Synergies of EP/Anti Wear
Additives for Metal Working
Fluids
Dover Chemical Corporation
John Nussbaumer
Technical Service Manager-Metalworking
Dover Chemical Additives
 Dover Chemical manufactures a variety of
metalworking additives for oil based as well as
water based applications.
 These additives include Functional Additives,
Sulfur containing, Phosphorous containing and
Chlorinated Paraffins.
 Dover Chemical is the largest producer of
Chlorinated Paraffins in North America.
Synergies
 The interaction of different types of additive chemistry
promoting an enhanced effect in tool life, life of the
fluid and/or increased production.
 Interactions include those between Chlorinated
Paraffins, Sulfur compounds, Phosphorous
compounds and Functional Additive type products.
 All interactions do not promote favorable outcomes.
i.e. What works for one may not work for all and may
be application specific.
Why Consider Synergies?
 There are several reasons to consider
synergies:
 Increased through put
 Increased tool life
 Lower overall cost of additives
Testing Methodology
 Testing will include Microtap Tap and Torque, Falex Pin
and Vee Block, Vertical Drawbead and 4-Ball Wear.
 This round of testing will allow us to see how each
additive package will perform in a variety of
applications.
 In most cases we will see an increase in potential
efficiency. However, in a few cases, the interaction
between additives has a no impact on performance.
Additives Used as Standards
Additive
Chemistry
Mayco Base 1351
10.5% S
Mayco Base 1540
38% S
Paroil 54NR
54% Cl
Additives for Synergies
Additive
Doverlube FL 630
Functional Additive Chlorinated
TMP Oleate
----
Mayfree 133
Phosphate Amide,
4.5%P
----
DA 8506XS
Paroil 54NR
-------
Ester, 30% Cl
Olefin, 54% Cl
Doverlube NCEP
Nitrated Vegetable
Oil, 1%N
----
Formulations, Neat Oil
 Mayco Base 1351 and Paroil 54NR were
added to 100 SUS Naphthenic base oil at
10%. Mayco Base 1540 was diluted in 100
SUS Naphthenic base oil at 3%. All of the
above were used as standards.
Formulations, Neat Oil
 To enhance performance of each additive, a blend was
made using 90% of each standard and 10% of a
functional additive or chlorinated additive. This 90/10
blend was then added to 100 SUS Naphthenic base oil
at 10%. The exception would be when using Mayco
Base 1540, in which case the blend was diluted to 3%
in 100 SUS Naphthenic base oil. Ex. 90% P54NR is
blended with 10% Mayfree 133. This is then blended
in base oil at 10%.
Formulations, Neat Oil Standards
% in 100SUS Naphthenic Base Oil
Additive
10
Paroil 54NR
10
Mayco Base 1351
3
Mayco Base 1540
10
90% MB1351/10% Synergistic Additive
10
90% P54NR/10% Synergistic Additive
3
90% MB1540/10% Synergistic Additive
Evaluation Methods
 Microtap Tap and Torque
 Vertical Drawbead
 Falex Pin and Vee Block
 4-Ball Wear
 All testing was performed on steel
TESTING CAPABILITIES
Falex EP (Pin & Vee)
 Measures Torque Vs. Load
 Better fluids yield lower Torque
per unit load
Falex Pin and Vee Block Results-MB1540
 The blend of Mayco Base 1540 and Mayfree 133 reached a
higher load and produced lower torque per load values than
the sample containing only Mayco Base 1540.
Sample
Load Failure Weight, lbs
Torque at Failure, lb/in
MB 1540
1750
103
MB 1540/MF 133
2000
36
MB 1540/8506XS
1500
33
Falex Pin and Vee Block Results-MB1540
Falex Pin and Vee Block-MB 1540
120
100
Torque, lb/in
80
MB1540
60
MB1540/MF133
MB1540/DA8506
40
20
0
250
500
750 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250 3500 3750 4000 4250 4500
Load, lbs
Falex Pin and Vee Block Results-P54NR
 The samples containing Paroil 54NR alone, as well as the
sample containing Paroil 54NR and Doverlube NCEP passed this
evaluation by reaching a full load of 4500lbs.
Sample
Load Failure Weight, lbs
Torque at Max Load,
lb/in
Paroil 54NR
Passed
88
Paroil 54NR/NCEP
Passed
71
Paroil 54NR/MF 133
2500
41
Falex Pin and Vee Block Results-P54NR
Falex Pin and Vee Block Results-P54NR
100
90
80
Torque, lb/in
70
60
P54NR
50
P54NR/NCEP
40
P54NR/MF133
30
20
10
0
250
500
750 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250 3500 3750 4000 4250 4500
Load, lbs
Falex Pin and Vee Block-MB1351
 None of the samples passed this evaluation as
all failed to reach a full load of 4500lbs.
Sample
Load Failure Weight, lbs
Torque at Max Load,
lb/in
MB 1351
1750
58
MB 1351/FL 630
1500
37
MB 1351/P54NR
2750
91
Falex Pin and Vee Block Results-MB1351
Falex Pin and Vee Block-MB1351
100
90
80
Torque, lb/in
70
60
MB1351
50
MB1351/FL630
40
MB1351/P54NR
30
20
10
0
250
500
750 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250 3500 3750 4000 4250 4500
Load, lbs
TESTING CAPABILITIES
Vertical Drawbead
 Measures Force required for
drawing operation
 Compares required forces
between fluids
 There is a +/- 5% margin of
error associated with this test
 Better fluids require less
force thus a lower efficiency
Drawbead Results- MB 1540
 The samples containing Doverlube NCEP, May
Free 133, DA 8506XS and Paroil 54NR all
performed better than the Mayco Base 1540.
Sample
MB 1540
%
100
Efficiency
MB1540/ MB1540/ MB1540/ MB1540/ MB1540/
NCEP
MF133
FL 630
DA
P54NR
8506XS
110
111
103
106
125
Drawbead Results-MB 1540 Series
Drawbead
160
140
120
%Efficiency
100
80
60
40
20
0
MB1540
3% MB1540/NCEP
3% MB1540/MF133
3% MB1540/FL630
3% MB1540/8506XS
3% MB1540/P54NR
Drawbead Results-Paroil 54NR
 The samples containing Mayfree 133 and
Doverlube NCEP performed better than
the sample containing only the Paroil
54NR.
Sample
P54NR
% Efficiency 100
P54NR/
MF133
P54NR/
FL630
P54NR/DA
8506XS
P54NR/
NCEP
109
100
105
112
Drawbead Results - P54NR Series
Drawbead
114
112
110
108
% Efficiency
106
104
102
100
98
96
94
92
P54NR
P54NR/MF133
P54NR/FL 630
P54NR/8506XS
P54NR/NCEP
Drawbead Results-MB1351
 The samples containing Doverlube NCEP, DA
8506XS and Paroil 54NR performed better than
the sample containing only the Mayco Base
1351.
Sample
MB1351
MB1351/ MB1351/ MB1351/ MB1351/ MB1351/
NCEP
MF133
FL630
8506XS
P54NR
%
Efficiency
100
106
104
94
109
106
Drawbead Results-MB1351 Series
Drawbead
115
110
% Efficiency
105
100
95
90
85
MB1351
MB1351/NCEP
MB1351/MF133
MB1351/FL630
MB1351/8506XS
MB1351/P54NR
TESTING CAPABILITIES
Microtap Tap & Torque
 Drill Press
 Compares fluids by measuring
force required to thread a drilled
hole
 Better fluids use less force to
thread a hole
+/- 3% margin of error
Microtap Results-Mayco Base 1351
Sample
% Efficiency
MB 1351
100.0
MB 1351/NCEP
105.2
MB 1351/MF133
105.4
MB 1351/FL630
104.2
MB 1351/8506XS
103.5
MB 1351/P54NR
111.0
Microtap Results-MB1351
Microtap Tap and Torque
112
110
108
% Efficiency
106
104
102
100
98
96
94
MB1351
MB1351/NCEP
MB1351/MF133
MB1351/FL630
MB1351/DA8506XS
MB1351/P54NR
Microtap Results-Mayco Base 1540
Sample
% Efficiency
Mayco Base 1540
100
Mayco Base 1540/NCEP
102
Mayco Base 1540/Mayfree 133
104
Mayco Base 1540/FL 630
105
Mayco Base 1540/DA 8506XS
99
Mayco Base 1540/Paroil 54NR
104
Microtap Results-MB1540
Microtap Tap and Torque
106
105
104
%Efficiency
103
102
101
100
99
98
97
96
MB1540
MB1540/NCEP
MB1540/MF133
MB1540/FL630
MB1540/8506XS
MB1540/P54NR
Microtap Results-Paroil 54NR
Sample
% Efficiency
Paroil 54NR
100
Paroil 54NR/NCEP
97
Paroil 54NR/Mayfree 133
97
Microtap Results-P54NR
Microtap
100.5
100
99.5
% Efficiency
99
98.5
98
97.5
97
96.5
96
95.5
P54NR
P54NR/NCEP
P54NR/MF133
TESTING CAPABILITIES
4-Ball Wear Test
 4 Ball Wear Test determines a
lubricant’s antiwear properties
under boundary lubrication (metal
to metal contact).
 Three steel balls are clamped
together to form a cradle upon
which a fourth ball rotates on a
vertical axis. The balls are
immersed in the oil sample at a
specified speed, temperature and
load.
 Wear scar diameter is then
measured for the three lower balls
at the end of a specified test time.
4-Ball Wear Results-MB 1540
Sample
Wear Scar, mm
Mayco Base 1540
0.73
Mayco Base 1540/NCEP
0.73
Mayco Base 1540/Mayfree 133
0.44
Mayco Base 1540/FL 630
0.43
Mayco Base 1540/DA 8506XS
0.52
Mayco Base 1540/Paroil 54NR
0.53
4-Ball Wear Results-MB 1540
4-Ball Wear
0.8
0.7
Wear Scar, mm
0.6
0.5
0.4
0.3
0.2
0.1
0
MB1540
MB1540/NCEP
MB1540/MF133
MB1540/FL630
MB1540/DA8506
MB1540/P54NR
4-Ball Wear Results-MB 1351
Sample
Wear Scar, mm
Mayco Base 1351
0.50
Mayco Base 1351/NCEP
0.44
Mayco Base 1351/Mayfree 133
0.53
Mayco Base 1351/FL 630
0.55
Mayco Base 1351/DA 8506XS
0.52
Mayco Base 1351/Paroil 54NR
0.46
4-Ball Wear Results-MB 1351
4-Ball Wear
0.6
0.5
Wear Scar, mm
0.4
0.3
0.2
0.1
0
MB1351
MB1351/NCEP
MB1351/MF133
MB1351/FL630
MB1351/DA8506
MB1351/P54NR
4-Ball Wear Results-P54NR
Sample
Wear Scar, mm
Paroil 54NR
0.52
Paroil 54NR/NCEP
0.49
Paroil 54NR/Mayfree 133
0.55
Paroil 54NR/FL 630
0.51
4-Ball Wear Results-P54NR
4-Ball Wear
0.56
0.55
0.54
Wear Scar, mm
0.53
0.52
0.51
0.5
0.49
0.48
0.47
0.46
P54NR
P54NR/NCEP
P54NRMF133
P54NR/FL630
Summary
Falex Pin and Vee
Block
Drawbead
Microtap Tap and
Torque
4-Ball Wear
MB1540/MF133
MB1540/NCEP,
MF 133,P54NR
MB1540/MF133,
FL630,P54NR
MB1540/MF133,
FL630
P54NR/NCEP
P54NR/MF133,
NCEP
P54NR/
P54NR/NCEP,FL630
MB1351/P54NR
MB1351/NCEP,
8506XS,P54NR
MB1351/NCEP,
MF 133,P54NR
MB1351/NCEP,
P54NR
Summary
 The results shown here today are examples of how
additive synergies can benefit the end user.
 We have discussed the blending of multiple additive
chemistries to increase tool life, surface finish and
through put.
 While the use of synergies can help in these areas, it
can also be application specific.
Summary, Cont.
 In many cases the synergistic effect of different
additives can not be predicted. Laboratory
blending and performance testing should be
carried out to determine if the additives are
compatible and if there is a positive effect in
blending the different additive chemistries.
Technical Service
 Dover Chemical offers technical service support
to customers using Dover additives. All of the
testing discussed in this presentation was
carried out in our lab. If comparative testing is
needed please contact Dover’s Technical
Service Department or feel free to stop by our
booth during the remaining time here at STLE
for contact information.
Thank You!
Questions?