Kao Chemicals
Solutions to Overcome Today’s Formulation Hurdles for Light Metal and Multi-Metal Metalworking Fluids
By Dr. Sabine Wohlfahrt, Kao Chemicals GmbH, Emmerich, Germany | TLT CMF Plus November 2022
KAO Chemicals is a supplier of surfactant technology used in high-end technical applications such as metalworking. Its global metalworking competence center develops emulsifiers, co-emulsifies, and solubilizers. Based on our application laboratory’s latest findings, this article guides you through the KAO Metalworking Toolbox and the benefits of using KAO additives for light metal (nonferrous) and multi-metal formulations, with a special focus on how AKYPO® (ether carboxylic acid) and FOSFODET (low-foaming phosphate ester) support corrosion and staining inhibition. All these findings share the goal of achieving low-foaming, environmentally friendly and sustainable formulations.
KAO’s metalworking expertise, which includes the production of specialty surfactants, has as its hub the global metalworking competence center at KAO Chemicals Germany, which is part of KAO Chemicals Europe.
KAO’s focus on this segment is on industrial lubricants, which are available worldwide, with distribution in North America being handled by the Sea-Land Chemical Company.
Surfactants, including emulsifiers, co-emulsifiers and solubilizers, have a great impact on formulations and their performance.
The challenges faced when formulating light metal (non-ferrous) and multi-metal metalworking fluids include emulsion stability, hard water tolerance, shrinking additive toolbox, supply chain issues, foam control, corrosion & staining protection, additive efficiency and sustainability requirements.
KAO produces two additive ranges for light metal (non-ferrous) and multi-metal metalworking fluids: AKYPO® and FOSFODET
(see Figure 1).
Figure 1
These ranges are multifunctional additives for longer lifetime metalworking fluids. They both help save water, raw materials and maintenance time.
AKYPO® ether carboxylic acids are used as co-emulsifiers. They have excellent lime soap dispersion power and electrolyte stability, and they support foam control and corrosion protection.
FOSFODET products, meanwhile, are alkoxylated phosphate esters and are used as co-emulsifiers. Compared to other leading phosphate esters, FOSFODET products have enhanced lime soap dispersion power and electrolyte stability, as well as low foaming behavior. Of course, they also prevent aluminum corrosion and staining.
The AKYPO® RO range and AKYPO®TEC AM VG enhance the foam control of metalworking fluids by limited foam formation tendency and faster foam collapse rates when combined with fatty acids. This is illustrated in the circulation experiment in
Figure 2, where the lower foaming profile also the ideal dispersion of aluminum soaps with AKYPO® is demonstrated.
Figure 2
The main properties of the AKYPO® RO range and AKYPO® TEC AM VG are the following:
Long alkyl chain (C16-18) ether carboxylic acid
•
Co-emulsifier / stabilizer
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Outstanding lime soap dispersion power
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Liquid and easy to formulate
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Globally registered or listed
And its main benefits are:
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Hard water and electrolyte stability extends the lifetime of metalworking fluids.
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It especially improves the emulsion stability.
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It improves fluid cleanliness.
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It helps control foam in combination with fatty acids.
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It has synergistic effects with AKYPO LF and AKYPO ROX / KAO FINDET
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It enables sustainable and label-free end-formulations.
The new AKYPO® IN-0202 is a low-foaming multifunctional co-emulsifier for multi metal treatment due to its corrosion protection performance on light non-ferrous and ferrous metals
(see Figure 3).
Figure 3
AKYPO® IN-0202 main properties are:
•
Short alkyl chain (C9) PO-EO ether carboxylic acid
•
Low foaming co-emulsifier
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Hydrotropic properties
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Liquid and easy to formulate
Its application benefits are:
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Increased hard water and electrolyte stability for extended fluid longevity
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Corrosion inhibiting properties on ferrous and light metals
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Stabilization of concentrate and emulsion
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Ideal for low foaming formulations
Another KAO product range, FOSFODET CS, provides a great combination of foam control and corrosion inhibition, making it perfect for light metal treatment.
FOSFODET CS (PO-EO) shows superior performance in lower foam profile and enhanced emulsion stability compared to standard phosphate esters (EO).
Figure 4 shows a comparison of the chemical structure of FOSFODET CS products vs. standard phosphate esters in combination with selected metalworking fluid test proofing the foaming profile as well as enhanced emulsion stability in formulation.
Figure 4
Benefits of FOSFODET CS:
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Ideal (co)-emulsification with enhanced foam control due to less foam formation and fast collapse of foam, as well as hard water and electrolyte stability.
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Corrosion inhibition, particularly aluminum staining inhibition.
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Anti-wear/extreme pressure performance.
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Typical applications include metalworking fluids, rolling oils, conveyer belt lubrication and hydraulic fluids.
The KAO Metalworking Toolbox is helping your way to cutting edge and sustainable metalworking fluids. Our multi-function and efficient additives improve emulsion stability and hard water and electrolyte tolerance, while enabling low-foaming formulation design, along with ideal corrosion and staining inhibition. KAO products are available world-wide and for the most part based on renewable raw materials, contributing to saving resources such as water due to enhanced fluid longevity.