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

Metalworking fluids (MWFs) increase productivity and the quality of manufacturing operations by cooling and lubricating during metal forming and cutting processes. Despite their widespread use, they pose significant health and environmental hazards throughout their life cycle. An obvious environmental improvement to MWF technology would be to improve the lifetime of the fluid while utilizing more environmentally friendly and less energy-consuming materials without compromising existing performance levels. This investigation focuses on the design of mixed anionionc:nonionic emulsifier systems for petroleum and bio-based MWFs that improve fluid lifetime by providing emulsion stability under hard water conditions, a common cause of emulsion destabilization leading to MWF disposal. Experimental conditions were designed to evaluate the impact of emulsifier structural characteristics (straight chain, branched tail, branched head) and the molar ratios of anionic to nonionic surfactant and oil to total surfactant. Results from the 2500 formulations generated indicate that the use of a twin-headed anionic surfactant can provide improved hard water stability for both mineral oil- and vegetable oil-based formulations, even in the absence of a chelating agent and a coupler. Results also suggest that an oil:total surfactant molar ratio of 0.5 or less is necessary for particle size stability in hard water conditions for these systems. The newly developed petroleum and bio-based formulations with improved hard water stability are competitive with commercially available MWFs in performance evaluations for tramp oil rejection, contact angle, and tapping torque efficiency. These results can be used to design MWF formulations with fewer components and extended lifetime under hard water conditions, both of which would lead to a reduction in the life cycle environmental impact of MWFs.