Scale Reduction in Hot Forging by

Dense Coating

Dr. Helmut W. Seidel1

Abstract
Scale formation leads to material defects, tool damages (wear), material
losses in hot forming operations of steel. Decrease or preventing the scale
formation leads better quality of the forgings, improved tool life, less aftertreatment
and reduced rejects quantity.
In order to achieve these goals, with LUBRODAL SR 300 a new, water-
based, environmental friendly coating, was developed which is applied before the
heating up simply on the billets or bars. Results from practice show advantages and
above all economy in the comparison to the state of the technique (inert gas, glass
coatings and others). The practical results are occupied by extensive laboratory
tests, which are presented briefly.
Relative forging operation and used steel grades on the basis of examples
the possibilities in addition, the borders are discussed.

1 Introduction & Basics

Scaling is a great annoyance when hot forging steel and related alloys
(Figure 1). Scale starts being produced when the material is heated to 1200-1300°C,
increasing during the forge operation up to the cool-down phase of the parts [1].
Oxidation of the steel components causes not only significant material losses, but
also negatively influences the reshaping process. Defects on the surface of the
finished parts require subsequent reworking and/or increase the rejection rate. The
abrasive scaling leads to increased tool wear and reduces the lifetime of the dies.
The expensive reshaping tools are a meaningful cost factor for the total production
process. Frequent tool replacement, reworking, defects in quality and rejection
reduce productivity, and with it the profitability of the process.

Figure 1: Scale
1 FUCHS LUBRITECH GMBH Werner-Heisenberg-Straße 1-67661 Kaiserslautern/Germany Phone: +49 (0) 6301
326-760 - Fax: +49 (0) 6301 3206-945 e-mail: helmut.seidel@fuchs-lubritech.de

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 In order to hinder the development of scaling, oxygen must also be hindered
from attacking the surfaces of the hot materials [2]. The current state of the
technology presents two basic approaches to solve this problem [3,4,5]:
I. Protective gas atmosphere (nitrogen, argon)
II. Coatings on the material surface (preferably glass coatings)

The practiced procedure with inert gasses (I.) is primarily limited to heating
and cooling. Attempting to perform complete handling and the actual reformation in
protective gasses is only possible with great technical effort. Especially for economic
reasons, this method is impractical for mass production. The second variant (II.) has
been successfully used for many years to forge special alloys [6]. Glass dispersions,
however, also have their price and require additional application and use technologies.
Here as well, economic factors speak against widespread use.
For this reason, it has been and remains an understandable challenge to
the steel industry to reduce the formation of scaling when reforming steel through
meaningfully cheaper and simpler methods. As a producer of specialty and forming
lubricants, FUCHS LUBRITECH set upon the concrete goal of developing appropriate
surfaces for this purpose.

2 Development Work

2.1 Requirement Profile

With the mentioned basic information from practice, the following
requirement profile resulted to develop a new, powerful coating for forged steel:
• Simple and economical to use
• Water-based, pH-neutral, environmentally friendly
• High thermal stability, good adhesive qualities
• No development of harmful gasses or flammable products
• Low friction
• Compatible with die lubrication
• No dangerous influence on induction and refractory
• Harmless to humans and the environment
• General availability

In order to fulfill the goals named above, a number of comprehensive initial

tests were necessary.

2.2 Thermogravimetric Measurements

For the selection of ingredients, from the very start only inorganic compounds
and mineral materials came into question. Legislation on chemicals, availability and

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physical properties combined with considerations on price to narrow the original circle
of candidates. Further, a selection needed to be made from a multitude of compounds.
Thermogravimetric measurements presented themselves for this purpose.

Figure 2: Thermogravimetry of inorganic components

We decided to evaluate the mass losses (mainly chemically bound water)

up to 1000°C as the decisive criterion. Materials that appeared appropriate were
then intensively tested for scaling reductions in a laboratory and tested in parallel
in industrial experiments. These tests took place in 20 forging shops with varied
reshaping processes while pressing, forge rolling, and hammering. Screening and
targeted evaluation led to a commercial product with the following properties.

2.3 Product Properties Lubrodal Sr 300

Figure 3: Physical and technical data 4

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 2.4 Press-In Test
The influence of the coating on the following forging process was examined
on a company-internal testing station. On it, a plated steel bolt was pressed through
a steel sleeve heated to 900°C. The diameter of the bolt is 0.5 mm larger than that
of the sleeve. The measured press-in force was, at 75 kN, on the same order of
magnitude of graphite-free die lubricants. The process took place nearly inaudibly
and in the absence of any stick-slip effect, which is undesirable for reshaping.
These results afterwards confirmed the positive effects of the coating on the
forging process.

Figure 4: Scheme Press-In Test

Figure 5: Press-In graph LUBRODAL SR 300 5

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 3 Results In Practise

3.1 Application Methods

LUBRODAL SR 300 is to be used in pure form and can be applied using
sprays, immersion, showering, and brushing on the cold material (billets, bars). The
surfaces of the material to be coated must be free of greases and oils. Sandblasted
parts are very advantageous, due to the more raw surface structure, to pick up
the separating layer and for better adhesion. Automatic spraying is the most cost-
effective and evenly distributed application method.
The average amount of LUBRODAL SR 300 through spray application can
be calculated as requiring a surface density of 140-160 g of product per square
meter.

Figure 6: Application by spraying

The plated billets should, if possible, be applied on-line to heating and

forging without interim storage. Since the coating is weakly hygroscopic, longer
periods of storage in moist atmospheres can lead to slight emergence of corrosion
on the precoated parts through water absorption.

3.2 Mechanical Press Forging

Multi-stage press (EUMUCO MP 3.150),
round parts (3-5 kg); 15 – 30 parts / min,
3 – 5 stations; 1200 °C (induction heating),
LUBRODAL SR 300 pure by spraying (Figure 6)
Results: up to 15% less scale, better lubrication, higher die life, better
quality, less rework and rejects

3.3 High Speed Forging (Horizontal Press)

Hatebur AMP 20; AMP 30
smaller parts (< 1 kg); 60 – 120 part / min
induction heating
LUBRODAL SR 300 pure by drop-flooding 6

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 Figure 7: Scheme drop-flooding

Results: up to 10% less scale, better lubrication, no negative influence on

re-circulating fluid, higher productivity by less tool changes

3.4 Hydraulic Press

18000 to dishing (coning) press,
railway rods (300 – 1300 kg),
LUBRODAL SR 300 by brushing before second heating (gas oven)
Results: less marks, better surface quality, less reworking

4 Further Investigations

4.1 Steel Grades

First results from the lab and from practice showed from early on that the
SR 300 coating is not appropriate for high quality steel grades to minimize scaling.
Indeed, it resulted in increased scale growth. Quality steels and special alloys
require a different concept for the coating.
For low-carbon steel grades like those primarily used for conventional warm
forged parts, on the other hand, up to 25% less scaling is produced on average
in comparison with untreated reference samples based on experimental tests.
Additional extensive thermogravimetric measurements and individual examinations
were necessary on this point.

4.2 Investigation On Diffusion Effects

A question which is often asked from practice was also how much the
chemical components diffused into the steel matrix. To answer it, combined REM
/ EDX measurements were launched (Figure 8). The evaluation of the diagrams
showed conclusively that the components of the coating were found only in the
scale and on the surface. 7

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 Figure 8: REM / EDX diagram

Two zones (lines) for scale and surface were detected, with a thickness of
10 µm each. Scale is easily removed. Slight decarburisation was found.

5 Summary and Outlook

LUBRODAL SR 300 provides a coating for use in the hot forming of
conventional forged steels that minimizes scaling. This ready-to-use material is
water-based, environmentally friendly and simple to use.
The components of the coating do not diffuse into the steel matrix. They are
located exclusively in the layers of waste scale. Lasting and reproducible results
were sought by performing an automatic spray application on fast-moving forge
presses with inductive heating. Statistically and cumulatively in quantity, reduced
post-processing, better part quality, and longer die life are the result. Productivity
and economy of the process increases.
LUBRODAL SR 300 supports die lubrication and does not develop residue
in the dies. After many years of use in practice, no negative influence on induction
coils, oven atmosphere or refractory have been found.
The range of application covers further areas of steel hot forming. Thus,
recently, hot rolling and open die forging methods have been developed.
For higher quality steel alloys (high carbon steel and special metals), another
concept of coating is required. First results with a new formula (LUBRODAL SR
900) show promising areas of application. It results in less scaling. Its mechanical
removal is easier. The skin decarburization is significantly reduced. It inhibits billet
adherence while passing through the oven. 8

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