METALWORKING FLUIDS
Redefining corrosion protection, surpassing standards
Callum Dorward, Product Manager, Lubrizol
The metal manufacturing industry has historically relied on petroleum wax-based formulations to protect steel coils, sheets, and components from corrosion. These formulations have provided a dependable thin-film barrier against environmental degradation, forming the cornerstone of corrosion control in steel manufacturing and metal fabrication. However, the industry is now facing new challenges, including evolving regulatory landscapes, supply chain disruptions, and heightened performance expectations. These factors are driving industry leaders to search for advanced solutions. The increasing demand for sustainability and efficiency is encouraging formulators to reassess traditional rust preventives and explore innovative additives that can redefine industry standards, prevent costly deterioration, and establish a new benchmark for corrosion protection in the metal manufacturing sector.
Metalworking that makes a difference Recent industry trends have prompted a shift in refinery base oil production, leading to a decrease in the capacity for Group I oils and an increase in the throughput of Group II oils. This transition has notably reduced the availability of petroleum waxes.
Calcium-based rust preventives have emerged as a viable solution to bridge this gap, addressing modern supply concerns by reducing reliance on key petrochemical feedstocks. These synthetic solutions provide formulators with an alternative to petroleum wax, simplifying the supply chain and mitigating exposure to industry supply challenges, while still offering strong corrosion protection. Unlike traditional wax solutions, calcium-based rust preventives are engineered for compatibility across a wide range of oil and solvent diluents, making them a versatile choice for transportation and industrial applications.
Real-world performance Corrosion is a major contributor to component failure, with its global economic impact estimated to exceed 3% of the global GDP, according to the
World Corrosion Organisation1 . Rust preventative
additives undergo rigorous testing, including exposure to salt spray, humidity, and specialised outdoor environmental trials, which are designed to simulate extreme real-world conditions. These evaluations aim to identify rust formation and assess the level of protection provided by the additives.
Modern rust preventatives, particularly calcium-based formulations, have shown superior performance compared to traditional wax-based solutions in controlled testing conditions. This has been demonstrated in the ASTM B117 Salt Spray test, and the outdoor exposure test (covered) which utilised a modified version of the ASTM D1014 standard.
Through rigorous evaluations such as salt-spray and outdoor testing, these advanced formulations consistently prevent rust formation across diverse conditions, showcasing superior corrosion protection. Additionally, they offer compatibility with a wide range of solvents and base oils, ensuring stability during various storage periods and minimising registration complexities. This innovative
1World Corrosion Organisation. Corrosion’s impact on the global economy. Retrieved [07.07.25], from
https://corrosion.org/
LUBE MAGAZINE NO.188 AUGUST 2025
19
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56 |
Page 57 |
Page 58 |
Page 59 |
Page 60 |
Page 61 |
Page 62 |
Page 63 |
Page 64
