Design of hard water stable emulsifier systems for petroleum- and bio-based semi-synthetic metalworking fluids

Milling Performance of CFRP Composite and Atomised Vegetable Oil as a Function of Fiber Orientation

Carbon fiber reinforced polymers (CFRPs) have found diverse applications in the automotive, space engineering, sporting goods, medical and military sectors. CFRP parts require limited machining such as detouring, milling and drilling to produce the shapes used, or for assembly purposes. Problems encountered while machining CFRP include poor tool performance, dust emission, poor part edge quality and delamination. The use of oil-based metalworking fluid could help improve the machining performance for this composite, but the resulting humidity would deteriorate the structural integrity of the parts. In this work the performance of an oil-in-water emulsion, obtained using ultrasonic atomization but no surfactant, is examined during the milling of CFRP in terms of fiber orientation and milling feed rate. The performance of wet milling is compared with that of a dry milling process. The tool displacement-fiber orientation angles (TFOA) tested are 0°, 30°, 45°, 60°, and 90°. The output responses analyzed were cutting force, delamination, and tool wear. Using atomized vegetable oil helps in significantly reducing the cutting force, tool wear, and fiber delamination as compared to the dry milling condition. The machining performance was also strongly influenced by fiber orientation. The interactions between the fiber orientation, the machining parameters and the tested vegetable oil-based fluid could help in selecting appropriate cutting parameters and thus improve the machined part quality and productivity.

The Role of Surfactant Structure on the Development of a Sustainable and Effective Cutting Fluid for Machining Titanium Alloys

In cutting operations of titanium alloys, most of the problems are related to the high consumption of cutting tools due to excessive wear. An improvement of metalworking fluid (MWF) technology would increase the productivity, sustainability, and quality of machining processes by lubricating and cooling. In this research article, the authors varied the surfactant’s charge, the hydrocarbon chain length, and the ethoxylation degree. Surfactants were dispersed at 1.2 mM in water and trimethylolpropane oleate to produce water-based MWF. Infrared reflection absorption spectroscopy and total organic carbon analysis were used to study the influence of surfactant structure on the film forming ability of the emulsion and performance was studied on Ti6Al4V using tapping torque test. The results showed that by changing the molecular structure of the surfactant, it is possible to vary the affinity between the ester and the substrate and reach an optimal combination, which improves the formation of a tribofilm. The mixture with anionic surfactants has good tribology performance, while non-ionic surfactants shorten the tool’s life. Moreover, the increase in the hydrocarbon chain length and the number of ethoxylations of surfactants promotes the adhesion of ester onto the metal surface, improving the lubricity properties of environmentally friendly MWF.

Process development of silica extraction from RHA: a cradle to gate environmental impact approach

India is one of the major rice-producing countries. Rice husk is a major agricultural by-product from rice production, which is used as a fuel in boilers. Its use as fuel produces huge amounts of silica-rich rice husk ash (RHA). This paper aims at providing an overall assessment of environmental impacts associated with the extraction of silica from RHA-a process developed by our study group. The functional unit used in this study is production of 100 kg of silica. The analysis included the extraction and transportation of other raw materials; RHA was assumed to be processed at the site. The study was conducted in accordance with the international ISO 14040 procedural framework. LCA is performed using GaBi Education software, and five midpoint indicators are chosen to assess the environmental impacts of silica extraction. The overall climate change (CC) of the extraction process is 7.26 kg CO₂ equivalent per kg of silica produced. A high contribution of calcination to CC is attributed to the use of electricity. The comprehensive environmental impacts of silica-rich RHA resulting from processing of RHA and improvement options to achieve sustainable production are presented. The negative impacts that can be avoided during silica extraction are also discussed. It is observed that calcination is a major contributor to the overall environmental indicators. The work also stresses on the use of renewable energy for electricity generation, which would help in decreasing the overall greenhouse gas emissions during extraction while ensuring waste utilization.

Tunable Oleo-Furan Surfactants by Acylation of Renewable Furans

An important advance in fluid surface control was the amphiphilic surfactant composed of coupled molecular structures (i.e., hydrophilic and hydrophobic) to reduce surface tension between two distinct fluid phases. However, implementation of simple surfactants has been hindered by the broad range of applications in water containing alkaline earth metals (i.e., hard water), which disrupt surfactant function and require extensive use of undesirable and expensive chelating additives. Here we show that sugar-derived furans can be linked with triglyceride-derived fatty acid chains via Friedel-Crafts acylation within single layer (SPP) zeolite catalysts. These alkylfuran surfactants independently suppress the effects of hard water while simultaneously permitting broad tunability of size, structure, and function, which can be optimized for superior capability for forming micelles and solubilizing in water.

Preparation of water-soluble nanographite and its application in water-based cutting fluid

Water-soluble nanographite was prepared by in situ emulsion polymerization using methacrylate as polymeric monomer. The dispersion stability and dispersion state of graphite particles were evaluated by UV-visible spectrophotometry and scanning electron microscopy, respectively. The water-soluble nanographite was then added into the water-based cutting fluid as lubricant additive. The lubrication performance of water-based cutting fluid with the nanographite additive was studied on four-ball friction tester and surface tensiometer. Results indicate that the modification method of in situ emulsion polymerization realizes the uniform and stabilized dispersion of nanographite in aqueous environment. The optimal polymerization condition is 70°C (polymerization temperature) and 5 h (polymerization time). The addition of nanographite decreases the friction coefficient and wear scar diameter by 44% and 49%. Meanwhile, the maximum non-seizure load (PB) increases from 784 to 883 N, and the value of surface tension (32.76 × 10-3 N/m) is at low level. Nanographite additive improves apparently the lubrication performance of water-based cutting fluid.

Physicochemical properties of selectively oxidized 1-monolaurin from 2,2,6,6-tetramethyl-1-piperidinyl oxoammonium ion/sodium hypochlorite-mediated reaction

The primary alcohol group of 1-monolaurin (1-ML) was selectively oxidized using 2,2,6,6-tetramethyl-1-piperidine oxoammonium ion/sodium hypochlorite (NaOCl) without NaBr at two different conditions. The selective oxidation occurred more efficiently at 35 degrees C and 32.2 mmol of NaOCl than at 25 degrees C and 18.7 mmol of NaOCl. Regioselective oxidation of the primary alcohol without oxidation of a secondary alcohol was confirmed by a chemical shift at 175 ppm and no resonance between 198 and 205 ppm in (13)C NMR and the presence of a peak at 1560-1570 cm(-1) in IR spectra. The water solubility of oxidized 1-monolaurin (OML) was remarkably increased by 33.2 times as compared to that of 1-ML. Creaming velocities resulting from fat flocculation in a 0.2% level of OML and 1-ML were 0.16 and 1.13 mm/h, respectively, implying that OML showed higher efficiency and emulsion stability in preventing fat flocculation than 1-ML due to the selective oxidation of primary alcohol.

Comparison of life cycle emissions and energy consumption for environmentally adapted metalworking fluid systems

A number of environmentally adapted lubricants have been proposed in response to the environmental and health impacts of metalworking fluids (MWFs). The alternatives typically substitute petroleum with vegetable-based components and/or deliver minimum quantities of lubricant in gas rather than water, with the former strategy being more prevalent than the latter. A comparative life cycle assessment of water- and gas-based systems has shown that delivery of lubricants in air rather than water can reduce solid waste by 60%, water use by 90%, and aquatic toxicity by 80%, while virtually eliminating occupational health concerns. However, air-delivery of lubricants cannot be used for severe machining operations due to limitations of cooling and lubricant delivery. For such operations, lubricants delivered in supercritical carbon dioxide (scCO2) are effective while maintaining the health and environmental advantages of air-based systems. Although delivery conditions were found to significantly influence the environmental burdens of all fluids, energy consumption was relatively constant under expected operating conditions. Global warming potential (GWP) increased when delivering lubricants in gas rather than water though all classes of MWFs have low GWP compared with other factory operations. It is therefore concluded that the possibility of increased GWP when switching to gas-based MWFs is a reasonable tradeoff for definite and large reductions in aquatic toxicity, water use, solid waste, and occupational health risks.

Optimization of metalworking fluid microemulsion surfactant concentrations for microfiltration recycling

Microfiltration can be used as a recycling technology to increase metalworking fluid (MWF) life span, decrease procurement and disposal costs, and reduce occupational health risks and environmental impacts. The cost-effectiveness of the process can be increased by minimizing fouling interactions between MWFs and membranes. This paper reports on the development of a microfiltration model that establishes governing relationships between MWF surfactant system characteristics and microfiltration recycling performance. The model, which is based on surfactant adsorption/desorption kinetics, queueing theory, and coalescence kinetics of emulsion droplets, is verified experimentally. An analysis of the model and supporting experimental evidence indicates that the selection of surfactant systems minimally adsorb to membranes and lead to a high activation energy of coalescence results in a higher MWF flux through microfiltration membranes. The model also yields mathematical equations that express the optimal concentrations of anionic and nonionic surfactants with which microfiltration flux is maximized for a given combination of oil type, oil concentration, and surfactant types. Optimal MWF formulations are demonstrated for a petroleum oil MWF using a disulfonate/ ethoxylated alcohol surfactant package and for several vegetable oil MWFs using a disulfonate/ethoxylated glyceryl ester surfactant package. The optimization leads to flux increases ranging from 300 to 800% without impact on manufacturing performance. It is further shown that MWF reformulation efforts directed toward increasing microfiltration flux can have the beneficial effect of increasing MWF robustness to deterioration and flux decline in the presence of elevated concentrations of hardwater ions.

Structural aspects of surfactant selection for the design of vegetable oil semi-synthetic metalworking fluids

This paper presents a set of surfactant-selection guidelines that can be used to design bio-based semi-synthetic metalworking fluid (MWF) microemulsions as a renewable alternative to conventional petroleum formulations. Ten surfactant classes (six anionic and four nonionic) with different head and tail structures and three vegetable base oils (canola oil, soybean oil, and a fatty acid trimethylolpropane ester) were investigated as representatives of oil and surfactant options currently under consideration in the MWF industry. All combinations of these surfactants and oils were formulated at the full range of oil to surfactant ratios and surfactant concentrations. The stability of each formulation was evaluated based on visual transparency, light transmittance, and droplet diameter. The experimental results yield the following guidelines that produce stable bio-based MWF microemulsions with minimum necessary concentrations of surfactants: (1) a combination of two surfactants, one nonionic and one water soluble co-surfactant (either nonionic or anionic) is preferred over a single surfactant; (2) the nonionic surfactant should have a carbon tail length greater than or equal to the nominal carbon chain length of the fatty acids in the oil as well as a head group that is not excessively small or large (e.g., 10-20 ethylene oxide groups for a polysorbitan ester, ethoxylated alcohol, or ethoxylated glyceryl ester); (3) the difference in tail lengths between the surfactant and the co-surfactant should be less than 6 to maximize the feasible range of oil to surfactant ratios yielding stable emulsions. These guidelines are consistent with general results of micelle solubilization theory and evidence is provided to suggest that common semi-synthetic MWF systems can be thought of as swollen micelle systems.