Page 97 - MetalForming October 2015

Analysis of New Hampshire Stamping Samples
motor had degraded every lubricant used, due to the extraordinarily high operating speed and the excessive vol- ume of ozone it produced. Due prima- rily to the inherent properties of chlo- rinated-paraffin technology, the generator ran seamlessly for 3000 hr.— at the time, an unbelievable techno- logical feat.
Following World War II, with a boost from this mind-boggling German application, the manufacture and con- sumption of chlorinated paraffins for a multitude of industries skyrocketed.
New Hampshire Stamper Tests Alternative
But it would seem that the usage of chlorinated-paraffin technology is coming to a close, with the pursuit of alternatives a prudent approach for metalformers.
That’s exactly what Steve Costain of New Hampshire Stamping (NHS), Goff- stown, NH, did when, in June 2013, he contacted International Chemical Company (ICC).
NHS, a manufacturer of precision stampings, uses stainless and carbon steel, brass, copper, aluminum, silver, gold and hundreds of thousands of pounds of Inconel per year. It primari- ly employs progressive-die stamping presses operating at speeds to 200 strokes/min. Lubricant sprays onto coil and at intermittent stages of the stamp- ing process.
NHS had a big problem: Chlorinated lubricant was causing the trichloroeth- ylene in vapor-degreasing equipment to break down, requiring the addition of expensive stabilizers. Under extremely high temperatures, chlorinated paraf- fins break down and become highly acidic, coating the equipment and acid- ifying the bath.
As a remedy, NHS’s chemical sup- plier recommended the use of nonchlo- rinated oil. NHS contacted J.B. Associat- ed, Sagamore Beach, MA, the local ICC representative, which in turn put NHS in contact with Mike Pelham at ICC.
ICC offered to perform comparative lubricant tests at no cost to NHS, both at the ICC lab and at an independent
Chlorinated Oil ε mm/mm
31
32
33
34
35
36
37
38
39
40
Average
Std. Dev.
Umax
49.9669
49.9847
49.9694
49.9796
49.9948
49.9618
49.9669
49.9669
49.9796
49.9755
0.01111
Pmax
4280.90
4245.30
4214.15
4240.85
4245.30
4369.90
4240.85
4272.00
4205.25
4254.20
51.0158
do
25.770
25.419
25.425
25.604
25.221
25.745
25.460
25.442
25.564
df
Sample #
mm
49.9669
N
4272.00
mm
25.389
mm
27.257
27.329
27.272
27.148
27.389
27.048
27.444
27.264
27.118
27.337
0.07358
0.06050
0.07290
0.06777
0.06972
0.07244
0.06599
0.07086
0.06588
0.06936
0.06936
0.00268
Nonchlorinated Oil ε mm/mm
31
32
33
34
35
36
37
38
39
40
Average
Std. Dev.
Umax
49.9694
49.9745
49.9745
49.9669
49.9466
49.9974
49.9897
49.9669
49.9516
49.9669
0.01330
Pmax
4205.25
4254.20
4223.05
4191.90
4303.15
4191.90
4231.95
4294.25
4263.10
4235.84
54.1594
do
25.675
25.554
25.343
25.494
25.262
25.536
25.538
25.239
25.737
df
Sample #
mm
49.9694
N
4142.95
mm
25.944
mm
27.624
27.357
27.090
27.250
27.143
27.078
27.045
27.248
27.016
27.382
0.06475
0.06551
0.06011
0.07525
0.06468
0.07189
0.05909
0.06696
0.07041
0.06392
0.06603
0.00373
and other mostly military applications rose steeply. Though heavily used by the U.S. military, the expanded use of chlorinated hydrocarbons began in Germany.
The October 1946 issue of Harper’s magazine contains an article by C. Lester Walker entitled “Secrets by the Thousands,” detailing the exploits of the U.S. military in the months follow- ing the surrender of Nazi Germany. It is estimated that the U.S. government obtained more than 1 million individ-
ual items of Nazi secrets pertaining to scientific, industrial and military tech- nologies. A needle in the haystack was chlorinated-paraffin grease used to lubricate a small generator, which increased the voltage from that of a conventional flashlight battery to upward of 15,000 V.
This generator operated an infrared device enabling soldiers of the Wehrmacht to see at night, with the device containing a tiny electric motor spinning a rotor at 10,000 rpm. The
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