanizing, stainless steel screws) protect the parts against galling or cold welding easy disassembly of the connection even after long-term operation at high temperatures or exposure to harsh environments and many others Two possible technologies available: Wet – lubricating pastes Dry – Anti-Friction-Coatings (AFC)

16. Wet lubrication: Pastes A paste is a solid lubricant in an easy applicable form Consists of two main components: Solid Lubricants (up to 60%): Molybdenum disulfide Graphite Calcium hydroxide Calcium or aluminum phosphate Inorganic oxides Various metals i.e. copper, tin, zinc, aluminum, (lead, nickel more and more banned) Carrier oils: Mineral base oil – paraffinics (branched paraffinics ), napthenics , aromatics Synthetic base oil – PAO, PAG, Silicone,

17. Pastes Molykote ® pastes are products specially formulated for challenging conditions. Molykote ® anti-seize pastes create and maintain a lubricating layer, despite extreme loads and temperatures. Molykote ® pastes provide: Wear protection Required performance across wide temperature ranges Consistent coefficient of friction ( CoF ) Water washout resistance Corrosion protection Long-term lubrication Consisting of a high concentration of solid lubricants dispersed in oil, pastes may outperform greases and oils in slow speed applications subjected to extreme loads.

18. Molykote ® Pastes Based on composition: Black pastes - up to 60% black solids (e.g., MoS2, Graphite) White pastes - up to 60% white solids (e.g., PTFE) Metal pastes - up to 60% metal powders Grease pastes - ~ 25% of solid lubricants Oil pastes - 10-20% of solid lubricants Metal-free pastes - up to 60% of white/black solids Typically applications of pastes can be: Threaded connection Assembly pastes and running-in Continuous, lifetime lubrication

19. Molykote ® Pastes Applicable by spraying or brushing Specific range of COF (e.g., 0.08 - 0.12) Low scattering of COF values From one part to another one On different material By multiple tightening Avoid the self loosening of the connection High load carrying capacity and protection against galling, and helps prevent seizure Support the corrosion protection, suppress the fretting corrosion Enable non-destructive disassembly Stable in high temperature environment

20. Anti-Friction Coatings AFCs can be described as lubricating paints, which cure to form a dry lubricating film that bonds to the surface and helps prevent wear and corrosion. AFCs typically consist of a solid lubricant and a binder designed to adhere the coating to the substrate Once cured, Molykote ® AFCs are formulated to offer: Dry lubrication a film that does not attract dirt and dust additional corrosion protection Long-term lubrication without evaporation Effective lubrication even after prolonged service live Application methods include hand or drum spraying, dipping, centrifuging, brushing, roll coating or printing.

21. Molykote ® Anti-Friction Coatings (AFC) Resins or binder system Provide the adhesion of the solid lubricants to the substrate Chemical resistance and corrosion protection Organic (T up to 250°C) and Inorganic (T up to 600°C) systems Pigments or solid lubricants Give the required dry lubrication to the substrate Graphite and/or MoS2 for high loads (up to 1000 N/mm2) PTFE and/or plastic waxes for low loads (up to 250 N/mm2) Solvents Keep the AFC in fluid form in order to apply it to the substrate Regulate the viscosity during the application process Organic or water based Additives to eliminate undesirable, improve existing or impart new properties

22. Molykote ® Anti-Friction Coatings (AFC) Limitations of dry lubrication: Not recommended for high speed/long sliding distances & rolling applications Under hydrodynamic conditions used with greases and oils (offer running-in and emergency lubrication) Application process (cost, curing) Economical aspects have to be considered

23. Molykote ® Anti Friction Coatings Hot Dip Galvanization

24. Hot Dip Galvanization (HDG) Solution for hot dip galvanized bolts HDG is a form of galvanization: Process of coating the iron, steel or aluminum with a thin zinc layer Parts are passing through a molten bath of zinc ~ 460°C When exposed to air, the zinc reacts with O2 and later with CO2 to form the zinc carbonate (ZnCO3) – grey in color Created barrier layer protects the steel from corrosion Plus Delta Thick layer compared to AFC – good protection of sensitive edges Self-healing corrosion protection process (scratch protection) Well established process Industry norms e.g. DIN prescribe usage of HDG Could be brittle (depends on e.g. steel grade) Strong influence of high scatter of values of COF Typically needs additional lubrication to achieve the prescribed level of COF

25. Threaded connections - Test Equipment Test equipment capability: M A – F V testing machine from the company Schatz to measure the coefficient of friction of various threaded connections

26. Threaded Connections - (AFC Typical Applications)

27. Threaded Connections – HDG

28. Threaded Connections – HDG Corrosion resistance: The HDG layer only – 168h White rust being build up: Reaction of zinc layer on O2 – oxidation Zinc oxide is created – white colour, voluminous As soon as the all zinc created zinc oxide – no more protection of the steel Red rust develops Strong white rust: ~ after 120h starts to develop HDG only, Molykote ® D-96, Molykote ® D-321R Medium (low) white rust: Molykote ® 3400A LF, Molykote ® D-708 Both creates more robust/compact layers which protect the zinc/steel Slower penetration of oxygen through the layer

29. Threaded Connections

30. Potential solutions for more reliable operations with Molykote ® specialty lubricants

31. Molykote ® brand Lubricants for Aluminum Industry Due to extraordinary requirements and extreme conditions, the following Molykote products are well known in Oil & Gas Industry: Molykote ® D-321R Anti-Friction Coating Molykote ® P37 Pastes for Anode Clamps Molykote ® P-40 Paste Molykote ® 1000 Paste Molykote ® BG 20 grease for Fans and Blowers Molykote ® FB 180 Grease for the casting Machine Molykote ® Longterm 2 Plus and 00 Grease Molykote ® 111 Compound Dow Corning 7091 sealants for Gestating

32. Molykote ® D-321R Application: Air-curing dry lubricant for metal/metal combinations with slow to medium fast movements and high loads Composition: Inorganic binder MoS2 based organic solvents Temperature range: -180°C up to +450°C Features: good performance on untreated clean surfaces good fretting corrosion protection good lubrication and load carrying capacity  Falex LFW1: 500 and 1000 N/mm²  Falex Pin&Vee: up to 3000 N/mm²

33. Molykote ® G-Rapid Plus Application: Solid lubricating paste with particulary low coefficient of friction for assembly and running in of metal components Composition: Black solid lubricants Mineral oil Temperature range: -35°C up to +450°C Features: Low coefficient of friction Excellent high load carrying capacity Prevents seizure and scoring Suppresses stick-slip (pressfits) Reduced formation of fretting corrosion Provides emergency running performance

34. Molykote ® P-37 Paste Application: Solid lubricant paste used in assembly and fitting of a wide range of components such as metal threaded connections Composition: Solid lubricants Synthetic oil Thickener system Adheasion promoter Temperature range: -40°C up to +200°C Up to 1500°C as dry lubricant Features: Metal free Prevention of stress cracking and brittleness Wide service temperature range Good corrosion protection

35. Molykote ® P-40 Paste Application: Metal free adhesive lubrication paste for assembly and lubricating jobs, especially those with corrosive and humid enviroment Composition: Solid lubricants Semi-synthetic oil Additives Temperature range: -40°C up to +230°C Up to 1200°C as dry lubricant Features: Metal free Excellent adhesion Good corrosion protection Good water resistance Provides protection against fretting-corrosion

36. Molykote ® 1000 Paste Application: Solid lubricant paste for bolted metal joints Composition: Solid lubricants, copper, graphite mineral oil Thickener system Temperature range: -30°C up to +650°C Features: Contains no lead or nickel Enables non-destructive disassembly (even after long use at high temperatures) Good corrosion protection Low scattering of friction factor

37. Molykote ® Longterm 2 Plus Application: Lubricating grease for metal/metal combinations with slow to medium movement speed and high loads Composition : Solid lubricants Mineral oil Corrosion inhibitor EP additives Adhesion improver Temperature range: -25°C up to +110°C Short term: max. 130°C Features: High load carrying capacity Wear protection (at mixed friction state) Good corrosion protection Good adhesion

38. Features : Good resistance to most chemicals Low vapor pressure, low volatility Excellent water resistance suitable for drinking water equipment Wide service temperature range Molykote ® 111 Compound Application : Valve lubricant and sealing compound Composition: Silicone oil Inorganic thickener Additives Temperature range: -40°C up to +200°C

39. Application examples

40. Customer’s Critical Requirements Anode clamp thread is lubricated with Copaslip Earlier product is a Copaslip which hardens and cakes off at short high-low temperature cycle Require frequent maintenance hence production delays and increase man hours 40

41. Customer’s Area of Concerns Customer’s description of components: Protection of galvanized nuts and anti-seize properties Previous solution / product previously used: Various products without the success like ours. ERT 2012 – Wiesbaden - Germany 41

42. Operational Parameters Load: Not measured Environment: Sea and salt environment Temperature ( o C ): Ambient Speed (RPM): N/R Application process description: Tightening of nuts and screws . ERT 2012 – Wiesbaden - Germany 42

43. Dow Corning Solution Selected Which product have you selected? Molykote G-Rapid Plus. What was different about our product? Reduced friction and wear on parts during assembly. How is it being applied? Manually, we tried aerosols, but they prefered to swab. What are the benefits for the end-user? One reliable product. Customer‘s cost saving? Yes, but, not measured. Have you used information that you have gathered during previous ERT meetings? Recommended product for galvanised and stainless steel surfaces. ERT 2012 – Wiesbaden - Germany 43

44. #6- Cooling Table Fan bearings lubrication What Dow Corning Solution would you recommend? Ans : ( molykote G-4700)

45. #7 -Aging Oven Temperature : 200-250 oC Lubrication point : roller bearings of conveyor line Chain of oven door What Dow Corning Solution would you recommend? Ans : ( molykote U-n & M-30

46. 46 ELECTRICAL CONTACTS HEAT MONITORING T (Ar1)max , °С 40,9 T (Ar2)max , °С 27,7 Δ T, °С 13,2 ■ Contact lubricated with Solidol Zh gets e xtreme temperature → developing damage ERT-2012 - Wiesbaden - Germany

47. 47 DOW CORNING SOLUTION SELECTED ■ Product: Molykote® S-1002 Electrical Contact Cleaner Spray - Reduces electrical resistance - Fast evaporation without residue - Does not attack plastic, rubber or painted surfaces ■ Product: Molykote® HSC Plus. Solid lubricant paste - Good electrical conductivity - Can be used over a wide service temperature range - Enables non-destructive dismantling - Good corrosion protection ■ Application manner: manually ■ Benefits: - Provides reliable equipment operation, reduces maintenance costs - Molykote® HSC Plus is available in spray form ERT-2012 - Wiesbaden - Germany

48. 48 MOLYKOTE® HSC PLUS APPLICATION RESULTS ERT-2012 - Wiesbaden - Germany