6th International
Metalworking Fluids Conference
January 8-10, 2024 in Atlanta, GA
MEETING AGENDA SUBJECT TO CHANGE
Monday, January 8
2:00 p.m. – 6:00 p.m.
Check-in / Registration
5:00 p.m. – 6:30 p.m.
Opening Reception
Sponsored by Ergon
MEETING AGENDA SUBJECT TO CHANGE
Tuesday, January 9
7:30 a.m. – 5:00 p.m.
Check-in / Registration
7:30 a.m. – 8:30 a.m.
Breakfast
8:30 a.m. – 9:15 a.m.
General Session
➣ John Burke, Quaker Houghton
➣ Holly Alfano, ILMA
➣ Catharine Golden, Etna Products
9:30 a.m. – 10:00 a.m.
Sustainability Aspects in the Use of Processing Media for Forming or Cutting – How to Reduce Environmental Impact and Health Hazard in Production Processes
➣ Stefan Joksch, Oemeta Chemische Werke
Sustainability is the most important megatrend of the 2020s. The 17 UN Sustainable Development Goals (SDGs) consider three dimensions of development: economy, ecology and social justice. The sustainability question also arises in connection with the production of components by machining or forming. How can production processes be made sustainable? Which SDGs can be addressed and pursued in the manufacturing process chain, and which evaluation standards can be used for this purpose? Sustainability of manufacturing processes is determined by several aspects: construction material (type and consumption), energy consumption, process fluids (type and consumption), and as a resulting scenario, workplace health hazard. Practical examples show how sustainability aspects can be sensibly considered concerning the use of process media in the manufacturing process chain. It can be assumed that sooner or later the planning and implementation of production processes will no longer be possible without a “sustainability check.”
9:30 a.m. – 10:20 a.m.
2023 STLE Trends Report – Emerging Issues and Trends In Tribology and Lubrication Engineering and their Impact on Metalworking Fluids
➣ Neil Canter, Chemical Solutions
The Society of Tribologists and Lubrication Engineers (STLE) just released its “4th Trends Report – Emerging Issues and Trends in Tribology and Lubrication Engineering” in July. This presentation discusses key trends that are and will be impacting the tribology & lubrication field, including supply chain, sustainability, electrification, manufacturing, medical/health and government regulation. Sustainability will be prominently discussed in this presentation because it is impacting how end users of lubricants (including metalworking fluids) are operating. Electrification is a term that defines the move towards decarbonization, encompassing applications beyond just electric vehicles. Manufacturing focuses on the benefits tribology can provide through efficiency improvements that reduce emissions and boost sustainability. Medical/health includes ways tribology is in use to help improve the way patients deal with health issues. Government regulation continues to be an important factor in determining what lubricants can be used and how they should be used. The impact that these key trends will have on metalworking fluid raw material, manufacturing and end users will be discussed for each subject area. The case will be made that the metalworking fluid industry will have opportunities to grow in each of these areas.
10:10 a.m. – 10:40 a.m.
Understanding the Environmental Science of Chlorinated Paraffin– A Scientific Review of Recent Environmental Testing, Environmental Field Work
➣ Tom Federle, CPIA
10:10 a.m. – 10:40 a.m.
Innovation in Sustainability for a Better Tomorrow
➣ Shannon McGee, Quaker Houghton
Quaker Houghton believes that focusing our goals on sustainability is imperative from both an environmental aspect; and, for leading innovation to be more socially responsible, energy and resource efficient, while still delivering optimal performance. Here, we present our current goals to target sustainable innovation in our company, how we measure our progress, and what we have already been able to achieve. We believe that targeting sustainability through reasonable goal setting and accurate metric measurements is an important step. Our sustainability pillars are “Innovating Together for a Better Tomorrow”, “Protecting our Planet”, “Empowering our Colleagues and Communities”, and “Sourcing our Material Responsibly”. We have set our current projects to focus on supporting these pillars and achieving our sustainability short-term and long-term goals for 2023 and 2030. We have already made sustainability improvements in our current technical R&D chemistries in productivity, environmental and health impacts, and longevity compared to older product lines. Through uniting our people, expertise, and resources, we will deliver contributions that result in a better, safer world and make a positive difference in the lives and organizations we touch.
10:30 a.m. – 11:20 a.m.
Considerations in the Selection of Drawing Lubricants for the production of Copper Wire and Aluminum Wire used to produce Magnet Wire and Power Conductor for Electric Vehicles
➣ Ike Tripp, Etna Products
10:50 a.m. – 11:20 a.m.
Regulatory Landscape – Overview of Recent Changes in U.S, EU, Canada, and Globally (POPs)
➣ Andrew Jaques, CPIA
10:50 a.m. – 11:20 a.m.
ASTM Subcommittee E34.50 Standards Addressing Metalworking Fluid Health And Safety Issues
➣ Fred Passman, BCA
ASTM Subcommittee E34.50 on standards addressing metalworking fluid health and safety issues was chartered in 1992. The subcommittee’s initial focus was to provide usable guidance that would help metalworking fluid end-users to reduce health risks associated with inhalation, skin-contact, or ingestion exposures. Over the course of the past 30 years, E34.50 has developed fourteen new standards and has two more in progress. The subcommittee’s standards address metalworking fluid exposure control, test protocols for microbiological contaminants, and guides for testing metalworking fluid properties not related to performance and exposure. This presentation will provide an overview of E34.50’s standards and their continued relevance to industry stakeholders.
11:30 a.m. – 12:00 p.m.
Phosphorus and Silicone Free Staining Inhibitor for Light Weight Metals
➣ Jiali Jiang, Solvay
Non-ferrous metals, including aluminum, magnesium and titanium, are increasingly used in various markets due to the rapid growth of communication, construction and transportation industries. The recent trends of automotive electrification and fuel economy improvement accelerate the adoption of lightweight metals such as aluminum alloys. Aluminum alloys are susceptible to staining during fabrication. It brings new challenges to metalworking fluids formulators and end users. In this presentation, we will discuss the current staining inhibition technologies and introduce the next generation staining inhibitor, which is phosphorus and silicone free. We will compare its anti-staining performance at low dosage in different environments and discuss the thermal stability and toxicity, comparing to other existing solutions.
11:30 a.m. – 12:00 p.m.
Industry Perspectives on Chlorinated Paraffin use in Metalworking Fluids
➣ Mike Pearce, CPIA
12:00 p.m. – 1:15 p.m.
Luncheon with Keynote
➣ Dr. Robert Jackson, Auburn University
The industrial landscape is evolving quickly with artificial intelligence (AI), additive manufacturing and alternative energy sources, and tribology will remain a critical aspect. However, it has become more difficult to recruit into the field. Dr. Robert Jackson of Auburn University, creator and director of the United States’ first minor in tribology, will give an update on the university's program, now in its 11th year. He will also share insight into what it's like to work with the current generation of students and what they are looking for with respect to career development. As the lubricants industry seeks to attract young employees, Dr. Jackson will explore how to market the field of tribology to the next generation.
1:30 p.m. – 2:00 p.m.
Medium Chain Chlorinated Paraffins in Water-Miscible Metalworking Fluids: Making The Case For Continued Use
➣ John Howell, GHS Resources
1:30 p.m. – 2:00 p.m.
Looking at Your ESG
➣ Beth Ann Jones, Hangsterfer's
A brief ESG overview, followed by a discussion of how to highlight what ESG accomplishments companies already have in place.
2:10 p.m. – 2:40 p.m.
Medium Chain Chlorinated Paraffins - Identifying Critical Uses And Why That Is So Important
➣ John Howell, GHS Resources
2:10 p.m. – 3:00 p.m.
Waste Treatment of Metalworking Fluids
➣ John Burke, Quaker Houghton
Proper treatment of industrial wastewater is a target of many companies’ sustainability goals and ESG scorecards. Metalworking fluids are complex mixtures of chemicals that can represent significant environmental contamination to the receiving environment if not effectively waste-treated. These contaminants are, but are not limited to, biochemical oxygen demand, chemical oxygen demand, oil and grease, nitrogen, and phosphorous. Along with the challenges of treating metalworking fluids by themselves, they can accumulate additional contaminants in their use, adding even more challenges for disposal. These additional contaminants are metals, tramp oils, metal cleaning solutions, and floor cleaners. Variations in spent metalworking fluids and additional contaminants on a day-to-day basis further add to the wastewater treatment challenges. This presentation will discuss wastewater disposal discharge requirements for users of metalworking fluids. It will then discuss several methods of wastewater treatment such as basic thermal evaporation, vapor compression distillation, ultrafiltration, chemical treatment, and finally waste oil recovery.
2:50 p.m. – 3:20 p.m.
Replacement of Chlorinted Parffins in Heavy-Duty Metalworking Processes
➣ Wilhelm Rehbein, Lanxess
Chlorinated paraffins were one of the earliest EP additives used in lubricants and are still widely used as additives in metalworking fluids. They prevent adhesive wear between metal surfaces by forming pressure stable adsorption layers under standard metalworking conditions. Though with increased machining speeds, resulting in higher temperatures of workpiece and tool surfaces, they tend to decompose and can cause chemical wear. Short-chain chlorinated paraffins were already banned and eliminated from metalworking fluid formulations in many countries due to their persistency in the environment with a high potential for bioaccumulation and because of their classification as toxic to aquatic organisms and possibly carcinogenic to humans. Medium-chain chlorinated paraffins are supposed to be banned as well within the next years because of their risks to the ecosystem and to human health. Sulfurized natural or synthetic esters or olefins are another class of commonly used EP additives that are versatilely used to reduce friction and to prevent adhesive and abrasive wear in metalworking processes. Compared to chlorinated paraffins, sulfur carriers show many benefits in terms of toxicity, environmental impact and energy efficiency. Despite the fact that it is possible to replace chlorinated paraffins with sulfur carriers in most metalworking applications, there are still heavy-duty metalworking processes like broaching or fine blanking of high alloyed and stainless steels where it’s difficult to achieve similar performance. The presentation will show how it is possible to meet or exceed the performance of chlorinated paraffins with chlorine-free metalworking fluids for machining high alloyed or stainless steels. Chlorinated paraffins were one of the earliest EP additives used in lubricants and are still widely used as additives in metalworking fluids. They prevent adhesive wear between metal surfaces by forming pressure stable adsorption layers under standard metalworking conditions. Though with increased machining speeds, resulting in higher temperatures of workpiece and tool surfaces, they tend to decompose and can cause chemical wear. Short-chain chlorinated paraffins were already banned and eliminated from metalworking fluid formulations in many countries due to their persistency in the environment with a high potential for bioaccumulation and because of their classification as toxic to aquatic organisms and possibly carcinogenic to humans. Medium-chain chlorinated paraffins are supposed to be banned as well within the next years because of their risks to the ecosystem and to human health. Sulfurized natural or synthetic esters or olefins are another class of commonly used EP additives that are versatilely used to reduce friction and to prevent adhesive and abrasive wear in metalworking processes. Compared to chlorinated paraffins, sulfur carriers show many benefits in terms of toxicity, environmental impact and energy efficiency. Despite the fact that it is possible to replace chlorinated paraffins with sulfur carriers in most metalworking applications, there are still heavy-duty metalworking processes like broaching or fine blanking of high alloyed and stainless steels where it’s difficult to achieve similar performance. The presentation will show how it is possible to meet or exceed the performance of chlorinated paraffins with chlorine-free metalworking fluids for machining high alloyed or stainless steels.
2:50 p.m. – 3:20 p.m.
What an End User Wants From a Fluid Supplier
➣ Don Smolenski, SMO Consulting
MEETING AGENDA SUBJECT TO CHANGE
Wednesday, January 10
7:30 a.m. – 11:00 a.m.
Check-in / Registration
7:30 a.m. – 8:30 a.m.
Breakfast
8:30 a.m. – 9:00 a.m.
Sustainability Strategies From the Perspective Of A Performance Additive Manufacturer
➣ Michael Stapels, KAO Chemical
While for decades optimum performance and a competitive price were the decisive factors for the success of a cooling lubricant on the market, sustainability aspects have recently come into focus. In particular, factors such as the product carbon footprint as well as renewable carbon content are at the center of these discussions. The presentation will address various strategies for formulating more sustainable metalworking fluids while critically questioning the sole focus on the product carbon footprint.
8:30 a.m. – 9:00 a.m.
High Performance Lubricity Additives For New Challenges
➣ Selim Erhan, Process Oils
New technologies require the lubricant industry to evolve continuously. Fuel efficiency requiring lighter but more difficult to machine metals, lower viscosity base oils needing enhanced lubricity additives, and changes in machine designs necessitating lower foaming metalworking fluids are some of the current challenges for the lubricant industry. We will look at biobased additives that provide high performance to meet these challenges in formulating lubricants, metalworking fluids and greases. The significant advances that have been made in vegetable oil-based unique esters provide sustainable renewable lubricants that are high performing on any metal. Their unique chemistry allows machining operations to run cooler and with very low foam. Their functional groups and geometry make them easy to formulate and ideal for these high performance requiring applications.
9:10 a.m. – 9:40 a.m.
Activity and Structure of Sulfurized Olefins
➣ Jay Wang, Dover
It is well known in the lubricants field that sulfur, commonly used as an EP, has two different compound types: active sulfur and inactive sulfur, where active sulfur stains and is corrosive to yellow metals and inactive sulfur does not stain nor corrode yellow metals. In this paper, we seek to find out what makes the difference. At what sulfur chain length does sulfur become active? Does the cross linking make a difference in inactive vs. active? In this paper and presentation, olefins and fatty acid esters will be sulfurized using a standard black sulfurizing process at varying molar amounts of sulfur vs 1 mole of the unsaturation. After sulfurizing the material the various sulfur compounds will be separated using a LC-MS by sulfur chain length amounts and by cross linkage and then checked using ASTM D0130-19 at 5% in 100 naphthenic oil by weight. From this study, we will show at what sulfur chain number a sulfur compound becomes active and if cross linking is a factor.
9:10 a.m. – 9:40 a.m.
Optimizing High Performance Wire Drawing Lubes
➣ Kathleen Havelka, Advancion (Previously Angus)
Increasing vehicle electrification and growing needs for energy are driving demand for improve wire drawing fluids. Wire drawing is a critical operation requiring fluid formulations that re tailored to provide several important characteristics. This presentation highlights the use of specialized amino alcohols in wire drawing fluids as elegant solutions enabling formulators to develop high-performing fluids that improve the efficiency and sustainability profile of electrical wire. This systematic study demonstrates that the use of specialty amino alcohol chemistries in wire drawing fluid formulations provides excellent lubricity, good cleanliness, low foaming and extended fluid life. Structure-property relationships have been developed to explain these benefits and can be used by formulators as a model to develop high-performing wire drawing fluids. The unique multifunctionality of amino alcohols offers new potential in optimizing next-generation wire drawing fluids that produce defect-free wires while minimizing operating costs and reducing waste.
9:10 a.m. – 10:00 a.m.
Regulatory Update
➣ Jeff Leiter, Bassman, Mitchell, Alfano and Leiter
Regulation continues to be a key driver for businesses in the lubricants industry. Challenging economic conditions, the need for operational resilience, changing consumer demands, and environmental, social and governance (ESG) concerns are influencing regulatory agendas around the globe. At the same time, governments around the globe are doubling down on the view that heavy-handed government interference is needed to right all of society’s wrongs. The U.S. EPA, for example, intends to take 37 economically significant actions in 2024. The presentation will provide insights into regulators’ top regulatory priorities that likely will affect participants in the lubricants industry in 2024 and beyond. Additionally, there will be a discussion of the significant jump in public policy risks facing the lubricants industry from constant shifts in political power in Washington, D.C., with an increasingly partisan approach to pursue aggressive policy changes through administrative regulation rather than congressional legislation. Against this backdrop of regulatory and public policy risks, the presentation will include suggestions as to how companies in the lubricants industry can anticipate, monitor, manage, navigate and mitigate the risks posed by regulators around the globe.
9:50 a.m. – 10:20 a.m.
Metalworking Fluids in Hybrid Manufacturing
➣ Dr. Rob Jackson, University of Auburn
9:50 a.m. – 10:20 a.m.
SCAQMD Proposed Rule 1435 and the Impact on Metal Heat Treating Operations
➣ John Burke, Quaker Houghton
10:30 a.m. – 11:00 a.m.
Controlling Metalworking Fluid Failure (Part 1)
➣ John Burke, Quaker Houghton
Outside of the machining environment, metalworking fluids can last almost indefinitely. However, as soon as these fluids are introduced into the machining environment, they begin to fail, and in some cases very rapidly. These fluids fail to such an extent that they can cause premature tool wear, damage to the tool and workpiece, and be irritating to workers in the machining area. When these conditions exist, either all or in part, the fluids are discarded. This presentation will address why metalworking fluids fail and methods that the end user can employ to slow down the rate of failure, increase tool life, and have a positive impact on worker safety.
10:30 a.m. – 11:00 a.m.
Meeting Sustainability Standards in Metal Working Fluids Using Specialty Additives
➣ Stefanie Velez, Münzing
As interest in developing sustainable water-based metal working fluids (MWFs) continues to increase, so does the number of sustainability standards and strategies in the marketplace. This is a broad area that involves a balance between environmental impact, health and safety, and economic performance of the MWF. A review of Münzing’s current sustainability initiatives along with bio-based and biodegradable specialty additives will be discussed. To further investigate the sustainability of a MWF, a comprehensive study highlighting the considerable positive impacts that high-performance additives have on the overall performance and lifespan of the fluid will be explored. Understanding how to balance the different aspects of sustainability using specialty additives can be key in developing a more sustainable MWF.
11:10 a.m. – 11:40 a.m.
Controlling Metalworking Fluid Failure (Part 2)
➣ John Burke, Quaker Houghton
Outside of the machining environment, metalworking fluids can last almost indefinitely. However, as soon as these fluids are introduced into the machining environment, they begin to fail, and in some cases very rapidly. These fluids fail to such an extent that they can cause premature tool wear, damage to the tool and workpiece, and be irritating to workers in the machining area. When these conditions exist, either all or in part, the fluids are discarded. This presentation will address why metalworking fluids fail and methods that the end user can employ to slow down the rate of failure, increase tool life, and have a positive impact on worker safety.
11:10 a.m. – 11:40 a.m.
Synthetic Esters in Metalworking Fluids: Pioneering Sustainability for Enhanced Performance and Reduced Carbon Footprint
➣ Valentina Serra-Holm, Perstorp
The metalworking industry is witnessing a shift towards synthetic fluids driven by performance requirements and environmental considerations. This speech examines the sustainability contributions of metalworking fluids from two perspectives: the impact of bringing products to the market and the impact of products in use and end-of-life. As the transition towards synthetics progresses, an important role is expected to be played by esters, including polyol esters. This speech will focus on the role of polyol esters in contributing to enhanced fluid performance and delivering Scope 3 emission reductions. The paper covers aspects such as raw material origin, as well as processing, which significantly influence Scope 3 emissions. The utilization in ester formulations of building blocks derived from sustainable sources, such as renewable and recycled materials, contributes to a reduced product carbon footprint (PCF) and decreased reliance on fossil raw materials. The speech will include a case study to exemplify how employing sustainable building blocks affects the PCF reduction potential. The methodology applied aligns with global greenhouse gas and ISO standards, as well as industry standards recently published by organizations such as API TR 1533 and UEIL in collaboration with ATIEL. The speech will show how, by leveraging synthetic esters derived from sustainable sources and incorporating sustainable building blocks, the metalworking industry can make significant strides towards achieving its sustainability goals while maintaining high operational efficiency and performance standards.
Online registration open now - Dec 29