Metalworking lubrication

Abstract

Processes for working of refractory metals and other metals employing a lubricant comprising perfluorocarbon compounds (PFCs), including aliphatic perfluorocarbon compounds (α-PFCs) having the general formula: C n F 2n+2 , perfluoromorpholines having the general formula: C n F 2n+1 ON, perfluoroamines (PFAs) and highly fluorinated amines (HFAs), and perfluoroethers (PFEs) and highly fluorinated ethers (HFEs), and their polymerization products.

What is claimed is:  
     
         1 . Process for metalworking comprising the lubrication of the metal during the working process with a fluorinated, inert fluid selected from the group consisting of aliphatic perfluoroalkanes having the general formula C n F 2n+2 ; perfluoromorpholines having the general formula C n F 2n+1 ON, wherein n is at least 5, and a boiling point of at least 50° C.; perfluoroamines, having the general formula C n F 2n+3 N, wherein n is at least 3, and a boiling point of at least 155° C.; highly fluorinated amines; and their polymerization products; wherein said fluorinated, inert fluids occur in substituted and unsubstituted forms effective to enable the metalworking process to be performed at high speeds, but in a way that lubricant-residue removal is not required at the end of the process.  
     
     
         2 . Process in accordance with  claim 1  wherein said fluorinated, inert fluid is provided in combination with at least one inert carrying agent, such as in compositions selected from the group consisting of greases, pastes, waxes, and polishes.  
     
     
         3 . Process in accordance with  claim 1  wherein, the material to be worked is a refractory metal.  
     
     
         4 . Process in accordance with  claim 3  wherein the refractory metal is tantalum.  
     
     
         5 . Process in accordance with any of claims  1 - 4  wherein the metalworking process is a wire-drawing process with multiple die passes and the lubricant is perfluorocarbon liquid and the wire as drawn has an average diameter between 5 mils (0.127 mm) and 20 mils (508 mm).  
     
     
         6 . Process in accordance with  claim 1  wherein the fluorinated, inert liquid compounds comprise fluoroaliphatic compounds having 5 to 18 carbon atoms.  
     
     
         7 . Process in accordance with  claim 1  wherein the fluorinated, inert liquid compounds comprise at least one catenary heteroatom, selected from the group consisting of divalent oxygen, hexavalent sulfur, or trivalent nitrogen and have a H:F ratio under 1:1.  
     
     
         8 . Process in accordance with  claim 6  wherein the fluorinated, inert liquid compounds have a hydrogen content of less than 5% by weight.  
     
     
         9 . Process in accordance with  claim 7  wherein the fluorinated, inert liquid compounds have a hydrogen content of less than 1% by weight.  
     
     
         10 . Process in accordance with  claim 1  wherein the perfluorocarbon fluid is selected from the group consisting of perfluoroalkanes.  
     
     
         11 . Process in accordance with  claim 10  wherein the fluid is a perfluoroalkane selected from the group consisting of perfluoropentane, perfluorohexane, perfluoroheptane, and perfluorooctane.  
     
     
         12 . Process in accordance with  claim 1  wherein the perfluorocarbon fluid is a perfluoroamine.  
     
     
         13 . Process in accordance with  claim 12  wherein the perfluoroamine is selected from the group consisting of perfluorotributylamines, perflurotriethylamine, perfluorotriisopropylamines, and perfluorotriamylamines.  
     
     
         14 . Process in accordance with  claim 1  wherein the perfluorocarbon fluid is a perfluoromorpholine.  
     
     
         15 . Process in accordance with  claim 14  wherein the perfluoromorpholine is selected from the group consisting of perfluoro-N-methylmorpholines, perfluoro-N-ethylmorpholines, and perfluoro-N-isopropylmorpholines.  
     
     
         16 . Process in accordance with any of claims  1 - 4  wherein the metal is drawn to a fine wire form and bonded as a lead wire to a porous electrode mass.  
     
     
         17 . A tantalum electrolytic capacitor anode and attached lead wire as made by the process of  claim 20 .  
     
     
         18 . Process in accordance with any of claims  1 - 4  wherein the metalworking process is the rolling of seamless, metal tubes, comprising the steps of pulling a large diameter tube or rod into a tube-rolling machine having at least one set of reduction rolls; lubricating the material during the rolling process with a fluid selected from the group consisting of perfluoroalkanes having the general formula C n F 2n+2 ; rolling the tube or rod through the at least one set of reduction rolls lubricated with a perfluorocarbon fluid; and repeating the process until the necessary tube size is obtained.  
     
     
         19 . Process in accordance with  claim 18  wherein the tube has an average diameter between 10 mm and 50 mm and wall thickness between 0.5 mm and 10 mm.  
     
     
         20 . Process in accordance with any of claims  1 - 4  wherein the metalworking process is the drawing of seamless metal tubes using multiple die passes and the lubricant is perfluorocarbon liquid and the tubes drawn have an average diameter between 0.005″ (0.127 mm) and 2.0″ (50.8 mm) and wall thickness between 0.001″ and 0.050″ (0.025 to 1.27 mm).  
     
     
         21 . A process of providing lubrication wherein the lubricant is a fluorinated, inert fluid selected from the group consisting of aliphatic perfluoroalkanes having the general formula C n F 2n+2 , perfluoromorpholines having the general formula C n F 2n+1 ON, perfluoroamines, and highly fluorinated amines; wherein said perfluoroamines and highly fluorinated amines occur in substituted and unsubstituted forms.  
     
     
         22 . Process in accordance with  claim 21  wherein said fluorinated, inert fluid is provided in combination with at least one inert carrying agent, such as in compositions selected from the group consisting of greases, pastes, waxes, and polishes.  
     
     
         23 . Process in accordance with any of claims  1 - 4 ,  21  or  22  wherein the fluorinated inert fluid is mixed with a solid lubricant and provided in solid form therewith as a paste, gel or other solid form.  
     
     
         24 . Process in accordance with  claim 23  wherein the solid lubricant is selected from the class consisting of graphite, TEFLON™, fused fluorides, MoS 2 , WS 2 , MoSe 2 , MoTe 2  and similar solid lubricants.  
     
     
         29 . Process in accordance with any of claims  1 - 4 ,  25  or  26  wherein the metalworking process is a powder metallurgy compaction of metal particles coated with said inert fluid.  
     
     
         30 . Process in accordance with either or claims  27  or  28  wherein the metalworking process is a powder metallurgy compaction of metal particles coated with said inert fluid and co-lubricant