The use of Superplastic Tin-Lead Alloy as A solid Lubricant in the Free Upsetting of Aluminum and Brass

Adnan I.O.Zaid1,a*, Hebah B. Melhem2,b Ahmad Qandil

Jordan

1). The main function of a lubricant in any forming process is to reduce friction between the work piece and the die set, hence reducing the force and energy requirement for forming process and to achieve homogenous deformation.

2). Different types of lubricants are used in forming processes: liquid. Semi-solid,(grease) and solid.In this paper, superplastic tin-lead alloy is used as solid lubricant in the free upsetting test of non-ferrous metals and compared with eight different lubricants using three different criteria.

3). One Criterion: is comparing the value of the reduction in height percentages, i.e. the engineering strain, in identical specimens of the same material under the effect of the same compressive force. The used lubricant which produces more engineering strain in identical specimens is more efficient.

Fig. 2: Force for Producing 40% Reduction in Height in Aluminum Specimens

Fig. 3: The Required Force for Producing 40% Reduction in Height in brass Speci

4). Second Criterion: is comparing the amount of specific energy, i.e. energy per unit volume consumed in forming identical specimens to produce the same reduction in height i.e engineering strain. The lubricant which gives less specific energy is more efficient.

Fig. 4: The Consumed Energy for Producing 40% Reduction in height in aluminum specimens.

Fig. 5: The Consumed Energy for Producing 40% Reduction in Height in Brass Specimens.

5). Third Criterion: is comparing the amount of barreling produced in each of the identical specimens, at each lubricant. The lubricant which produces less barreling in the identical specimens is more effective or efficient. 

The Original and Final Profiles of Sectioned Aluminum Specimens Using Different Lubricants where a, b, c, d, e, f, g, h, and i for 80W90, the Dry Condition, 20W50, MoS2, SAE 40, Olive Oil, Teflon, Superplastic Tin-lead Alloy, and Paraffin Wax Respectively. 

6). It was found that the superplastic tin-lead alloy lubricant has produced higher values of reductions in height percentage and less barreling in the two non-ferrous materials, used in this work namely: aluminum and brass. 7). It was found that the superplastic tin-lead alloy lubricant has produced higher values of reductions in height percentage and less barreling in the two non-ferrous materials , used in this work, under the same compression force among the different used lubricants. 

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