Steel product range

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Steel product range

• Your advantage in
• Coil production for the automotive industry

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Coil production for the automotive industry

• Castrol Advantage. Helping you to meet higher
  automotive expectations. Sharpening your
  competitive edge.
• Health, safety and environment
• Best-in-class products
• Global quality standards, local support
• Detail of dry film
• Steel casefiles

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Health, safety and the environment
HSE is the cornerstone of our business. We
conform to the highest standards of HSE because
we recognise that this directly benefits our
customers, their employees and the communities in
which they operate. Castrol is committed to
compliance with all applicable environmental laws
and regulatory standards, worldwide. Our
preventative maintenance service helps you to
significantly reduce maintenance costs whilst
minimising waste and usage of production fluids.
And our Iloform blank wash range is based on low
VOC components, with no unfriendly materials such
as barium, zinc or organic chlorine compounds.
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Best-in-class Steel mill applied products
Castrol Advantage means a dedicated range of
mill-applied lubricants, suitable for use on all
todays uncoated and coated steels. All our mill
lubricants can be applied using your existing
equipment, including electrostatic oilers. They
are compatible with process fluids while
satisfying the diverse needs of the global
automotive industry.

• IloformTM PN 950 DF is an advanced lubricant,
  specially designed to provide extreme drawing
  properties on automotive steel coated sheet and
  aluminium.
• IloformTM PL 40 is a modern, thixotropic pre-lube
  designed to meet exacting automotive
  specifications.
• RustilloTM S 40 is a thixotropic mill oil that is
  specially formulated to meet global automotive
  and steel specifications.

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New Generation The complete Range Castrol
Automotive/Steel Pressing Products

• Steel mill applied
• Iloform PN950DF Dry Film
• Rustilo S40 Mill oil
• Rustilo SL40 Pre-lube
• Press shop applied
• Rustilo SL8 Blankwash
• Rustilo SL17 Blankwash
• Rustilo SL40 Pre-lube
• Rustilo SL120 Spot Lube

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What Is a Pre- Lube?

• Pre-lube....Designed to produce a Pre lubricated
  and rust preventative coated Strip
• Based on Mineral oil based/Thixotropic
• Typically Automotive customers
• Applied at Continuous galv line and/or Finishing
  lines
• Combined Corrosion Presentative and Pressing oil

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Castrol BusinessRust Preventatives
Deformation Products

• Global supplier of Rust Prevenatives
• Supply all leading Automotive Mananufacturers
• Preferred Supplier to the Ford Group
• Our Brands Castrol, BP, Aral, Optimol and Tribol
• Steel RPs Tube/Wire/Narrow strip
• Aerospace/Bearings/Primary Metals/Transport
• Leading Supplier of Automotive Blankwash Press
  Fluids

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History of European Mill oils, pre-lubes,
blankwash fluids
DRY FILM LUBRICANTS BASED ON POLYMER
CORROSION PREVENTIVES
THIXOTROPIC CORROSION PREVENTIVES
1990
PRELUBES Blankwash
DRY FILM LUBRICANTS BASED ON WAX DISPERSION
1996
2000
2. GENERATION PRELUBES Blankwash
2. GENERATION THIXOTROPIC CORR.PREVENTIVES
DRY FILM LUBRICANTS BASED ON PARAFFIN
2001
SEMI DRY FILM LUBRICANTS
DRY FILM LUBRICANTS BASED ON ESTER
Automotive applied
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Castrol Product ReferencesAutomotive Blank Wash
Pressing Fluids

• Ford Dagenham, UK GM Elizabeth, SA
• Ford Sarlouis, Ger GM, Rayong, Thailand
• Ford Chennai, India Maruti Suziki, India
• Volvo Gothenburg Proton, KL, Malaysia
• Nissan UK Ingress Precision, KL
• GM Ellesmere UK Proton/Perodua/GM

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Castrol Rust prevevenative technolgy - Today

• Dry Film Pre-lube
• Mineral oil Based RPs/Mill oils
• Low Viscosity Blank/coil wash products
• Emulsions/PAOs
• Dewatering fluids
• Microemulsions

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Castrol Iloform PN 950 DF

• Castrol Iloform PN 950 DF is a unique
  mill-applied dry film that creates a new standard
  in pressing performance.
• Health Safety and the Enviroment
• Background to dry film
• Benefits Steel plant and press shop
• Research and development underpins the technology
• Press Shop compatibility
• Case study/field trials
• Steel plant Application
• How you your customer benefits From Dry film
• Extreme pressing performance

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Health, safety and the environment
HSE has been at the core of the Castrol offering
for many years. We conform to the highest
standards of HSE because we recognise that this
directly benefits our customers, their employees
and the communities in which they operate.
Castrol is committed to compliance with all
applicable environmental laws and regulatory
standards, worldwide. Iloform PN 950 DF is based
on renewable resources and requires only half the
coating weight of traditional mill applied
lubricants, yet it delivers significantly more
performance. Our goals no accidents, no harm to
people, no damage to the environment.
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Innovating to improve performance
Our steel and automotive customers required dry
film technology that could save millions of
dollars yet be applied on existing equipment.
Our solution was Iloform PN 950F dry film.
Designed, tested and delivered by Castrol, this
is the next-generation technology that will
deliver competitive advantage to automotive
manufacturers and add real value to your coiled
steel. Castrol Advantage is currently engaged on
a worldwide feasibility study with automotive and
steel partners.
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Castrol Dry Film Brief - Background

• Significant increase in pressing performance for
  Automotive customers
• Potential to remove/decrease blankwashing
  operations
• Process Benefits in press Shop
• Half the coating weight of standard pre-lubes
  to control cost
• Applied with existing steel plant spray equipment
  
• Total compatibility with existing Automotive
  processes
• One product for both steel and aluminum

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What Are the types of - Dry Films?
Ester Hot melt
Iloform PN950DF Ester Based technology
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Iloform PN 950 DF Dry Film Lubricant
Appearance Light beige, solid Appearance
(Coating 1gm-2) Light Waxy film Viscosity
at 20 C solid Viscosity at 50 C 34
mm²/s Flash point gt 200 C
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Dry Film TechnologyA Iloform PN 950 DF- Coated
coil
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Steel plant - Benefits of Illoform 950DF

• Significantly improved environment No loss/run
  off of Prelube
• Improved quality of shipped product Even coating
  weight across coil Consistent pressing
  performance
• Differentiated product in the market place
  offering significantly improved deformation
  performance
• Lower Ductility coils can be sold to reduce
  client costs and offset benefits of Aluminium.
• Higher strength steels can be pressed and reduce
  weight

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Press Shop - Benefits of Iloform PN950DF
HSSE/Housekeeping Benefits

• Allows cleaner working environment
• Dry-to-the-touch waxy film/Self healing
• Does not dewet
• No chlorinated, Zinc, Barium, solvents.
• No mineral oil
• No Toxic fumes/interference with welding
• Reduced consumption
• How did we come to these conclusions?

When compared to leading Pre-lubes
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Research TechnologyDevelopment Testing
New Generation Castrol Automotive/Steel
Pressing Products
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Typical Coefficients of Friction for Lubricants
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Castrol Dry Film Lubricant Iloform PN 950 DFR
K Tester Cup Drawing Test, Substrate ZE
highly chlorinated Spotlubricant
Dry Film Lubricant
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VDA Flat Die Test
FN
Benchmarking of Dry Film Lubricants determines
max clamp force FN , friction coefficient µ and
appearance of stick slip FN 4 24 N/mm² Drawing
speed 50 mm/s Contact surface 10000 mm² Stroke 98
mm
FZ

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Flat Die Test RigUniversity of Waterloo
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Flat Die Test RigUniversity of Waterloo
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Dry Film Lubricant on Bare SteelFlat Die Test
Station University of WaterlooPreliminary Test
Results Iloform PN 950 DF analog VDA 230-201
January 2003
Load limit set to 400 kN, shut-off during trial
Pre-lubes typically 0.08 to 0.10 COF
Maximum normal force was only limited by the
setting of the test equipment, after adjusting
this setting we will be capable to perform tests
up to 75 N/mm². During our preliminary testing no
stick-slip was observed.
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Sealer and Adhesive Compatibility
Adhesive used on coating with
Oil, compatible
Dry Film, Acrylate
Dry Film, Paraffin
Dry Film, Ester
after application
after curing
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Press Shop Compatibility
Dry Film Coated coils
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Adhesive CompatibilityTesting according to VDA
230-201
Adhesive Iloform DF
XW 1185 Epoxy (GEX) all substrates o.k.
Terostat 3216 Rubber (Henkel) all substrates o.k.
Terokal 8552 PVC (Henkel) all substrates o.k.
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Cataphoretic Dip Paint Compatibility according
to VDA 230-201 revisedIloform PN 950 DF
Type Crater
PPG Enviroprime 0
PPG Enviroprime 2000 0
Source PPG
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Removability Test according to VDA 230-201 and
Renault SpecificationIloform PN 950 DF
Substrate bare steel electrogalv. hot dip galv. galvanealed
Renault Spec./ Sollac-Test passed passed passed passed
Substrate bare steel electrogalv. hot dip galv. galvanealed
VDA-Test passed passed passed passed
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Iloform PN 950 DFField Trials/Case studies
Innovating to improve performance
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Case files

• Castrol Advantage brings together world-class
  products, extensive services and innovative
  support. As a leading supplier of
  high-performance metalworking fluids and
  lubricants to the automotive industry, we help
  increase quality and reduce costs for millions of
  vehicles each year.
• Metallwerk Hofmanninger, Austria
• Castrol Trials cat Saarlois
• Electrolux USA

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Case study - Benchmarking in action
Metallwerk Hofmanninger, Austria
Concrete mixer drum DC 03 hot dip galvanized
1mm One-Step draw
Iloform PN 950 DF was the only Dry Film Lubricant
tested successfully
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Case Study - Saarlouis trial June 2003

• Inner body side panel, Focus 3-door hatchback,
• Blank size 1525 x 3475 x 0.75 mm,
• Hot-dip galvanized sheet metal,
• Coating weight 1.2 1.4 g/m²,
• Prepared by electrostatic spraying
• ThyssenKrupp Stahl Neuwied.

500 parts successfully produced and assembled
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Observed benefits and value

• Improved yield and production efficiency
• Reduced scrap minimum 50 reductions expected
  in high scrap operations (those with 5 scrap
  rate)
• Reduced downtime
• Improved tool performance and life
• No build up visible on dies in all trials to date
  
• Improved HSSE performance
• Energy saving
• Renewable resource
• Cleaner environment
• More operator friendly
• Streamline stamping process and improve plant and
  operations flexibility
• No need for blank wash operations
• No need for spot lubrication

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Case study - Saarlouis trial Nov 2004

• Inner rear wheel house C-MAX
• Hot-dip galvanized sheet metal,
• Coating weight approx. 1.0 g/m²,
• Prepared by Arcelor, Belgium

1000 parts successfully produced and assembled
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Saarlouis trial Nov 2004

• Benefits
• Much improved Deformation of a difficult profile
• Removal of previous cleanliness issues caused by
  high application rates. Should lead to
  significant savings
• Tooling costs tools visibly much cleaner and
  tooling costs for this operation are high
• Scrap rates and costs
• Illimination of problems in following welding
  process caused by high lube usage
• Reduced application rate from 5 g / m² to 1g / m²
• Lower total cost of lubricant

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Case study USA

• Electrolux, Swainsboro, SC
• Drawing of extremely critical lawn mower decks
• Reduced scrap rate from 50 to less than 5
• Downgrading from IF steel to regular cold rolled
  can provide savings of approx. USD 1.000.000

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Current benefits and value

• Improved yield and production efficiency
• Reduced scrap minimum 50 reductions expected
  in high scrap operations (those with 5 scrap
  rate)
• Reduced downtime
• Improved tool performance and life
• No build up visible on dies in all trials to date
  
• Improved HSSE performance
• Energy saving
• Renewable resource
• Cleaner environment
• More operator friendly
• Streamline stamping process and improve plant and
  operations flexibility
• No need for blank wash operations
• No need for spot lubrication

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Steel casefiles

• Today, the automotive industry demands more than
  ever before from steel manufacturers and their
  suppliers. This has driven technological
  developments in pressing and stamping, together
  with accelerated usage of zinc coated steel,
  stainless, high-strength steels, and even
  aluminium and plastics.
• Castrol Advantage brings together world-class
  products, extensive services and innovative
  support to help you meet this challenge

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Electrostatic Application Equipment by Fara
Technology (modified)TKS (Thyssen) Rasselstein
Neuwied - May 2003 Castrol Dry Film Lubricant
Iloform PN 950 DF
Product temperature 70 C Spray bar 60
C Voltage 80 kV Coating weight 1.2 1.5
g/m² Atomization fine Surface
wetting good Substrate HDG
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Application Via - Electrostatic Spray Equipment
DUMA electrostatic unit
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Spray pattern Electrostatic Spray Equipment
TOTALSTAT spray bar
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Electrostatic Spray Application

• Castrol steel mill applied corrosion preventives,
  prelubes and dry film lubricants are designed to
  be applied by common electrostatic spray
  equipment.
• Examples are
• DUMA Maschinen- und Anlagenbau GmbH Germany
• Fara Technology PLC UK
• GFG (Peabody) USA
• SMR de Haan Germany
• Ravarini Castoldi C. srl Italy
• United Air Specialist INC. USA

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Coated Coil - Ready for market
Light Waxy Film
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How your client benefits
I asked for superior pressing performance I got
major cost savings.

• Extreme performance. Castrol Iloform dry film
  offers enhanced formability, even with
  difficult-to-draw materials.
• Major cost savings. Castrol dry film helps to
  increase press shop productivity, reduce
  maintenance, scrap and rework costs and can even
  mean the reduction or elimination of blankwash
  operations.
• Clean, safe and environmentally friendly. For
  once it is possible to improve results, save
  money and enjoy HSE benefits!

gtgt the result
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Extreme performance - Creating options for steel
and auto makers
Iloform PN 950 DF has been developed for todays
automotive industry by Castrol Advantage, in
close cooperation with automotive and steel
customers.

• Offers extreme pressing performance with all
  grades of coated steel, aluminium, stainless
  steel, zinc coated steel, tailor welded blanks
  and high strength steel.
• Alternative Steel qualities
• Lower cost
• Higher strength lower weight
• Totally compatible with all downstream press
  operations.
• Easy to remove and compatible with Castrol blank
  wash fluids, Iloform PL8 and PL17 and similar
  technology-based products.

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Major cost savings
In trials, Castrol Iloform PN 950DF dry film
proved effective in reducing overall press shop
costs. The maximum savings could be as great as
15 million, based on recent analysis by a
leading steel manufacturer.
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gtgt more
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Steel Lubricant scrap calculator
Steel Lubricant Cost
Grade 1 Grade 2 Grade 3 Grade 4
Steel (ton) 350 400 450 500
Lubricant (gal) 15 13 11 8
Lubricant (ton) 7 6 5 4
Total 357 406 465 504
Combined Annual Steel Lubricant Cost per Ton
20,000 7,140,000 8,120,000 9,100,000 10,080,000
40,000 14,280,000 16,240,000 18,200,000 20,160,000
60,000 21,420,000 24,360,000 27,300,000 30,240,000
80,000 28,560,000 32,480,000 36,400,000 40,320,000
100,000 35,700,000 40,600,000 45,500,000 50,400,000
Annual Tons
Annual Cost of 1 Scrapped Steel
20,000 71,400 81,200 91,000 108,000
40,000 142,800 162,400 182,000 201,600
60,000 214,200 243,600 273,000 302,400
80,000 285,600 324,800 364,000 403,200
100,000 357,000 406,000 455,000 504,000
Annual Tons
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Additional cost savings in the press shop

• These are achieved by
• enhanced formability of difficult-to-draw
  materials
• reduction in powdering on galvanised coated
  steels through increased uptime, reduced tool
  rework and regrinding
• reduced scrap and defects during metal forming
  operations, though less splitting and wrinkling
• reduction/removal of blank washing operations
• reduced blank wash/coil wash consumption
• reduced lead time in product development
• improved housekeeping no oily floors or work
  areas to clean

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gtgt typical coefficients of friction
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The result

• A new standard in pressing performance with major
  cost savings, and a cleaner, safer workplace.

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