Rust and corrosion are two of the most common problems encountered by the metal manufacturing industry. The damage caused by corrosion can affect not only finished products but machine tools, representing a much more expensive problem to address. As a result, corrosion can cause significant losses to businesses working in the metal production industry unless measures are taken to prevent the problem.
Unfortunately, there are several potential causes of corrosion, so it is not always simple to diagnose the source. The issue may be affected by temperature, climate, the metalworking fluids you use, the condition of your tools, and other factors that we will explain in more detail below.
While it may take some effort to find what is causing rusting or corrosion, there are several best practices that manufacturers can implement to reduce their risk, and these might also provide a permanent solution to the problem. Here, the industrial fluid experts at Broughton Lubricants will explain the most common causes of corrosion - both behavioural and environmental - and suggest changes you can make throughout your production process to protect your freshly machined metal from deterioration.
No matter the cause of rust, following these guidelines will help to ensure that your products remain as high in quality as possible, and cut the threat they face from corrosion to the absolute minimum.
What causes rust and corrosion?
There are several potential causes of rust or corrosion, and these might be environmental, behavioural or procedural. When trying to understand what is causing rust to appear on finished products (or to damage metalworking tools), consider whether any of the following factors may be responsible:
- High bacteria count
- Heat or humidity
- Unsuitable metalworking fluids or procedures, including:
- Incorrect fluid concentration
- pH that is too high or low
- Ineffective corrosion-inhibiting additives - Inappropriate storage practices
It may be that a combination of factors is to blame, or that you will need to address multiple potential causes to fully tackle the problem.
How can I determine the source of the problem?
One way to diagnose the causes of corrosion is to think about conditions that have recently changed within your facility or production processes. When a problem arises unexpectedly, this suggests that there has been a change to the circumstances under which your products are produced or stored, the processes through which your products are made, or the efficacy of the fluids you are using.
Changes in the efficacy of metalworking fluids may require more investigation as there can be several causes of this problem. In some cases, a product will work perfectly well for a long time, only for problems with rust to suddenly arise, and examining the changes that might have spurred this problem can help you to address it.
For example, fluids suddenly ceasing to prevent corrosion may be caused by changes in the conditions within your facility. Humidity and temperature affect the rates of chemical reactions, and even the weather can have an impact: for example, on a sunny day, the viscosity of certain products will be reduced and this can seriously affect their efficacy.
The most common factor that causes tools to corrode is a lack of adequate cleaning. Allowing metalworking fluids to build up on surfaces without regularly cleaning them can lead to bacterial growth, and a high bacteria count is one of the most common causes of corrosion and damage.
Will metalworking fluid with rust inhibitors solve the problem?
Often, the easiest way to resolve corrosion problems is to look at the different types of metalworking fluid you use and ensure that they are optimised to provide protection against rust and corrosion. In particular, you must make sure that the cutting fluid you use contains effective corrosion inhibitors. These fluids leave a protective sheen on finished products that can offer enhanced protection, making this one of the most fundamental and effective preventive measures against corrosion.
However, it is not always as simple as changing the product you use. Most metalworking fluids contain additives designed to provide corrosion resistance, but it is important to use them correctly and according to industry best practices in order to achieve the best possible results. The most important consideration for water-diluted metalworking fluids is to find the right concentration. Using the wrong ratio of fluid to water can dilute the corrosion protection properties of metalworking fluids, or change the pH balance of the fluid in a way that raises the risk of corrosion. In many cases, you will get the best results by following the metalworking fluid manufacturer's proposed dilution ratio, but if corrosion remains a problem, research and experimentation could help you to find a better balance.
Different types of metalworking fluid are used throughout the manufacturing process, so you can also check to make sure that every product you use has the proper additives for appropriate corrosion resistance.
What are the best practices for corrosion resistance using metalworking fluids?
You may need to adjust the concentration of your fluid under different conditions to get the best results - as we have said, an unbalanced ratio of metalworking fluid to water is one of the primary causes of corrosion.
Bimetallic corrosion, where metals corrode when they are put in contact with each other, is another common problem. Like all industrial lubricant products, each metalworking fluid contains a different combination of additives designed to benefit a specific application, and you may be able to purchase a cutting fluid that offers bimetallic corrosion resistance as a simple solution. Otherwise, applying waterproof greases or using thin sheets of plastic to separate different metals is a viable way to reduce the risk of this problem arising.
Finally, make sure that you are using the very best products you can. Castrol's Hysol SL 35 XBB is a metalworking fluid that offers superior corrosion control and prevention and is designed to deliver excellent product stability throughout machining processes. You can pair this with Castrol Techniclean™ 90 XBC, an industrial cleaning fluid, to compound the corrosion resistance properties and offer optimal protection to your products. It is vital to use fluids that are designed for compatibility, as additives can otherwise counteract one another's properties and be rendered ineffective.
For advice on choosing the right metalworking fluids or industrial lubricants for a specific application, contact the technical experts at Broughton Lubricants today. Our years of experience and deep knowledge of the metalworking industry mean that we can quickly identify the best product for a particular process, and we can also provide testing to ensure you get the best results from the fluid you choose.
Call us on 03300 555 655, or use our online enquiry form to arrange a call back at your convenience.
