Making things out of metal, like springs, wire mesh, and nails, involves a lot of hard work.
One of the steps in this process is called wire drawing, where a big, thick wire is pulled through smaller and smaller holes to make it thinner.
This process, known as cold forming, is tricky because it needs special slippery stuff called lubricants to make sure the wire doesn’t get too hot, stick to things, or wear out the tools used to shape it.
Before, preparing the wire for drawing took a lot of effort and used harsh chemicals that were bad for the environment.
The slippery stuff they used sometimes didn’t work well enough, causing problems like wires sticking together when they shouldn’t.
But now, there’s good news!
A team of smart people from different companies and research groups, including the Fraunhofer Institute for Applied Polymer Research IAP, have come up with a new kind of lubricant made from polymers, which are a type of plastic. They called this project “Polyschmierung,” and their new slippery stuff is really special.
These new polymer lubricants are better for the planet and make the whole process cheaper. They can be put straight onto the metal without needing all those harmful pre-treatments, and they’re water-soluble, which means they can be washed off easily without harming the environment.
This is a big deal because it makes everything much simpler and more efficient. The metal can be shaped more easily with less energy, and the tools used don’t wear out as quickly, which saves money and is better for the planet.
The people who made these new lubricants worked closely with companies that face these challenges every day. Thanks to their hard work, these new polymers are already being used by the industry. Some wires made with this new slippery stuff have been sold and are working great.
One company said that their tools last longer now, which saves resources and is good for the environment. Another mentioned that they’re testing a way to use even less lubricant, which could make things even better in the future.
These new lubricants are not just good news for making wires. They could also help with other metal shaping processes, like making tubes or forging metal without heating it up first. And since there are many companies in Germany alone that could use this new technology, it could save them over 10 million euros a year.
The companies involved can make lots of this new lubricant for others to try out. This new development could change the way metals are shaped and processed, making it easier, cheaper, and much kinder to our planet.
