Metalworking formulations with corrosion inhibitor formulations

Abstract

Metalworking formulations and corrosion inhibitor formulations are provided. The metalworking fluids have excellent performance as coolants in the manufacture of thin-walled metal containers such as aluminum beverage cans.

1 . A metalworking formulation comprising:
 an esterified lubricity additive;   a block copolymer;   an amine; and   a corrosion inhibitor formulation,   
       wherein the corrosion inhibitor formulation comprises an acyl amino acid derivative of formula Ia, Ib or Ic:
   R 1 —(CO)—N(R 2 )—(CH 2 ) n —CO 2 X  (Ia)
 
   [R 1 —(CO)—N(R 2 )—(CH 2 ) n —CO 2 ] m Y  (Ib)
 
   [R 1 —(CO)—N(R 2 )—(CH 2 ) n —CO 2 ] m —Z—(OH) p   (Ic)
 
 
       where:
 R 1  is C 6 -C 30  optionally substituted alkyl or C 6 -C 30  optionally substituted alkenyl, and 
 R 2  is hydrogen or C 1 -C 4  optionally substituted alkyl; 
 X is hydrogen, C 1 -C 30  optionally substituted alkyl, or C 2 -C 30  optionally substituted alkenyl; 
 Y is an alkali metal or an alkaline earth metal; 
 Z is a residue remaining after removal of a hydroxyl group from a polyhydric alcohol; 
 m is an integer of 1 or greater, which is 1 when Y is an alkali metal and 2 when Y is an alkaline earth metal; 
 p is an integer of zero or greater; 
 n is an integer of 1 to 4, and 
 m+p is the valency of Z. 
 
     
     
         2 . The metalworking formulation of  claim 1 , wherein the corrosion inhibitor formulation further comprises a succinic acid derivative, a triazole, a C 6 -C 20  branched carboxylic acid, a sugar alcohol, an imidazoline, or a mixture thereof. 
     
     
         3 . The metalworking formulation of  claim 2 , wherein the formulation comprises a triazole:oleyl sarcosine weight ratio of from 0:1 to 7:1. 
     
     
         4 . The metalworking formulation of  claim 1 , wherein the corrosion inhibitor formulation comprises:
 N-oleyl sarcosine;   a water soluble succinic ester;   an amidated succinic acid derivative;   a sodium salt of tolyl triazole; and   neodecanoic acid.   
     
     
         5 . The metalworking formulation of  claim 1 , wherein the acyl amino acid derivative is from 0.1% to 5% by weight of the formulation. 
     
     
         6 . The metalworking formulation of  claim 1 , wherein the acyl amino acid derivative is N-oleyl sarcosine. 
     
     
         7 . The metalworking formulation of  claim 1 , wherein the formulation does not significantly stain aluminum. 
     
     
         8 . The metalworking formulation of  claim 7 , wherein the formulation is substantially free of phosphoric acid derivatives. 
     
     
         9 . The metalworking formulation of  claim 7 , wherein the formulation is substantially free of boric acid derivates. 
     
     
         10 . The metalworking formulation of  claim 7 , wherein the formulation is substantially free of corrosion inhibiting components that are film-formers on metal surfaces. 
     
     
         11 . The metalworking formulation of  claim 1 , wherein the esterified lubricity additive is a water dispersible esterified dimer or trimer acid, wherein the dimer or trimer acid is the esterification product of: (1) an acid component comprising a dimer acid, a trimer acid, or a mixture thereof; and (2) an alcohol component comprising an alkylalkoxy alcohol, optionally in combination with an alkyl alcohol. 
     
     
         12 . The metalworking formulation of  claim 1 , wherein the esterified lubricity additive is an esterification reaction product selected from the group consisting of: (a) a polyalkanoic or polyalkenoic acid derived from hydroxyfatty acids and a block copolymer selected from the group consisting of polyoxyethylene-polyoxypropylene and a reverse block copolymer of polyoxypropylene-polyoxyethylene-polyoxypropylene; (b) the reaction product of (a) with a maleic acid or anhydride; and (c) mixtures thereof. 
     
     
         13 . The metalworking formulation of  claim 1 , wherein the esterified lubricity additive is a partial or half-ester of a compound derived from the Diels-Alder reaction of a conjugated fatty acid and an acid precursor dienophile. 
     
     
         14 . The metalworking formulation of  claim 1  comprising the esterified lubricity additive and the block copolymer at a ratio of from 3:1 to 1:3 w/w. 
     
     
         15 . The metalworking formulation of  claim 1  wherein the block copolymer comprises a structure represented by formula (IIa), (IIb) or (IIc):
   R 3 —(EO) x —(PO) y —R 4   (IIa)
 
   R 3 —(EO) x —(PO) y -(EO) z —R 4   (IIb)
 
   R 3 —(PO) x -(EO) y —(PO) z —R 4   (IIc)
 
 where w, x, y and z are independently any integer; 
 R 3  and R 4  are independently selected from —H, —OH, —(CR 5 R 6 ) w H, or —(CR 5 R 6 ) w OH; 
 R 5  is independently selected from hydrogen and C 1 -C 4  optionally substituted alkyl, and 
 R 6  is independently selected from hydrogen, C 1 -C 30  optionally substituted alkyl, or C 2 -C 30  optionally substituted alkenyl. 
 
     
     
         16 . The formulation of  claim 15 , wherein the block copolymer comprises a structure of formula IIc, and R 5  is H and R 6  is C 1 -C 4  optionally substituted alkyl. 
     
     
         17 . The metalworking formulation of  claim 1  wherein the block copolymer comprises two or more block copolymers of formula IIc. 
     
     
         18 . The metalworking formulation of  claim 1 , wherein the composition comprises:
 from about 3.25% to about 13.5% of the esterified lubricity additive;   from about 4% to about 19.5% of the block copolymer;   from about 1% to about 5% of a polymeric surfactant antifoaming agent;   from about 0.1% to about 2% of N-oleyl sarcosine;   from about 0.1% to about 2% of a water soluble succinic ester;   from about 0.1% to about 2% of an amidated succinic acid derivative;   from about 0.1% to about 2% of a triazole; and   from about 2% to about 8% of carboxylic acid.   
     
     
         19 - 29 . (canceled) 
     
     
         30 . A diluted metalworking composition comprising the metalworking formulation of  claim 1  in an amount effective to provide lubricity, and a diluent. 
     
     
         31 - 34 . (canceled) 
     
     
         35 . A method of making a thin-walled metal can comprising the steps of:
 (a) forming a metal disk;   (b) drawing the metal disk to form a shallow cup;   (c) applying the metalworking formulation of  claim 1  to the shallow cup;   (d) redrawing and wall ironing the shallow cup to form a thin-walled tubular can body having an open end and an opposing closed end; and   (e) washing the metalworking formulation off the thin-walled tubular can body.   
     
     
         36 - 39 . (canceled)