Development of Replacements for

Phoscoating Used in Forging, Extrusion and

Metal Forming Processes
Final Report

Prepared under NCMS Project Number 140168

and DOE Agreement Number DE-FC07-94CE41123

Compiled by
National Center for Manufacturing Sciences
3025 Boardwalk
Ann Arbor, Michigan 48108-3266

March 2003
 2003 National Center for Manufacturing Sciences, Inc.

This report was prepared by the National Center for Manufacturing Sciences (NCMS) as an account of work sponsored
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 National Center for Manufacturing Sciences

Table of Contents
Section Page

List of Figures.......................................................................................................................................v

List of Tables ..................................................................................................................................... vii

Acronyms and Abbreviations ......................................................................................................... viii

Executive Summary .............................................................................................................................1

Survey of Coatings and Surface Modification Processes for Cold Forging Tooling .....................4
Introduction......................................................................................................................................4
Candidate Coatings and Surface Modification Processes................................................................4
Combined PVD and CVD Coating ............................................................................................5
Thermochemical Diffusion Processes........................................................................................6
Comparison of Tool Treatments ......................................................................................................8
Selection of Candidate Processes ..............................................................................................8
Basis for Comparison.................................................................................................................8
Coefficient of Friction ...............................................................................................................8
Treatment Cost...........................................................................................................................9
Recommendations..........................................................................................................................10

Development of Replacements for Phoscoating Used in Forging, Extrusion and Metal Forming
Processes .............................................................................................................................................12
Introduction....................................................................................................................................12
Lubrication in Cold Forging ....................................................................................................12
Problems Associated with the Use of Zinc Phosphate Coating Based
Lubricants in Cold Forging......................................................................................................12
Objectives and Approach...............................................................................................................12
Objectives ................................................................................................................................12
Approach..................................................................................................................................13
Survey of Lubricants for Replacement of Phoscoating .................................................................14
Introduction..............................................................................................................................14
MEC HOMAT .........................................................................................................................14
Daido AquaLub........................................................................................................................14
Metal Casting International (MCI) Z-Coat..............................................................................14
Acheson....................................................................................................................................15
Finite Element Simulations of the Double Cup Backward Extrusion Test ...................................15
Introduction..............................................................................................................................15
General Conditions for the FE Simulations .............................................................................15
FE Simulation Results and Discussion ....................................................................................15
Evaluation of Candidate Lubricants by Double Cup Backward Extrusion Test Using
Tool Steel Punches.........................................................................................................................16
Introduction..............................................................................................................................16
Preparation of Specimens ........................................................................................................16

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Application of Lubricants and Surface Characterization.........................................................18

Experimental Setup..................................................................................................................19
Determination of Appropriate Punch Stroke ...........................................................................19
Tests .........................................................................................................................................20
Results and Discussion ............................................................................................................23
Evaluation of Candidate Lubricants by Double Cup Backward Extrusion Test
Using Carbide Punches ..................................................................................................................24
Introduction..............................................................................................................................24
Preparation of Specimens ........................................................................................................24
Application of Lubricants ........................................................................................................32
Experimental Setup..................................................................................................................32
Tests .........................................................................................................................................33
Results and Discussion ............................................................................................................39
Summary and Concluding Remarks ..............................................................................................40

References...........................................................................................................................................42

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List of Figures
Figure Page

1. Forging Dies Undergoing Ion Nitriding (Advanced Heat Treat) .................................................7

2. Hardness Profile for Ion Nitrided D2 Tool Steel..........................................................................7

3. Schematic of TD Process (Arvin TD Center) ...............................................................................8

4. Wear and Friction Test Results for a MoST® PVD Coating on M42 Tool Steel ........................9

5. Coefficient of Friction for Ion Nitrided Alloy Steels and Stainless Steels...................................9

6. Coefficient of Friction for a D2 Tool Steel Surface Treated by the TD Process........................10

7. Double Cup Backward Extrusion Test .......................................................................................14

8. FE Model (Friction Factor m – 0.1)............................................................................................16

9. Definition of the Cup Height Ratio and Real Stroke ..................................................................17

10. Friction Factor Calibration Curves (AISI 1038).........................................................................17

11. Friction Factor Calibration Curves (AISI 8610).........................................................................17

12. Double Cup Backward Extrusion Test Tooling..........................................................................18

13. Optical Micrographs of Lubricated Billet Surfaces Before Tests...............................................20

14. Double Cup Backward Extrusion Tooling: 3D Cross-Section View .........................................21

15. Surface Cracks in Billets Coated with MEC HOMAT at 27 mm Stroke ...................................21

16. Damage Value Distribution in Double Cup Extrusion for Low and High Friction....................21

17a. Photographs of Selected Extruded Parts (AISI 8610) ................................................................22

17b. Photographs of Selected Extruded Parts (AISI 1038) ................................................................23

18. Lubricant Performance as a Function of Cup Height Ratio and Friction Factor
(AISI 8610) .................................................................................................................................25

19. Bar Graph for Lubricants Used with AISI 8610.........................................................................25

20. Lubricant Performance as a Function of Cup Height Ratio and Friction Factor
(AISI 1038) .................................................................................................................................25

21. Bar Graph for Lubricants Used with AISI 1038.........................................................................26

22. Performance Comparison Between Acheson and Phoscoating Lubricants ................................26

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23. Performance Comparison Between MEC HOMAT and Phoscoating Lubricants......................26

24. Optical Micrographs After Tests in the Upper Cups (AISI 8610)..............................................27

25. Optical Micrographs After Tests in the Lower Cups (AISI 8610) .............................................28

26. Optical Micrographs After Tests at the Outside Surface (AISI 8610) .......................................29

27. Optical Micrographs After Tests in the Upper Cups (AISI 1038)..............................................30

28. Optical Micrographs After Tests in the Lower Cups (AISI 1038) .............................................31

29. Optical Micrographs After Tests at the Outside Surface (AISI 1038) .......................................32

30. RP-48 Converted Radial Press with Extrusion Capability .........................................................33

31. Double Cup Backward Extrusion Tooling..................................................................................34

32. Phoscoating: Determination of Friction Factor Value m (Stroke = 12 mm) ..............................35

33. Phoscoating: Determination of Friction Factor Value m (Stroke = 15 mm) ..............................35

34. Phoscoating: Determination of Friction Factor Value m (Stroke = 19 mm) ..............................36

35. Acheson Lubricant: Determination of Friction Factor Value m (Stroke = 12 mm) ...................36

36. Acheson Lubricant: Determination of Friction Factor Value m (Stroke = 15 mm) ...................36

37. Acheson Lubricant: Determination of Friction Factor Value m (Stroke = 19 mm) ...................37

38. Phoscoating: Determination of Friction Factor Value m (Stroke = 21 mm)..............................37

39. Acheson Lubricant: Determination of Friction Factor Value m (Stroke = 21 mm) ...................37

40. Lubricant Performance as a Function of Cup Height Ratio and Friction Factor
(12 mm Stroke and TiN Coated Punches) ..................................................................................38

41. Lubricant Performance as a Function of Cup Height Ratio and Friction Factor
(15 mm Stroke and TiN Coated Punches) ..................................................................................38

42. Lubricant Performance as a Function of Cup Height Ratio and Friction Factor
(19 mm Stroke and TiN Coated Punches) ..................................................................................38

43. Lubricant Performance as a Function of Cup Height Ratio and Friction Factor
(21 mm Stroke and TiAlN + WCC Coated Punches) .................................................................39

44. Friction Factor for Various Stroke Lengths and Lubricants .......................................................39

45. Performance Comparison for Acheson and Phoscoating Lubricants (19 mm Stroke) ...............40

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List of Tables
Table Page

1. Common PVD and CVD Coatings ...............................................................................................5

2. Comparison of Thermochemical Diffusion Processes..................................................................6

3. Friction Coefficient Measured During Cold Forming with Phoscoating Lubricant.....................9

4. Cold Forging Case Histories and Cost Per Part for the Four Selected Tool Treatments............11

5. Providers of Tool Surface Treatments ........................................................................................11

6. Material Properties Obtained from the Compression Test .........................................................15

7. Chemical Composition of AISI 1038 .........................................................................................18

8. Chemical Composition of AISI 8610 .........................................................................................18

9. Lubricants Used for the Tests .....................................................................................................18

10. Experimental Matrix for the Double Cup Backward Extrusion Test .........................................21

11. Double Cup Backward Extrusion Tooling Materials .................................................................33

12. Experimental Matrix Used by Kinefac Corporation...................................................................34

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Acronyms and Abbreviations

CETIM Centre Technique des Industries PVD Physical vapor deposition
Mécaniques
OIT Office of Industrial Technology
CVD Chemical vapor deposition
SwRI Southwest Research Institute
ERC/NSM Engineering Research Center for
Net Shape Manufacturing TD Thermochemical diffusion

HV Vickers Hardness TiC Titanium carbide

MCI Metal Coating International U.S. United States

NCMS National Center for Manufacturing

Sciences

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Executive Summary
Background and Introduction processes. However, without a proactive
approach to phoscoating replacement, many
Many forging, extrusion, heading and other metal forming processes could find themselves
metal forming processes use graphite-based without a cost effective tribology material
lubricants, phosphate coatings, and other necessary for the metal forming process.
potentially hazardous or harmful substances to
improve the tribology of the metal forming The Problem
process. These lubricants provide relief in some
or all of the following areas depending on the Graphite coatings applied in the metal forming
application and metal forming requirements: process tend to contribute to the housekeeping
problems that plague metal forming operations,
• Overall friction reduction
exist as air-borne particulate, and have generally
• Improved heat transfer (both for process limited the metal forming industry’s confidence
heating and for component cooling during in microprocessor controls technology due to
forming potential contamination concerns. Similarly,
phosphate coatings require chemical processes
• Release agent at the die/workpiece
that may be in danger of legislative phase-out
interface
and would require substantial investments in
• Billet Protection where anti-oxidation environmental controls technology to enable the
may be possible metal forming industry to continue to process its
• Reduce metal forming friction loss parts. There exists a need to develop and adopt
between die and work clean lubrication products and standards for the
metal forming industry that would be compatible
• Prevent die failure due to pickup of with complex metal forming requirements,
workpiece material on dies enhance die and tooling life, be capable of high
• Improve die life due to reduced surface temperature product manufacturing, and would
erosion pre-empt environmental legislation that could
impact graphite and phosphate coatings and
• Increase the level of metal flow
their usage in the future. A focus on environ-
achievable by forming mentally conscious manufacturing is consistent
• Reduce process heat with the objectives of metal forming companies,
metal forming equipment manufactures and the
• Provide anti-oxidation protection.
material and coating suppliers.
The application of phosphate-based coatings has
long been studied to determine if other synthetic Proposed Solution
“clean” lubricants could provide the same degree
of protection afforded by phoscoatings and its The National Center for Manufacturing Sciences
formulations. So far, none meets the cost and (NCMS) held a workshop on September 28,
performance objectives provided by phoscoatings 1999 in Dearborn, MI which provided the basis
as a general aid to the metal forming industry. for a new project initiative of vital interest to the
In as much as phoscoatings and graphite have metal forming community. A holistic approach
replaced lead-based lubricants, the metal to replacement of phoscoatings was developed
forming industry has had previous experience by the NCMS team and a description of the
with a legislated requirement to change project and its tasks are provided by this report.

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The team, led by Delphi Saginaw, Kinefac • Cleanability for post-processing (some
Corporation, Metaldyne, Acheson Colloids, Ohio operations require removal of phoscoating
State University, Southwest Research Institute to accommodate downstream machining
(SwRI), and NCMS organized itself around the or finishing operations.
replacement of phoscoatings to address legis-
lation and environmental pressures in progress. Results and Recommendations
Using tooling provided by the NCMS team, a
number of alternative billet and tool coating Survey of Coatings and Surface Modifica-
materials would be assessed as independent and tion Processes for Cold Forging Tooling
dependent variables for metal forming opera-
tions. Acheson Colloids, a supplier of lubricants Of the commercially available coatings and sur-
and coatings to the metal forming industry, pro- face modification processes, the most suitable for
posed that one of its most important emerging cold forging under severe conditions were those
technologies be evaluated through this program. with surface hardness above 1000 Vickers
The Kinefac Corporation agreed to provide a Hardness (HV) and a very low coefficient of
hydraulic extrusion press to form billets supplied friction (high lubricity). A thin-film coating
by Metaldyne Company using a double cup could be used, but only if supported by an
specimen test developed at Ohio State Univer- underlying coating or a surface modified
sity. Delphi Saginaw would provide test tooling. underlayer. Surface modification could also be
used on its own, and several thermochemical
The following attributes were to be evaluated diffusion processes were suitable.
during this pilot program:
• Ease of application
SwRI has selected four tool treatments. These
were a MoST® physical vapor deposition
• Durability of coating (survives harsh and (PVD) coating overlying a titanium carbide
changing environment) (TiC) chemical vapor deposition (CVD)
• Coating adhesion coating, ion nitriding, boriding and the
thermochemical diffusion (TD) process. The
• Coating uniformity processes were compared on the basis of
• Reduction of co-efficient of friction coefficient of friction and treatment cost per
part. Friction data was obtained from laboratory
• Prediction of part forming temperatures
test results. The cost per part was estimated
• Part tolerance upon forming. from case histories for treated cold forging
tools.
The environmental issues to be addressed
included the following: The friction data suggested that the combined
• Generation of hazardous waste products
PVD/CVD coating or the ion nitriding process
have the potential to replace phoscoating in cold
• Sludge forging. This was because the coefficient of
• Zinc based by products friction for these treatments was comparable to
that measured for phoscoating. However, a
• High water usage quantitative comparison between the four
• Human exposure to toxic chemicals and selected treatments was difficult due to unknown
fumes contact pressures in some of the friction tests.
• High energy consumption The cost per part for three of the four tool
treatments appeared to be comparable to or

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lower than the cost of phoscoating. But the only The punches and die container used for the
accurate cost estimate was for the combined double cup backward extrusion tooling were
PVD/CVD coating, with which the need for made from tool steel (M2).
phoscoating was completely eliminated.
Four lubricants, MEC HOMAT, Daido AquaLub,
SwRI recommends evaluation of all four tool MIC Z-Coat, and phoscoating, were tested on the
treatments as possible replacements for AISI 8610 billets. In this set of tests, MEC
phoscoating in cold forging operations. HOMAT was found to have the best perfor-
mance. For the AISI 1038 billets, only the
Development of Replacements for Phos- Acheson lubricant and phoscoating were tested.
coating Used in Forging, Extrusion and In these tests, phoscoating performed better than
Metal Forming Process the Acheson lubricant. In addition, a ranking
showing the performance of the candidate lubri-
In order to replace zinc phosphate partially or cants in comparison to the conventional phos-
completely, candidate lubricants were sought coating was achieved. In the future, subsequent
from lubricant manufacturers worldwide. Four testing of the viable candidate lubricants should
lubricant candidates were identified, namely: be completed in a production environment.
MEC HOMAT, Daido AquaLub, MCI Z-Coat
and Acheson. In order to further evaluate the Acheson lubri-
cant as compared to phoscoating, a series of
The performance evaluation of these lubricants double cup backward extrusion tests were
was conducted using the double cup backward conducted at the Kinefac Corporation. The
extrusion test developed at Ohio State Univer- billets were cut from the same AISI 1038 stock
sity’s Engineering Research Center for Net as the billets used by the ERC/NSM. The geome-
Shape Manufacturing (ERC/NSM). The prin- try of the forming tooling was identical to that
ciple underlying this test was that the cup height developed at the ERC/NSM; however, the
ratio was an indication of lubricity. In this test, punches were made from carbide as opposed to
however, friction factor was determined M2 tool steel. In addition, the Kinefac Corpora-
indirectly by combining FEM and experiments. tion was able to incorporate two punch coatings,
Thus, calibration curves, i.e. cup height ratio vs. namely TiN and TiAlN + WCC, into their tests.
punch stroke, were established with FEM by
varying friction factor (m) from m=0 to m=0.15. Just as in the tests performed at the ERC/NSM,
In order to conduct the FE simulations, the flow the phoscoating performed better than the Ache-
stress of the materials used in the experiments son lubricant. In addition, the results showed
had to be determined. Two billet materials, AISI little difference between the TiN and the TiAlN
8610 and AISI 1038, were used in this study. + WCC punch coatings.

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Survey of Coatings and Surface Modification Processes for

Cold Forging Tooling
Introduction treatments for tooling are under way elsewhere,
for example at the Darmstadt University of
The Ohio State University’s Engineering Technology in Germany.
Research Center for Net Shape Manufacturing
(ERC/NSM) is investigating the replacement of Since ERC/NSM already has a substantial list of
phoscoating used for lubrication in forging, possible replacement lubricants, SwRI has limi-
extrusion and metal forming processes. The ted its search to coatings and surface modifica-
objective of the project is to replace phoscoating tion processes for cold forging tooling. Tools
without losing the favorable properties of the for cold forging are usually made from a tool
lubricant. The particular emphasis of the study steel, sometimes with carbide inserts.
is cold forging under extreme conditions, a
process in which good lubrication is essential. Candidate Coatings and Surface
Without a lubricant, the billet being forged is Modification Processes
likely to crack.
Cold forging under extreme conditions involves
Phoscoating consists of zinc phosphate coating very high forces on the tooling, with contact pres-
followed by application of a reactive soap, a sures typically in the range 0.8–1.5 GPa (120–
combination discovered by German engineers 220 ksi or 50–100 tons per in2). A lubricant like
making steel shell casings in the 1930s. The phoscoating is needed for all types of cold
soap reacts with the phosphate to form what is forming at such high pressures, and any replace-
believed to be a chemically bonded lubricant ment lubricant or tool surface treatment must also
layer. Zinc phosphate has the ability to absorb be able to withstand these harsh conditions. At
and hold lubricants such as the stearates in soap, lower contact pressures, other lubricants that are
even under severe conditions of heat and pres- more environmentally benign can be substituted.
sure. Because phoscoating is so effective, its use
has continued to the present. Surface treatments for tooling can be divided
into coatings and surface modification processes.
However, phosphate sludge and wastewater from Coating processes deposit an overlayer on the
the phoscoating process are environmentally surface while surface modification alters the
hazardous, and their proper disposal is becom- properties of the near-surface region without a
ing increasingly costly. In addition, phosphating new layer being added.
and dephosphating of parts adds to the cost of
cold forming. The cold forging industry in parti- Most thin-film coatings will not stand up to
cular is pushing for an alternative to phoscoating. cold forging pressures when used alone. Such
coatings are generally thinner than the case
A formal survey of candidate lubricants has been depth of a surface modification process. Under
completed by ERC/NSM. Southwest Research cold forging conditions, thin-film coatings
Institute’s (SwRI) role in the project is to search deposited by physical vapor deposition (PVD)
for additional possibilities. These include other or chemical vapor deposition (CVD) are likely
lubricants, as well as surface treatments for the to crack or even delaminate. This immediately
tooling used in cold forging operations. The excludes the vast majority of commercially
ultimate goal is to eliminate the need for a available PVD or CVD coatings as a treatment
lubricant altogether. Similar efforts on surface for forging tools.

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However, a PVD or CVD coating can be used methods are cathodic arc evaporation, electron
for cold forging tools when deposited over an- beam evaporation and sputtering. PVD is
other coating, or on top of a surface modified sometimes referred to as “the cold process.”
underlayer. In this instance, the underlying coat-
ing or surface modification process provides CVD, often called “the hot process,” involves a
support for the overlay coating. The top coating chemical reaction between gases on the surface
is not subject to the “eggshell effect” experienced of a heated substrate. The reaction product
by a thin, unsupported coating on a softer sub- condenses on the substrate. CVD temperatures
strate. are usually 800–200°C (1470–2190°F), high
enough to cause distortion and loss of bulk
The best coating combination is probably a hardness in many materials. However, the high
lubricious PVD film deposited over a CVD temperatures lead to metallurgical bonding of
coating. Not only are CVD coatings thicker than the coatings.
PVD coatings, but they are also more robust.
This is because the high deposition temperature Many PVD and CVD coatings are single-layer.
causes coating atoms to diffuse into the substrate, However, multi-layer coatings, that combine the
so that the films are strongly adherent. CVD properties of the component layers, are becoming
coatings, however, do not have high lubricity. increasingly popular. Multi-layer CVD coatings
have been used for some time on cutting tool
An alternative treatment for cold forging tooling inserts, and several multi-layer PVD coatings
is a surface modification process. Surface have recently emerged also. An interlayer is
modification can be used either on its own or as sometimes deposited between a PVD coating
support for an overlying PVD coating. The deep, and the substrate, to enhance adhesion.
hardened case that results from most surface
modification processes will hold up even under Some common PVD and CVD coatings are
the extreme pressures of cold forging. listed in Table 1.

Combined PVD and CVD Coating The most important needs in a coating on tool-
ing are high hardness and a low coefficient of
PVD is a thin-film deposition process based on friction. Tool wear decreases with increasing
emission of vapor from a source, its transport in hardness and decreasing coefficient of friction.
a vacuum and its condensation on a heated Friction data for the candidate coatings and
substrate. For deposition of chemical compounds, surface modification processes will be reviewed
a reactive gas is introduced into the vapor later in this report. For long tool life, the surface
stream. Substrate temperatures range from about hardness should be 1000 HV or higher, a
200°C (390°F) to 550°C (1020°F), depending condition satisfied by essentially all PVD and
on the PVD method. The most common CVD coatings.
Table 1. Common PVD and CVD Coatings
PVD or Typical Coating
Coating Hardness, HV Adhesion1
CVD Thickness, µm
TiN PVD 1–5 2,300 – 2,900 70
TiCN PVD 1–5 3,000 – 3,500 62
Diamond-like carbon (DLC) PVD 1 – 10 1,000 – 5,000 Unknown
MoST®2 PVD 2–5 1,500 – 2,100 >120
TiC CVD 7 – 10 3,000 – 3,200 Unknown
TiC/TiN CVD 7 – 10 2,600 – 2,800 110
1 Critical normal force (newtons) required to remove coating from substrate in scratch test
2 MoS2/Ti composite coating developed by Teer Coatings and licensed to IonBond

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Thermochemical Diffusion Processes can penetrate 500 µm or more when required.

The TD process produces a case no more than
Surface modification processes include 20 µm deep. However, even this depth should
thermochemical diffusion and ion implantation. be adequate for cold forging dies.
Implantation is unsuitable for applications invol-
ving heavy loading like cold forging, because of As with thin-film coatings, the surface hardness
the shallow depth of the process. The principal for long tool life should be 1000 HV or higher.
thermochemical diffusion processes are This requirement restricts the choice of possible
summarized in Table 2. diffusion treatments (Table 2) to nitriding,
boriding and the TD process. Each of these is
Thermochemical diffusion (TD) involves now discussed in turn.
adsorption of an element such as carbon or
boron on a heated metal substrate. This is Ion Nitriding
followed by a chemical reaction between the
element and substrate, and diffusion of the Within nitriding, SwRI has selected the ion
element into the metal. Several methods of nitriding (plasma nitriding) method, since this
diffusion can be used. The methods are: salt has the lowest process temperature and shortest
bath (from the liquid state), gas, vacuum, ion process time of all the available diffusion
(plasma), fluidized bed and pack cementation methods. In ion nitriding, nitrogen is diffused
(solid). Process temperatures for diffusion can into the substrate from a glow discharge plasma
be as high as 1050°C (1920°F), which may (Figure 1). The substrate is negatively biased to
result in distortion of a tool and loss of core about -1 kV and the bias voltage is usually
hardness. pulsed to minimize arcing.

Of the various diffusion treatments, carburizing An ion nitrided steel surface comprises an outer
results in the deepest case layers, but is restricted compound zone and an underlying diffusion
to carbon and alloy steels. Case depths for zone. The compound zone, often called the white
nitriding and carbonitriding processes range up layer, consists of iron compounds and is up to
to 750 µm for carbon and alloy steels, and up to 15 µm thick. The much deeper diffusion zone
250 µm for stainless and tool steels. Nitrocar- consists of nitrogen in solid solution, together
burizing and boriding generally produce with finely dispersed nitride precipitates.
shallower case layers less than 100 µm deep, but

Table 2. Comparison of Thermochemical Diffusion Processes

Typical Case Depth, µm Surface Hardness, Typical Process
Process
(mils) HV Temperature, °C (°F)
75 – 1,500 850 – 950
Carburizing 700 – 900
(3 – 60) (1,560 – 1,740)
75 – 750 500 – 570
Nitriding 300 – 1,050
(3 – 30) (930 – 1,060)
50 – 750 750 – 900
Carbonitriding 600 - 850
(2 – 30) (1,380 – 1,650)
25 – 750 560 – 670
Nitrocarburizing 500 - 6501
(1 – 30) (1,040 – 1,240)
25 – 125 820 – 980
Boriding (boronizing) 1,600 – 2,000
(1 – 5) (1,510 – 1,800)
2.5 – 20 850 – 1,050
TD Process 3,200 – 3,800
(0.1 – 0.8) (1,560 – 1,920)
1 Mild steel

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with high compressive stress. Formation of con-

tinuous layers of FeB, that could lead to spalling,
can be minimized by diffusion annealing after
boriding. Also, boriding powders that reduce
formation of FeB are available.

As in ion nitriding, the hardness following bo-

riding is highest at the surface. Although the
core hardness of a tool steel is generally lowered
by the high temperature (820–980°C) of boron
diffusion, most tool steels can be rehardened
without affecting the borided surface layer.
Figure 1. Forging Dies Undergoing Ion
TD Process
Nitriding (Advanced Heat Treat)

One of the characteristics of thermochemical The TD process, originally developed by Toyota,

diffusion is that the increased hardness from the uses the salt-bath diffusion method to create a
process is graduated. The hardness has its high- carbide layer at the surface. The carbide is
est value at the surface and gradually falls to the formed from the diffused element and carbon
bulk value over the case depth. An example is already present in the substrate. Most commonly,
shown in Figure 2. vanadium is diffused to form a vanadium
carbide layer (Figure 3). The substrate must
Boriding contain a minimum of 0.3% carbon for the
necessary chemical reaction to occur.
Boriding (boronizing) is done by the pack
cementation method. In this method, parts are Vanadium carbide is very hard, with hardness
immersed in a powder material containing a ranging from 3,200 to 3,800 on the Vickers
source of boron. The powder pack is placed in a scale. This hardness is retained at temperatures
sealed container that is then transferred to a up to 550°C (1,020°F). The case layer produced
furnace. Boron diffuses into the parts and forms by the TD process exhibits uniform hardness, in
borides of the base metal. contrast to the graduated hardness produced by
other thermochemical diffusion processes.
Two boride phases can form on steels. The FeB However, despite the abrupt transition from the
phase is brittle and results in a surface under vanadium carbide layer to the undiffused metal
high tensile stress. The Fe2B phase is preferred underneath, the layer shows extremely strong
because it is less brittle and results in a surface bonding to the substrate.

Because the TD process temperature is so high

(850–1,050°C), steels are processed at their
recommended austenizing temperature. After
TD processing, parts are quenched, and then
tempered to restore the original core hardness.

Figure 2. Hardness Profile for Ion Nitrided D2

Tool Steel

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 National Center for Manufacturing Sciences

project. In less arduous applications, MoST®

PVD has proved superior to TiC/TiN CVD
coatings.

The three selected diffusion processes discussed

are: ion nitriding, boriding and the TD process
(highlighted in Table 2).

Basis for Comparison

The four selected tool treatments are now com-
pared for their potential to reduce or eliminate
the use of phoscoating in cold forging.

Figure 3. Schematic of TD Process

Our first basis for comparison of the treatments
(Arvin TD Center) is coefficient of friction. The purpose of a
lubricant is to prevent the two surfaces in
Comparison of Tool Treatments sliding motion from coming into direct contact,
a condition that leads to severe adhesive wear
Selection of Candidate Processes (galling). A lubricant film, either liquid or solid,
keeps the surfaces separated and lowers fric-
There are many possible combinations of a PVD tional forces. The coefficient of friction between
coating with another coating or a surface the surfaces is a measure of the lubricity.
modified underlayer. In this search, SwRI has
selected a PVD deposited over a CVD coating, A second basis for comparison is the treatment
together with three thermochemical diffusion cost per part produced, relative to phoscoating.
processes on their own. This is an important attribute, since the cold
forging industry is already concerned about the
The selected coating combination is an MoST® high overall cost of the phoscoating process.
PVD coating overlying a TiC CVD coating
(highlighted in Table 1). This has been chosen Coefficient of Friction
for two reasons:
Phoscoating Lubricant
• MoST® is a PVD solid (dry film) lubricant
that exhibits an ultralow coefficient of fric- The coefficient of friction during cold forming
tion, often lower than that of Teflon® or with a phoscoating lubricant has been measured
graphite. But unlike other solid lubricants, by the Centre Technique des Industries Mécani-
MoST® has a hardness approaching that of ques (CETIM) in France. The measurements
TiN. The only other commercial PVD coating were part of an investigation of a new cold forg-
with comparable lubricity and hardness is ing lubricant developed by Dacral. Information
DLC. on this lubricant, gathered in the earlier survey,
• The combination of MoST® PVD with TiC was provided to SwRI by ERC/NSM.
CVD has already been used successfully on a
cold forging tool. An M2 tool steel punch CETIM determined the coefficient of friction
used in backward extrusion was treated by both for wire drawing and forward extrusion
IonBond. The treatment not only prolonged operations, under actual production conditions.
tool life, but it also eliminated the need for Although wire drawing is not a cold forging
phoscoating—the objective of the present process, contact pressures on wire drawing dies

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 National Center for Manufacturing Sciences

are often in the cold forging range (0.8–1.5

GPa). Values of the friction coefficient µ were
measured using phoscoating as well as the new
Dacral lubricant. The phoscoating results are
shown in Table 3.

It is seen that µ ranges from 0.062 to 0.10, and

increases as the contact pressure increases.

Candidate Tool Treatments

Friction data for the candidate tool treatments
have been obtained from laboratory test results.
For direct comparison to the phoscoating data,
results for unlubricated motion (dry sliding)
are necessary. The presence of a lubricant
modifies the frictional behavior of the coating or
diffusion treatment.
Figure 4. Wear and Friction Test Results for a MoST® PVD
Typical data from unlubricated pin-on-disk Coating on M42 Tool Steel
testing of an MoST® PVD coating, without an
underlying TiC coating, are presented in Figure
4. Only the tool steel disk was coated, not the
WC-6%Co pin.

Results from unlubricated pin-on-disk tests of

an ion nitrided surface are shown in Figure 5.
For these tests, both the steel disks and the 440C
stainless steel pin were nitrided.

Figure 6 shows results from a lubricated sliding

test of a TD-treated tool steel surface. Wear was
produced by a diamond tip under load, and the
lubricant was MoS2. No graphical data are
available for an unlubricated TD-treated
surface, nor for a borided surface.

Because of the unknown contact pressures, a

quantitative comparison between the processes Figure 5. Coefficient of Friction for Ion Nitrided Alloy
Steels and Stainless Steels
is not straightforward. As expected, the values
of µ for lubricated sliding are lower than those Treatment Cost
for unlubricated sliding.
The cost of phoscoating in cold forging opera-
Table 3. Friction Coefficient Measured During Cold
Forming with Phoscoating Lubricant
tions has been examined by MEC International.
Like Dacral, this company developed a new
Contact Friction cold forging lubricant, information on which
Cold Forming Process
Pressure, GPa Coefficient
was provided to SwRI by ERC/NSM. At least in
Wire drawing 0.8 0.062
Forward extrusion 1.38 0.10

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TiC CVD coating, and $0.036 per part for the

TD process, are promising. However, only with
the combined PVD/CVD coating was the need
for phoscoating eliminated altogether. For both
ion nitriding and the TD process, the true cost
per part is higher than the calculated cost in
Table 4 because phoscoating was still necessary,
though at a reduced level.

Recommendations
Figure 6. Coefficient of Friction for a D2 Tool Steel Surface
Treated by the TD Process The friction and cost data suggest that three of
the selected tool treatments have the potential to
Japan, MEC International estimates that phos-
replace, or at least reduce the use of, phoscoating
coating costs approximately $0.09 (11.7 yen)
in cold forging. These are the MoST® PVD
per part in cold forging. Much of this cost is
over TiC CVD coating, ion nitriding and the TD
associated with the steps involved in phosphat-
process. Boriding appears to have a higher
ing, and with waste disposal.
coefficient of friction and to be more expensive.
To estimate the cost per part for the four selected However, a detailed comparison between the
tool treatments, SwRI has obtained information four treatments is difficult due to unknown
on treated tooling from providers of the treat- contact pressures in some of the friction tests,
ments. For three of the four treatments, detailed and lack of reliable cost information for
case histories for cold forging tooling were boriding.
available. For boriding, no cold forging history
Therefore, SwRI recommends evaluation of all
was available, and only a general cost com-
four tool treatments as possible replacements for
parison can be made between boriding and ion
phoscoating in cold forging operations.
nitriding.
Providers of the treatments are listed in the
Table 4 compares the costs for the four selected
Table 5. In the case of the combined PVD/CVD
treatments with the cost of phoscoating.
coating, and also the TD process, there is only
For all selected treatments except boriding, the one U.S. provider for each process. In the case
calculated cost per part is lower than the esti- of ion nitriding and boriding, the two largest and
mated cost of $0.09 for phoscoating. The costs most well-known providers are listed for each
of <$0.05 per part for the MoST® PVD over process.

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Table 4. Cold Forging Case Histories and Cost Per Part for the Four Selected Tool Treatments
Tool Treatment Number of Cost per
Tool Application Comments
Treatment Cost Parts Part
Replaced
MoST® PVD + Extrusion Backward extrusion of 1035 steel,
$1,500 >30,000 <$0.05 phoscoating
TiC CVD punch (M2) 400 ton press
lubricant
Use of
Cold forging
Ion nitriding Unknown $600 8,000 $0.075 phoscoating
die (D2)
reduced
Approx. 5x
No history Typically same
Boriding cost of ion
available as ion nitriding
nitriding
Use of
Extrusion Backward extrusion of 1010 steel,
TD process $1,720 48,000 $0.036 phoscoating
punch (M2) pressure 1.5 – 1.7 GPa
reduced
No treatment
Extrusion Backward extrusion of 1010 steel, Cost in
(phoscoating Unknown Unknown $0.09
punch (M1) pressure 1.5 GPa Japan
only)

Table 5. Providers of Tool Surface Treatments

Treatment Company Address Contact, Title Phone
1598 E. Lincoln Bernie Janoss
PVD/CVD IonBond
Madison Heights, MI Business Director, Stamping 248-398-9100
coating www.ionbond.com
48071 & Forming
Advanced Heat Treat 1625 Rose Street Dr. Ed Rolinski
Ion nitriding 734-243-0063
www.ahtweb.com Monroe, MI 48162 VP of Technology
George Idriceanu
Sun Steel Treating 550 Mill Street, Box U
Director of R&D and Process 248-471-0844
www.sunsteeltreating.com South Lyon, MI 48178
Engineering
Bodycote Thermal Processing 620 Buffalo Road
Boriding Keith Stewart 585-436-7876
www.bodycote.com Rochester, NY 14611
Materials Development Corporation 81 Hicks Avenue
781-391-0400
www.vbcgroup.com/vbc/borofuse.htm Medford, MA 02155
Steve Harper
Arvin TD Center 2020 Fifteenth Street
TD process Manager of Engineering and 812-378-1592
www.arvintd.com Columbus, IN 47201
R&D

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Development of Replacements for Phoscoating Used in

Forging, Extrusion and Metal Forming Processes
Introduction • Several baths at temperatures between 40 and
95°C containing different solutions are
Lubrication in Cold Forging necessary. This results in high costs to
purchase and maintain the equipment and
In cold forging operations, pressures as high as high energy consumption to heat the baths.
2,500 MPa (363 ksi) are developed at the tool-
workpiece interface. In addition, the spike • The amount of hazardous waste that is gener-
temperature may reach as high as 600°C, and ated is a concern. The baths contain acids,
the surface enlargement may reach 3,000% ions of the basic metal, the alloying constitu-
[Bay, 1994]. ents, and phosphates. The wastewater contains
organic compounds and emulsifying agents.
Thus, the lubricants used in cold forging are After phosphating, the baths become polluted
subjected to very severe conditions. Failure to with heavy metals like lead and cadmium.
withstand the above-mentioned conditions The wastewater treatment and the baths result
implies failure to satisfactorily form the desired in solids, which contain metals, heavy metals,
part and may lead to significant die wear or even oils, and other pollutants. Most of this waste
die failure. A good lubrication system is essential cannot be reused and thus becomes hazardous
for cold forging processes and it is the determin- waste.
ing factor for making the process competitive. • The machines and facilities become polluted.
Dust accumulates as the result of surface
Since 1934, nearly all steel cold forging pro-
enlargement during forging. This dust is a
cesses have used a zinc phosphate coating based
health risk to the workers in the facility. The
lubricant in order to withstand the severe condi-
baths are also a source of toxic chemicals and
tions described above. The use of this lubricant,
fumes, which lead to unhealthy working
however, has a negative environmental impact.
conditions.
Thus, an environmentally friendly lubricant
capable of replacing zinc phosphate based • The mechanical properties of the base
coatings is needed. material that the zinc phosphate coating is
applied to are affected. Zinc phosphate can
Problems Associated with the Use of Zinc increase corrosion and diffuse into the
Phosphate Coating Based Lubricants in workpiece material during heat treatment.
Cold Forging This is a common cause for surface
embrittlement.
Before addressing candidate lubricants for the
replacement of zinc phosphate coating based Objectives and Approach
lubricants in cold forging, the problems asso-
ciated with this lubrication system must be Objectives
clearly stated. These problems include
[Schmoeckel et al. 1997]: The objective of this project was to replace
phoscoating with other lubricants without losing
• It is costly to apply and remove the zinc the favorable properties that are obtained in
phosphate layer. metal forming operations using phoscoating. To
select candidate lubricants, a testing apparatus
and procedure was developed to compare the

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 National Center for Manufacturing Sciences

candidate lubricants to phoscoating. In doing so, friction, the cup heights will be the same and the
the candidates are ranked based on their perfor- ratio, H1/H2, will be equal to one.
mance during the test. Additionally, the follow-
ing lubricant attributes are noted and compared The container has a relative velocity to the upper
from the experiments: punch, but not to the lower punch. Therefore,
the material flow to the lower punch is more
• Ease of application restricted. Thus, in the presence of friction, the
• Coating adhesion height of the upper cup is larger than the height
• Coating uniformity of the lower cup.
• Coating quality
• Coefficient of friction. In Figure 7, H1 is the upper cup height and H2 is
the lower cup height. The cup height ratio, Rch,
In selecting candidate lubricants, the following is defined by H1 divided by H2. This ratio is an
aspects were considered:
indication of lubricity. If the friction factor
• Generation of hazardous waste products increases, the cup height ratio will increase as
• Sludge well. In this test, however, FEM is used in
• Zinc combination with the experiments to determine
• High water usage the friction factor.
• Human exposure to toxic chemicals and
fumes (if any) With the use of the commercial FEM code
• Energy consumption. DEFORM, friction factor calibration curves
(cup height ratio vs. stroke) can be established
Note that the term “phoscoating” is used here to for different friction factor values (m). By
represent zinc phosphate coating based lubrica- matching the cup height ratio and punch stroke
tion. This term will be used throughout this obtained from experiments to that obtained from
report. FE simulations, the friction factor of the lubri-
cants can be obtained.
Approach
The following tasks were conducted in this
The double cup backward extrusion test was study:
used to evaluate the lubricants. The available
Survey of lubricants that can replace
single cup backward extrusion test at the Task 1
phoscoating.
ERC/NSM was retrofitted to suit the double cup Determination of the flow stress of the
backward extrusion test. The double cup Task 2
billet materials to be used for the tests.
backward extrusion test was chosen because: Finite element simulation of the double
• The test emulates severe deformation Task 3 cup extrusion test in order to generate
friction factor calibration curves.
conditions similar to that occurring in
Design and manufacture the tooling for
actual forging operations the double cup extrusion test. ERC/NSM
• The test is easy to conduct and lubricants Task 4
tooling for the single cup backward
can easily be ranked based on the extrusion test was retrofitted to suite the
difference in the cup heights. double cup backward extrusion
operation.
The principle of this test is illustrated in Figure 7. Test set up, specimen preparation,
Task 5 lubricant application. Five lubricants
The ratio of the cup heights, H1/H2, is an indi-
were used.
cation of lubricity. It has been found that the
Double cup extrusion tests and
ratio of the cup heights increases as the friction Task 6
evaluation of results.
factor increases. In other words, if there is no

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 National Center for Manufacturing Sciences

compared of the phoscoating

application, which takes 40 minutes
Upper Punch • Improvement of Work Environment—
there is no danger of strong alkali or
strong acid with this lubrication system
as compared to phoscoating
Billet
H1 • Energy Savings—this lubrication
system requires drying at 40°C as
compared to phoscoating lubricant
H2
baths, which are heated to 90°C.

Lower Punch Daido AquaLub

Figure 7. Double Cup Backward Extrusion Test
Daido Chemical Industries in Japan manufactures
Survey of Lubricants for the Daido AquaLub lubricant. This lubricant has
Replacement of Phoscoating the following advantages:
• Profitability—the installation space
Introduction and initial cost of the lubrication
system are drastically reduced
The survey of cold forging lubricant manufac- compared to phoscoating
turers revealed four candidate lubricants for the
• Waste—there is no wastewater
replacement of phoscoating. These included:
disposal as compared to the large
MEC HOMAT, Daido AquaLub, MCI Z-Coat,
amounts of sludge produced by the
and Acheson. The following sections describe
phoscoating process
each of these lubricants.
• Productivity—the application of this
MEC HOMAT lubrication system is much easier than
the application of a phoscoating
MEC International in Japan manufactures the
MEC HOMAT lubricant. This lubricant is a • Energy Savings—this lubrication
water-based lubricant whose main components system requires drying at room
are metal compounds and organic sulfur temperature as compared to
compounds. This lubricant has the following phoscoating lubricant baths, which are
advantages: heated to 90°C.
• Profitability—the installation space Metal Coating International (MCI)
and the initial cost of the lubrication Z-Coat
system are drastically reduced
compared to phoscoating Metal Coatings International manufactures the
• Waste—there is no waste disposal with
Z-Coat lubricant. The Z-coat lubricant forms
this lubrication system as compared to zinc/iron film on the surface of the billet. This
the large amounts of sludge produced film is porous and can be combined with forging
by a phoscoating system oils, metal soaps, or molybdenum disulfide. The
advantages of this lubricant are as follows:
• Productivity—the application of this
• Profitability—the installation space
lubricant only takes 5 minutes as
and the initial cost of the lubrication

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 National Center for Manufacturing Sciences

system are drastically reduced DEFORM. In the simulations, the constant

compared to phoscoating shear friction model was used. The material
properties of the billets (in the form of a power
• Waste—there is no wastewater
disposal as compared to the large law σ=Kεn) for the simulations were obtained
amounts of sludge produced by the using the uniform compression test. The
phoscoating process strength coefficient, K, and strain hardening
index, n, obtained from the compression test for
• Productivity—the application of this AISI 1038 and AISI 8620 are shown in Table 6.
lubrication system is much easier than
the application of a phoscoating The billet, with a height of 31.75 mm and a
• Improvement of Work Environment—
diameter of 31.75 mm (1.25 inches), was
there is no danger of strong alkali or meshed with 1,500 elements. In order to
strong acid with this lubrication system simulate a 25 mm punch stroke, the stroke per
as compared to phoscoating step was set 0.25 mm and the 100 step were
used. The shear friction factors used in the
• Energy Savings—this lubrication sys- simulations were m=0, m=0.02, m=0.03,
tem requires drying at room tempera- m=0.04, m=0.05, m=0.055, m=0.06, m=0.065,
ture as compared to phoscoating m=0.07, m=0.08, m=0.09, m=0.1 and m=0.15.
lubricant baths, which are heated to Figure 8 shows the FEM model at two different
90°C punch strokes.
• Material Properties—this lubrication
The cup height ratio, Rch, is defined by Equation
system does not degrade material
properties as compared to phoscoating. 4.1 and the real stroke, Sr, is defined by Equa-
tion 4.2 (Figure 9). This ratio is an indication of
Acheson lubricity. The ratio of the cup heights increases
as the friction factor increases. In other words, if
No technical information was made available there is no friction, the cup heights will be the
for the Acheson lubricant. same and hence the ratio, H1/H2, will be equal to
one.
Finite Element Simulations of the
Double Cup Backward Extrusion FE Simulation Results and Discussion
Test Figures 10 and 11 show the friction factor
calibration curves for AISI 1038 and AISI 8610,
Introduction respectively. The cup height ratio, Rch, between
the backward extrusion cup height, H1, and the
The aim of the simulations was to fully
forward extrusion cup height, H2, is plotted
understand the parameters affecting the metal
versus the punch stroke. The calibration curves
flow in the double cup backward extrusion
can be used to approximate the friction factor
process and to obtain friction factor calibration
for the double cup backward extrusion test using
curves. The friction factor calibration curves
a particular lubricant.
would later be used to identify the fiction factor
of the tested lubricants. Table 6. Material Properties Obtained from the
Compression Test
General Conditions for the FE Simulations
AISI 1038 AISI 8620
In order to get friction factor calibration curves, K = 140 ksi, n = 0.15 K = 100 ksi, n = 0.14
several simulations were conducted with

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Basically, it is a combination of single cup

forward and single cup backward extrusion
processes. The test setup is shown in Figure 12.
The container and the lower punch are fixed on
the bed of the press and the upper punch is fixed
on the ram of the press. In this test, the upper
punch moves downwards while the bottom
punch and the die are kept stationary. The
diameters of both punches are the same. The
upper cup is formed by a backward extrusion
process and the lower cup is formed by a
forward extrusion process. The simultaneous
action of the two punches inside the cylindrical
container generates the two cups.

The objective of the double cup backward

extrusion test is to establish a correlation
between the ratio of the extruded cup heights to
the friction conditions between the billet surface
and the punch and container. The friction
conditions at the workpiece container interface
are expressed as a number known as the friction
factor, m, which varies between 0 and 1. If such
Figure 8. FE Model (Friction Factor m – 0.1)
a correlation can be established, then the
It is shown that with increasing friction value existing friction conditions can be quantified.
“m” the cup height ratio ratios increase as well.
The friction conditions at the container-
The figures also show that the cup height ratio
workpiece interface control the ratio between
increases with increasing stroke up to a maxi-
backward and forward extrusion (cup heights).
mum value (H2/H1), and then gradually starts to
Studies on friction conditions in cold forming
decrease until a stroke of about 20 mm is
with this test method have shown that the cup
reached. At this point, the cup height ratio
height ratio is extremely sensitive to the friction
becomes constant with increasing stroke for all
factor [Altan, et al. 1992], [Forcellese, A. et al.
friction factor values. Therefore, the best punch
1994]. It has also been shown that no significant
stroke to be used in the experiment should be
influence of the initial sample geometry on
beyond 20 mm.
friction exists [Barcellona, A. et al. 1996].
Evaluation of Candidate Lubri- Preparation of Specimens
cants by Double Cup Backward
Extrusion Test Using Tool Steel The experimental tests were conducted with two
Punches different materials. One was supplied by Metal-
dyne, and the other was supplied by Piper
Introduction Impact. The Metaldyne material was an AISI
1038 grade carbon steel, whose composition is
The double cup backward extrusion test is a shown in Table 7. The Piper Impact material
method used to evaluate and compare lubri was AISI 8610 grade alloy steel, whose composi-
cants. It is used extensively in cold forging. tion is shown in Table 8.

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Cup Height Ratio

H1
Rch = . (Equation 4.1)
H2
H1
H Real Stroke
S r = 31.75 − ( H − H 1 − H 2 )
H2
(Equation 4.2)

Figure 9. Definition of the Cup Height Ratio and Real Stroke

Friction factor (m)

5.0 0

4.5 0.02
0.03
4.0
Cup height ratio [H 1/H2]

0.04
3.5
0.05
3.0 0.055
2.5 0.06

2.0 0.065
0.07
1.5
0.08
1.0
0.09
0.5 0.1
0.0 0.15
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
Stroke [mm]

Figure 10. Friction Factor Calibration Curves (AISI 1038)

Friction factor (m)

5 0

4.5 0.02
0.03
4
Cup height ratio [H1/H2]

0.04
3.5
0.05
3 0.055
2.5 0.06

2 0.065
0.07
1.5
0.08
1
0.09
0.5 0.1

0 0.15
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
Stroke [mm]

Figure 11. Friction Factor Calibration Curves (AISI 8610)

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Table 7. Chemical Composition of AISI 1038 Table 9. Lubricants Used for the Tests
C (%) Mn (%) P (%) S (%) Lub Lubricant Name Material Applied
AISI 0.04 No. To
0.32 – 0.38 0.70 – 1.00 0.05
1038 Max. Lub 1 Acheson AISI 1038
Lub 2 MEC HOMAT AISI 8610
Table 8. Chemical Composition of AISI 8610 Lub 3 Daido AquaLub AISI 8610
Lub 4 MCI Z-Coat AISI 8610
C Ni Cr Mo Mn Si (%) Lub 5 Phoscoating – Metaldyne AISI 1038
(%) (%) (%) (%) (%) Lub 6 Phoscoating – Piper Impact AISI 8610
AISI 0.7 – 0.15 –
0.1 0.55 0.5 0.25
8610 0.9 0.3
remaining lubricants were applied by the lubri-
cant manufacturers. The following procedure
Specimens for a given material were obtained was followed for the application of the MEC
from the same rod. The rods were 31.75 mm in HOMAT lubricant:
diameter and the specimens were cut to a length
of 31.75 mm. • Agitated the lubricant until it was
homogeneous and without trapped air
Application of Lubricants and Surface bubbles
Characterization
• Heat the lubricant to 40°C
Four lubricants were applied on the billets made
• Cleaned the billets with a standard
from AISI 8610, while only two lubricants were
degreasing agent
applied on the billets made from AISI 1038.
Table 9 summarizes this strategy. • Applied the lubricant to the billet with a
brush
The MEC HOMAT and Daido lubricants were
• Allowed the lubricant to dry on the billet.
applied by staff at the ERC/NSM while the

Load cell

Upper punch

Billet
Lower punch

Container (die)

Figure 12. Double Cup Backward Extrusion Test Tooling

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The same procedure was followed for the appli- dures were repeated every day a new test was
cation of the Daido lubricant except that it was conducted.
applied at room temperature instead of 40°C.
Determination of Appropriate Punch
The following optical micrographs (Figure 13) Stroke
compare the surfaces of the billets coated with
the different lubricants before the tests. The The variation of the cup height ratio with in-
widths of the micrographs are all equal. The creasing stroke limited the minimum stroke to
micrographs show that for the most part, the 20 mm. In addition, the billet height of 31.75
lubricants coated the billets evenly. The mm limited the maximum stroke to a approxi-
specimens were also visually inspected. It was mately 28 mm. Because the performance of each
observed that the Acheson lubricant was not lubricant varied for stroke lengths between 20
evenly applied. and 28 mm, the best stroke length for comparison
of the lubricants was evaluated. For this evalua-
Experimental Setup tion, trial experiments were conducted for the
strokes of approximately 27, 25, 23, and 21 mm.
Figure 12 shows the double cup backward
extrusion tooling developed by the ERC/NSM The results of this investigation showed that at
and Figure 14 shows a 3D cross-sectional view higher strokes (i.e., 27 mm) the billet coated
of the tooling. The photograph shows the upper with MEC HOMAT fractured (Figure 15). This
punch and the lower punch in their upper fracture was due to the fact that as the material
positions. Both the upper and lower punches flows upwards to form the upper cup and
were made from M2 tool steel material. downwards to form the lower cup, a region of
velocity discontinuity can be formed. This
For the tests, a 200T load cell was used for load phenomenon can occur if a certain maximum
measurement and a laser sensor was used for punch stroke is reached and this limiting stroke
stroke measurement. Data was obtained from is a function of how good the lubricant is. Finite
these instruments with a data acquisition system element simulation was used to confirm this
utilizing a sample rate of 250 scans/second. phenomenon (Figure 16). The FE simulations
show that the damage value on the surface of
In order to convert the output voltage of the load the billet with the lower friction factor value is
cell and the laser sensor to force and press stroke higher than the damage value on the surface of
respectively, calibration was performed. Stroke the billet with the higher friction factor value.
calibration was performed by moving the press When the friction is low, the material flows
to different heights and noting the output from almost equally in the forward extrusion and
the laser sensor. Then, a graph of voltage vs. backward extrusion directions, thus leading to
stroke was made in order to produce a calibra- high surface expansion and rupture at the
tion curve for the laser sensor. The stroke heights surface. However, by reducing the stroke, this
recorded were in the range where actual extru- effect can be prevented. A similar trend was
sion takes place. Load cell calibration was observed with a stroke of 25 mm; however, no
performed by balancing the strain gauge bridge cracks were observed with a stroke of 21 mm.
configuration in the load cell and then connecting Because cracks will lead to errors in the
a shunt resistor simulating the load capacity of determination of the shear friction factor of the
sensor. The recorded voltage was correlated to lubricant a stroke of 21 mm was chosen for the
the load capacity and a calibration factor was experiments.
obtained [Wenning, et al. 2002]. These proce-

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 National Center for Manufacturing Sciences

20µm
20µm

AISI 8610 billet lubricated with Piper Impact Phoscoating AISI 8610 billet lubricated with MCI Z-Coat

20µm 20µm

AISI 8610 billet lubricated with MEC HOMAT AISI 8610 billet lubricated with Daido AquaLub

20µm 20µm

AISI 1038 billet lubricated with Metaldyne Phoscoating AISI 1038 billet lubricated with Acheson lubricant

Figure 13. Optical Micrographs of Lubricated Billet Surfaces Before Tests

Tests were cleaned and checked for galling or scratch-

ing in order to insure the same conditions existed
The tests were conducted using a 160-ton hy- for every test. After the cup temperature reached
draulic press with a ram speed of 10 mm/second room temperature, the cup height ratio and real
and a 21 mm punch stroke. The experimental stroke were calculated easuring the upper and
matrix is shown in Table 10. The punch load was lower cup heights, as well as the total extruded
measured using a load cell; the stroke was mea- part height with a caliper (Figure 9). Finally, the
sured using a laser sensor. Directly following cup height ratio and the stroke obtained from
each test, a thermocouple was used to measure the experiment were matched with the cup
the temperature inside the upper cup of the height ratio and the stroke obtained from FE
extruded billet. Also the die and the punches simulation to determine the friction factor m.

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 National Center for Manufacturing Sciences

Cracks on
the
Surface

Container
Formed
Liner
Billet
Die Insert

Lower Punch Guide Plate

Adjusting plate
Bottom
Bolster

Figure 14. Double Cup Backward Extrusion Tooling: Figure 15. Surface Cracks in Billets
3D Cross-Section View Coated with MEC HOMAT
at 27 mm Stroke

Table 10. Experimental Matrix for the Double Cup Backward Extrusion Test
Lub No. Lubricant Name Material Applied No. of Specimens
To
Lub 1 Acheson AISI 1038 20
Lub 2 MEC HOMAT AISI 8610 20
Lub 3 Daido AquaLub AISI 8610 20
Lub 4 MCI Z-Coat AISI 8610 20
Lub 5 Phoscoating – Metaldyne AISI 1038 20
Lub 6 Phoscoating – Piper Impact AISI 8610 20

a) friction factor m=0.02 b) friction factor m=0.1

Figure 16. Damage Value Distribution in Double Cup Extrusion for Low and High Friction

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 National Center for Manufacturing Sciences

In addition, optical micrographs of the specimens forged billets were cut into two halves. Figures
were taken after the tests in order to further 17a and 17b show the photographs of selected
evaluate the performance of the lubricants. To extruded parts.
obtain micrographs from within the cups, the

Extruded Part
Lub Original Billet Extruded Part
(Cross Section)

Phoscoating
Piper

MEC
HOMAT

Daido
AquaLub

MCI Z-Coat N/A

Figure 17a. Photographs of Selected Extruded Parts (AISI 8610)

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 National Center for Manufacturing Sciences

Extruded Part
Lub Original Billet Extruded Part
(Cross Section)

Phoscoating
Metaldyne

Acheson

Figure 17b. Photographs of Selected Extruded Parts (AISI 1038)

Results and Discussion the data range, whereas the value of the friction
factor is read from the upper position of each
Performance Comparison of the Tested data range. It should be noted that these values
Lubricants are an average from the 20 samples. The aim of
a successful double cup extrusion operation is to
All of the load versus stroke curves show the reach processes with a minimum cup height
same trend. There is a rapid increase in load up ratio at a minimum friction factor. Therefore, in
to 50 U.S. tons at a 12 mm stroke and then the this diagram, the lubricant with the best
load slowly decreases with increasing stroke up performance is located closest to the origin.
to 21 mm. Therefore, the load cannot be used to
evaluate the performance of the lubricants. In Figure 18, the lubricant performance diagram
Also, because the temperature induced in the for the four lubricants used with the Piper
billet did not show a clear, measurable depen- Impact material (AISI 8610) is illustrated.
dence on the lubricant used, it cannot be used to Within this chart, it can be identified very easily
evaluate the performance of the lubricants either. that the best results were obtained with MEC
HOMAT, followed by Daido AquaLub.
To establish a ranking of the lubricants, lubri-
cant performance diagrams were made. With The aim of these tests was to find lubricants that
these diagrams, the cup height ratios, Rch, are were able to replace the conventional phoscoat-
plotted on the ordinate and the friction factor is ing. Both lubricants, MEC HOMAT and Daido
plotted on the abscissa. The value of the cup AquaLub, obtained better cup height ratios and
height ratio is read from the lower position of friction factors than phoscoating. MEC HOMAT

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reduced the cup height ratio, Rch, in comparison scratches are also observed. Contrary to these
to the phoscoating about 30%, from 2.25 to 1.6, lubricants, MCI Z-Coat leads to deep scratches
and the friction factor about 45%, from 0.065 to in the upper cup. In the lower cup, where the
0.035. Daido AquaLub decreased the cup height surface enlargement is smaller, MEC HOMAT,
ratio about 25%, and the friction factor about Daido AquaLub, and phoscoating perform very
40%. MCI Z-Coat did not perform better than well. There are few scratches observed. MCI Z-
phoscoating. For further clarification, these Coat again leads to deeper scratches. Thus, the
results are shown in Figure 19 in bar graph lubricants with the lowest friction factors also
format. attained the best surface qualities. With the AISI
1038 extruded billets, the Acheson lubricant
Figure 20 shows the lubricant performance shows no areas of lubricant remaining. The
diagram and Figure 21 shows a bar graph for the Acheson lubricant also shows more scratches in
lubricants used with the AISI 1038 material. the upper cup than phoscoating (Figure 27).
Phoscoating performed better than Acheson
lubricant. The average cup height ratio from Evaluation of Candidate
experiments conducted with the Acheson Lubricants by Double Cup
lubricant is 10% higher than the experiments Backward Extrusion Test Using
conducted with phoscoating. Also, the friction
factor increases 25%, from 0.050 to 0.065.
Carbide Punches
As shown in Figures 22 and 23, a large range of Introduction
cup height ratios was observed with the
In order to further evaluate the candidate lubri-
Acheson lubricant as compared to MEC
cants, a series of double cup backward extrusion
HOMAT. This indicates a large variation in the
tests were conducted at the Kinefac Corporation.
parameters affecting friction for the Acheson
The geometry of the forming tooling was identi-
lubricant tests. Visual observation of the billets
cal to that used by the ERC/NSM; however, the
coated with the Acheson lubricant revealed that
punches were made from carbide as opposed to
the lubricant was not evenly applied on the
M2 tool steel. In addition, the Kinefac Corpora-
surface. This may have been the cause of the
tion was able to incorporate two punch coatings,
large cup height ratio variation observed in
namely TiN and TiAlN + WCC, into their tests.
Figure 22.
Preparation of Specimens
Figures 24 – 29 show the optical micrographs
taken after the tests in order to compare the The experimental tests were completed with
surfaces of the billets when extruded with each billets of one material, namely AISI 1038. This
lubricant. These micrographs were taken by an material was spherodized annealed. The
optical microscope in the upper cup, lower cup, dimensions of the billets were 31.75 mm +/-
and on the outside surface on the positions .254 mm diameter and 31.75 mm +/- .254 mm
shown. With the AISI 8610 extruded billets, length. The ends were sawed and the billets
MEC HOMAT and phoscoating show remains were tumbled to remove burrs and sharp edges.
of lubricant in the upper cup; however, small

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2.6
0.075 (m)
2.4
0.065
2.37 (Rch)
2.2
2.25 (Rch)

Cup height ratio [Rch]

2.0

0.04 (m)
1.8
Piper Impact
0.035 (m) Phoscoating
1.6 1.73 (Rch) MEC Homat
1.60 (Rch)
1.4 MCI

1.2 Daido

1.0
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1
Friction factor [m]

Figure 18. Lubricant Performance as a Function of Cup Height

Ratio and Friction Factor (AISI 8610)

0.08 2.5
Cup height ratio [Rch]
Friction factor [m]

0.07
0.06 2.0
0.05
1.5
0.04
0.03 1.0
0.02
0.01 0.5
0
Phoscoating MEC MCI Daido 0.0
Phoscoating MEC MCI Daido
Figure 19. Bar Graph for Lubricants Used with AISI 8610
2.6

2.4

2.2 0.065 (m)

Cup height ratio [R ch]

2.0 0.050 (m) 2.07 (Rch)

1.8 1.88 (Rch)

1.6 Metaldyne
Phoscoating
1.4
Acheson
1.2

1.0
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1
Friction factor [m]

Figure 20. Lubricant Performance as a Function of Cup Height

Ratio and Friction Factor (AISI 1038)

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 National Center for Manufacturing Sciences

0.08 2.5

Cup height ratio [Rch]

0.07
Friction factor [m] 0.06 2.0
0.05 1.5
0.04
0.03 1.0
0.02
0.5
0.01
0 Phoscoating Acheson 0.0 Phoscoating Acheson
Figure 21. Bar Graph for Lubricants Used with AISI 1038
2.6
Range for
Acheson
2.4

2.2
Cup height ratio [Rch]

2.0 Acheson

1.8

Metaldyne
1.6 Phoscoating

1.4

Range for
1.2 Phoscoating

1.0
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1
Friction factor [m]

Figure 22. Performance Comparison Between Acheson and

Phoscoating Lubricants
2.6

2.4

2.2
MEC HOMAT
Cup height ratio [Rch]

2.0

1.8 Piper Impact

Range for Phoscoating
Phoscoating

1.6

1.4
Range for MEC
1.2 HOMAT

1.0
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1
Friction factor [m]

Figure 23. Performance Comparison Between MEC HOMAT and

Phoscoating Lubricants

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 National Center for Manufacturing Sciences

Upper
Cup

20µm 20µm

Phoscoating – Piper Impact Daido AquaLub

20µm
20µm

MEC HOMAT MCI Z-Coat

Figure 24. Optical Micrographs After Tests in the Upper Cups (AISI 8610)

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 National Center for Manufacturing Sciences

Lower
Cup

20µm 20µm

Phoscoating – Piper Impact Daido AquaLub

20µm 20µm

MEC HOMAT MCI Z-Coat

Figure 25. Optical Micrographs After Tests in the Lower Cups (AISI 8610)

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Outside
of Cup

20µm 20µm

Phoscoating – Piper Impact Daido AquaLub

20µm 20µm

MEC HOMAT MCI Z-Coat

Figure 26. Optical Micrographs After Tests at the Outside Surface (AISI 8610)

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 National Center for Manufacturing Sciences

Upper
Cup

20µm 20µm

Phoscoating - Metaldyne Acheson

Figure 27. Optical Micrographs After Tests in the Upper Cups (AISI 1038)

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 National Center for Manufacturing Sciences

Lower
Cup

20µm 20µm

Phoscoating - Metaldyne Acheson

Figure 28. Optical Micrographs After Tests in the Lower Cups (AISI 1038)

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 National Center for Manufacturing Sciences

Outside
of Cup

20µm 20µm

Phoscoating - Metaldyne Acheson

Figure 29. Optical Micrographs After Tests at the Outside Surface (AISI 1038)

Application of Lubricants the container. To resolve the problem, all

Acheson coated billets were chamfered on
Two different types of lubricants were applied both ends using .015 x 45-degree chamfers.
to the billets before testing: Still, some of the blanks with thicker coating
1. Phosphate coated and soaped provided by on the ends did not fit in the tooling so they
Mascotech – Color: Metallic grey. These had to be hand selected and checked prior to
blanks had uniform coating over the entire forming.
surface. The weight of phosphate and soap
It should be noted that the ERC/NSM also tested
are unknown.
and compared the Acheson lubricant to a phos-
2. Acheson-France coated using proprietary coating.
Acheson coating – Color: Silver black. These
blanks appeared to be sprayed or dipped in Experimental Setup
the coating media. The coating was not
uniform. A majority of the billets had thick An RP-48 converted radial press with extrusion
coat rims around the ends and they did not fit capability was used for the tests. Figure 30

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 National Center for Manufacturing Sciences

shows this equipment. Figure 31 shows the

double cup backward extrusion tooling. Table
11 summarizes the materials used in the con-
struction of this tooling. Two punch coatings
were used in the tests:
• Two punches supplied by Kinefac were
titanium nitrate (TiN) coated by Balzers
• Two punches supplied by Delphi were
coated by a multi-coat process called hard
lube (TiAlN + WCC).

Instrumentation was supplied by Sensing Sys-

tems Company. It was custom designed to fit the
RP-48 envelope. Two load cells were included:
one mounted under the bottom punch and con-
tainer and the second above the top punch
(Figure 31). Data was collected using a
notebook computer, a 16-bit PCMCIA data
acquisition interface, a signal conditioning unit
and Winview software. 4” Stroke

Tests
The double cup backward extrusion tests were
completed at Kinefac Corporation using the RP-
48 converted radial press. Tests were conducted
at four different stroke lengths. Table 12 shows
the experimental matrix used by Kinefac
Corporation.

Results and Discussion 26”Bore/ 8”Rod

x 4” Stroke
In evaluating the cup height ratios, Rch = H1/H2, Hydraulic
the average of 25 samples was taken.. Cylinder

Performance of Phoscoating with TiN Punch Figure 30. RP-48 Converted Radial Press with Extrusion
Coatings Capability

The average cup height ratios, H1/H2, for the measured to be 2.48, 2.32, and 2.21. In addition,
phoscoating tests with TiN punch coatings were the average real strokes were 12.09, 15.35, and
18.54 mm. By plotting these values on the
Table 11. Double Cup Backward Extrusion Tooling friction factor calibration curve, the average
Materials friction factors for this lubricant at the three
Punch Container Die Housing different stroke lengths were estimated to be
Impact Grade Micro-Grain m=0.060, m=0.060, and m=0.065 respectively
H-13,
Material GC-G50 GC-015 (Figures 32 – 34). In addition, the ranges were
46 – 48 HRC
(C-13) Carbide Carbide m=0.055 to m=0.065, m=0.050 to m=0.065, and
m=0.050 to 0.070 respectively.

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coatings was measured to be 2.12. In addition,

Top Load Cell
Channel 01
the average real stroke was 20.81 mm. By plot-
Top Punch ting these values on the friction factor calibra-
tion curve, the average friction factor for this
lubricant was estimated to be m=0.065 while the
Die Housing
Blank Prior to range was m=0.055 to 0.070 (Figure 38).
Forming
Container (Die)
Performance of Acheson Lubricant with TiAlN +
WCC Punch Coating
Bottom Load Cell Bottom Punch
Channel 00
The average cup height ratio, H1/H2, for the
Figure 31. Double Cup Backward Extrusion Tooling Acheson lubricant tests with TiAlN + WCC
punch coating was measured to be 2.34. In
Performance of Acheson Lubricant with TiN addition, the average real stroke was 21.19 mm.
Punch Coatings By plotting these values on the friction factor
calibration curve, the average friction factor for
The average cup height ratios, H1/H2, for the
this lubricant was estimated to be m=.075 while
Acheson lubricant tests with TiN punch coatings
the range was 0.055 to 0.085 (Figure 39).
were measured to be 2.75, 2.77, and 2.49. In
addition, the average real strokes were 11.95 Performance Comparison of Lubricants and
mm, 15.14, and 19.43 mm. By plotting these Punch Coatings
values on the friction factor calibration curve,
the average friction factors for this lubricant at Nearly the same forming load was experienced
the three different stroke lengths were estimated for all tests. Therefore, the load cannot be used
to be m=0.070, m=0.080, and m=0.075 respec- to evaluate the performance of the lubricants.
tively (Figures 35 – 37). In addition, the ranges
were m=0.065 to m=0.075, m=0.075 to To establish a ranking of the lubricants, lubri-
m=0.085, and m=0.050 to m=0.085 respectively. cant performance diagrams were made. With
these diagrams, the cup height ratios, Rch, are
Performance of Phoscoating with TiAlN + WCC plotted on the ordinate and the friction factor is
Punch Coatings plotted on the abscissa. The value of the cup
height ratio is read from the lower position of
The average cup height ratio, H1/H2, for the the data range, whereas the value of the friction
phoscoating tests with TiAlN + WCC punch factor is read from the upper position of each
Table 12. Experimental Matrix Used by Kinefac
data range. It should be noted that these values
Corporation are an average from the 25 samples. The aim of
a successful double cup extrusion operation is to
Billet Punch No. of
Stroke Lubricant reach processes with a minimum cup height
Material Coating Specimens
12 mm Phoscoating AISI 1038 TiN 25 ratio at a minimum friction factor. Therefore, in
12 mm Acheson AISI 1038 TiN 25 this diagram, the lubricant with the best
15 mm Phoscoating AISI 1038 TiN 25 performance is located closest to the origin.
15 mm Acheson AISI 1038 TiN 25
19 mm Phoscoating AISI 1038 TiN 25 In Figures 40 – 42, the lubricant performance
19 mm Acheson AISI 1038 TiN 25 diagrams for stroke lengths of 12, 15, and 19
TiAlN + mm respectively are shown. It should be noted
21 mm Phoscoating AISI 1038 25
WCC that these tests were conducted with TiN coated
TiAlN +
21 mm Acheson AISI 1038 25 punches. In Figure 43 the lubricant performance
WCC
diagram for a stroke length of 21 mm is shown.

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It should be noted that these tests were conduc- ducted with phoscoating. Also, the friction
ted with TiAlN + WCC coated punches. The factor increases by an average of 20%. Recall
figures show that the phoscoating performs that the ERC/NSM obtained the same result for
better than the Acheson lubricant at all stroke a stroke length of 21 mm. It should also be noted
lengths. The average cup height ratio from that no significant change is noted between the
experiments conducted with the Acheson lubri- TiN coated punches and the TiAlN + WCC
cant is 15% higher than the experiments con- coated punches (Figures 42 and 43).

Friction factor (m)

5.0
0
4.5 0.02

4.0 0.03
Cup height ratio [H1/H2]

H1/H2 from 0.04

3.5 Experiment
0.05
3.0
0.055
2.5 0.06

2.0 0.065
0.07
1.5
0.08
1.0 0.09

0.5 0.1
0.15
0.0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
Stroke [mm]

Figure 32. Phoscoating: Determination of Friction Factor Value m

(Stroke = 12 mm)

Friction factor (m)

5.0
0
4.5 0.02

4.0 0.03
Cup height ratio [H1/H2]

0.04
3.5 H1/H2 from
Experiment 0.05
3.0
0.055
2.5 0.06

2.0 0.065
0.07
1.5
0.08
1.0 0.09

0.5 0.1
0.15
0.0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
Stroke [mm]

Figure 33. Phoscoating: Determination of Friction Factor Value m

(Stroke = 15 mm)

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Friction factor (m)

5.0
0
4.5 0.02

4.0 0.03

Cup height ratio [H1/H2]

0.04
3.5 H1/H2 from
Experiment 0.05
3.0
0.055
2.5 0.06

2.0 0.065
0.07
1.5
0.08
1.0 0.09

0.5 0.1
0.15
0.0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
Stroke [mm]

Figure 34. Phoscoating: Determination of Friction Factor Value m

(Stroke = 19 mm)

Friction factor (m)

5.0
0
4.5 0.02

4.0 H1/H2 from 0.03

Cup height ratio [H1/H2]

Experiment 0.04
3.5
0.05
3.0
0.055
2.5 0.06

2.0 0.065
0.07
1.5
0.08
1.0 0.09

0.5 0.1
0.15
0.0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
Stroke [mm]

Figure 35. Acheson Lubricant: Determination of Friction Factor

Value m (Stroke = 12 mm)

Friction factor (m)

5.0
0
4.5 0.02

4.0 H1/H2 from 0.03

Cup height ratio [H1/H2]

Experiment 0.04
3.5
0.05
3.0
0.055
2.5 0.06

2.0 0.065
0.07
1.5
0.08
1.0 0.09

0.5 0.1
0.15
0.0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
Stroke [mm]

Figure 36. Acheson Lubricant: Determination of Friction Factor

Value m (Stroke = 15 mm)

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Friction factor (m)

5.0
0
4.5 0.02

4.0 0.03

Cup height ratio [H1/H2]

H1/H2 from 0.04
3.5 Experiment
0.05
3.0
0.055
2.5 0.06

2.0 0.065
0.07
1.5
0.08
1.0 0.09

0.5 0.1
0.15
0.0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
Stroke [mm]

Figure 37. Acheson Lubricant: Determination of Friction Factor

Value m (Stroke = 19 mm)
Friction factor (m)
5.0
0
4.5 0.02

4.0 0.03
Cup height ratio [H1/H2]

0.04
3.5
H1/H2 from 0.05
3.0 Experiment
0.055
2.5 0.06

2.0 0.065
0.07
1.5
0.08
1.0 0.09

0.5 0.1
0.15
0.0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
Stroke [mm]

Figure 38. Phoscoating: Determination of Friction Factor Value m

(Stroke = 21 mm)

Friction factor (m)

5.0
0
4.5 0.02

4.0 0.03
Cup height ratio [H1/H2]

H1/H2 from 0.04

3.5
Experiment 0.05
3.0
0.055
2.5 0.06

2.0 0.065
0.07
1.5
0.08
1.0 0.09
0.5 0.1
0.15
0.0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
Stroke [mm]

Figure 39. Acheson Lubricant: Determination of Friction Factor

Value m (Stroke = 21 mm)

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3 .0
0 .07 0 (m )
2 .8
2 .75 (R c h )
2 .6 0.0 60 (m )

Cup height ratio [R ch]

2 .4 2 .48 (R ch )
2 .2
2 .0
1 .8 P h o s c o a tin g
1 .6
1 .4
Ac h e s o n
1 .2
1 .0
0 0 .0 1 0 .0 2 0 .0 3 0 .0 4 0 .0 5 0 .0 6 0 .0 7 0 .0 8 0 .0 9 0 .1
F rictio n facto r [m ]
Figure 40. Lubricant Performance as a Function of Cup Height Ratio
and Friction Factor (12 mm Stroke and TiN Coated Punches)

3 .0
0 .08 0 (m )
2 .8
2 .77 (R c h )
2 .6
Cup height ratio [Rch]

0 .0 6 0 (m )
2 .4
2 .2 2 .3 1 (R c h )
2 .0
1 .8 P h o s c o a tin g
1 .6
1 .4
Ac h e s o n
1 .2
1 .0
0 0 .0 1 0 .0 2 0 .0 3 0 .0 4 0 .0 5 0 .0 6 0 .0 7 0 .0 8 0 .0 9 0 .1
F rictio n facto r [m ]

Figure 41. Lubricant Performance as a Function of Cup Height Ratio

and Friction Factor (15 mm Stroke and TiN Coated Punches)

3 .0
2 .8
0 .0 7 5 (m )
2 .6
Cup height ratio [Rch]

2 .4 2 .4 8 (R c h )
0 .0 6 5 (m )
2 .2
2 .2 0 (R c h )
2 .0
1 .8
P h o s c o a tin g
1 .6
1 .4
Acheson
1 .2
1 .0
0 0 .0 1 0 .0 2 0 .0 3 0 .0 4 0 .0 5 0 .0 6 0 .0 7 0 .0 8 0 .0 9 0 .1
F rictio n fa cto r [m ]

Figure 42. Lubricant Performance as a Function of Cup Height Ratio

and Friction Factor (19 mm Stroke and TiN Coated Punches)

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 National Center for Manufacturing Sciences

3 .0
2 .8
2 .6

Cup height ratio [Rch]

0 .0 75 (m )
2 .4
0 .06 5 (m )
2 .2 2.3 3 (R c h )

2 .0 2 .12 (R c h )

1 .8 P h o s c o a tin g
1 .6
1 .4
Ac h e s o n
1 .2
1 .0
0 0 .0 1 0 .0 2 0 .0 3 0 .0 4 0 .0 5 0 .0 6 0 .0 7 0 .0 8 0 .0 9 0 .1
F rictio n facto r [m ]

Figure 43. Lubricant Performance as a Function of Cup Height Ratio

and Friction Factor (21 mm Stroke and TiAlN + WCC
Coated Punches)

Figure 44 shows the friction factor for the vari- 0.09

ous stroke lengths and lubricants in bar graph 0.08
form. The figure shows that the average friction Friction factor [m] 0.07
factor increases as the stroke increases from 12 0.06
to 15 mm for the Acheson lubricant while the 0.05

friction factor remains nearly constant with in- 0.04

creasing stroke for phoscoating. It should also 0.03

Phoscoating Acheson
be noted that the friction factor range increases 0.02

dramatically for stroke lengths of 19 and 21 mm 0.01

for the Acheson lubricant. Finally, it should be 0

12 15 19 21 12 15 19 21
noted that no significant change is noted between Stroke (mm)
the TiN coated punches used at a stroke of Figure 44. Friction Factor for Various Stroke Lengths
19 mm and the TiAlN + WCC coated punches and Lubricants
used at a stroke length of 21 mm.
• Phoscoating performed better than the
As shown in Figure 45, a large range of cup Acheson lubricant. The average friction
height ratios was observed with the Acheson factor for phoscoating was m=0.065 for all
lubricant as compared to phoscoating. This test conditions and the average friction
indicates a large variation in the parameters factor for the Acheson lubricant was
affecting friction for the Acheson lubricant tests. m=0.075 for all test conditions.
Like the ERC/NSM, the Kinefac Corporation
• The trials were not showing any
noted the Acheson lubricant was not evenly
coated on the billets. This may have been the significant change in the forming forces
cause of the large cup height ratio variation regardless of type of billet or punch
observed in Figure 45. coating.
• A more detailed analysis of the numerical
Conclusions data may indicate small advantages of one
coating over another.
The following conclusions were made from the
tests conducted at the Kinefac Corporation:

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 National Center for Manufacturing Sciences

3.0 expansion during the test simulates the actual

Range for
2.8 Acheson forging process more closely than other such
2.6 tests.
Cup height ratio (H1/H2)

2.4
2.2
The following tasks were accomplished during
2.0
the course of this project:
1.8 Range for

• A test apparatus for evaluating lubricants by

Acheson
Phoscoating
1.6
1.4
Phoscoating
the double cup backward extrusion test was
1.2
built.
1.0
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1 • A survey of environmentally friendly cold
Friction factor (m)
forging lubricants was completed. Four
Figure 45. Performance Comparison for Acheson and
Phoscoating Lubricants (19 mm Stroke) companies, include MEC, Daido, Acheson
and MCI, were identified as companies
• A long term study based on larger produc- which manufactured potential lubricants for
tion runs is needed to determine the the replacement of zinc phosphate in cold
effectiveness of the Acheson coating and forging.
its effects on quality of formed parts and • The material properties (flow stress) of two
die/punch life. materials were determined by compression
• The coating application process used by tests.
Acheson should be improved to assure • The ideal stroke for the double cup backward
uniform and consistent coating thickness. extrusion test was determined in order to
The lack of consistency may lead to obtain cup heights that reduced the
problems during loading the die nests and probability of measurement error while
cause potential tooling damage. averting the formation of cracks in the outer
• The punches and the container did not billet surface.
show any signs of galling or pickup. • Double cup backward extrusion tests were
Summary and Concluding conducted using M2 tool steel punches with
each of the lubricants. The friction factor of
Remarks each lubricant was determined by using
calibration curves. These calibration curves
Presently, most cold forging processes require a were obtained using finite element
zinc phosphate based lubricant; however, there simulations.
are numerous problems with this lubrication
system. These problems include: hazardous The lubricants were not evaluated based on the
waste disposal, high equipment and energy ease of removal from the billet material. Also,
costs, and human health risks. Therefore, change in properties of the base material after
research worldwide is focused on developing the use of these lubricants has not been studied.
environmentally friendly cold forging A chemical analysis of the surface and the use
lubricants. of these lubricants in production runs will reveal
the performance of the lubricants with respect to
The double cup backward extrusion test is used these factors.
extensively for evaluating lubricants in cold
forging. It can be used to find the friction factor In order to further evaluate the Acheson lubri-
of lubricants and thereby serves as a good tool cant as compared to phoscoating, a series of
for ranking various lubricants. The high surface double cup backward extrusion tests were

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 National Center for Manufacturing Sciences

conducted at the Kinefac Corporation. The punches were made from carbide as opposed to
billets were cut from the same AISI 1038 stock M2 tool steel. In addition, the Kinefac Corpora-
as the billets used by the ERC/NSM. The geome- tion was able to incorporate two punch coatings,
try of the forming tooling was identical to that namely TiN and TiAlN + WCC, into their tests.
developed at the ERC/NSM; however, the

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 National Center for Manufacturing Sciences

References
[Altan, et al. 1992] Buschhausen, A., Lee, J. Y., Weinmann, K. and Altan, T., “Evaluation
of Lubrication and Friction in Cold Forging Using a Double Backward
Extrusion Process,” Journal of Materials Processing Technology,
1992, Vol. 33 (1-2), pp. 95-108.

[Barcellona, et al. 1996] Barcellona, A., Canizzaro, L., “Validation of Friction Studies by
Double Cup Extrusion Tests in Cold Forming,” Annals of the Cirp,
1996, Vol. 45 (1) pp. 211-214.

[Bay, 1994] Bay, N., “The State-of-the-Art in Cold Forging Lubrication,” Journal
of Materials Processing Technology, 1994, Vol. 46, pp. 19-40.

[Forcellese, et al. 1994] Forcellese, A., Gabrielli, F., Barcellona, A., Micari, F., “Evaluation of
Friction in Cold Metal Forming,” Journal of Materials Processing
Technology, 1994, Vol. 45, pp. 619-624.

[Schmoeckel, et al. 1997] Schmoeckel, D., Rupp, M., ”Umweltfreundlichere

Kaltmassivumformung – Fertigung von Draht ohne
Zinkphosphatschicht,” Vortragstexte des Symposiums “Neuere
Entwicklungen in der Massivumformung”, Fellbach bei Stuttgart,
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[Wenning, et al. 2002] Wenning, P., Gracious, N. and Altan, T., “Overview of National
Instruments SCXI Data Acquisition System: SCXI-1520 8-Channel
Strain Gauge Module & SCXI-1112 8-Channel Thermocouple
Module,” ERC Report in preparation.

Use and dissemination of the information contained in this 42

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