Aluminum Wire Drawing Oil

Aluminum Wire Drawing Oil (AWDO) is a specialized lubricant designed for the high-precision manufacturing process of aluminum and aluminum alloy wire drawing. By forming a dynamic lubricating film between the wire and the die, it reduces friction, dissipates heat, and prevents surface defects, ensuring the production of high-quality aluminum wires with consistent mechanical properties. This article explores its technical characteristics, application scenarios, and maintenance protocols based on industry-leading products and empirical data.

Technical Characteristics and Performance Data

1. Extreme Pressure Lubrication
   AWDO contains sulfurized fatty acid esters and synthetic additives that form a chemical adsorption film under high pressure (up to 3000 MPa). For instance, BECHEM Unopol AL 560 achieves a friction coefficient of ≤0.03 during aluminum wire drawing, extending die life by 200% compared to conventional lubricants. Its viscosity at 40°C ranges from 170 to 200 cSt, ensuring stable lubrication even at high drawing speeds (up to 15 m/s).

2. Thermal Stability and Oxidation Resistance
   Premium AWDO formulations, such as APAR POWEROIL MET SDL 20, exhibit a flash point of ≥250°C and a viscosity index (VI) of ≥100, minimizing viscosity degradation at elevated temperatures. During continuous operation, oxidation stability tests show a saponification value of ≤18 mg KOH/g, preventing sludge formation and maintaining system cleanliness.

3. Cooling Efficiency
   Water-miscible AWDO variants, like BECHEM Berudraw AL SEA, leverage emulsifiers to achieve a thermal conductivity of 0.6 W/m·K—three times higher than pure oils. This enables rapid heat dissipation, limiting wire surface temperatures to ≤60°C during fine-wire drawing (diameters ≤0.5 mm), thus avoiding thermal-induced grain growth and surface cracks.

4. Residue Control and Cleanability
   Low-residue AWDO formulations, such as BECHEM Berudraw AL 3, are engineered for easy filtration (pore size ≤10 μm) and post-drawing cleaning. After annealing at 400°C, wire surfaces exhibit a residual carbon content of ≤0.05%, meeting stringent requirements for enameled aluminum wires used in electrical transformers.

5. Corrosion Protection
   AWDO incorporates rust inhibitors like triazoles and carboxylates, achieving a copper strip corrosion rating of 1b (ASTM D130) after 3 hours at 100°C. This ensures aluminum wires remain corrosion-free during storage and transportation, even in humid environments (relative humidity ≤85%).

Application Scenarios

1. Electrical Conductor Manufacturing
   AWDO is critical for drawing high-purity aluminum wires (99.7% Al) used in power cables. For example, GRODAL STAR DE 1422 supports drawing diameters from 12 mm to 0.2 mm with a surface roughness (Ra) of ≤0.1 μm, ensuring minimal electrical resistance (≤0.028 Ω·mm²/m at 20°C).

2. Automotive Components
   In aluminum battery shell stretching, AWDO like K-LS815 provides a viscosity of 140 cSt at 40°C, enabling smooth deformation without cracking. Its anti-rust additives protect shells from white corrosion during electroplating, a common issue in electric vehicle (EV) battery production.

3. Electronics and Precision Engineering
   For enameled aluminum wires in inductors and motors, AWDO must balance lubrication and cleanability. BECHEM Unopol Roll 570 achieves this through a semi-synthetic base, allowing wire diameters as fine as 0.1 mm with a dielectric strength of ≥20 kV/mm after coating.

4. Aerospace and High-Speed Drawing
   Advanced AWDO formulations, such as Metal Drawing Oil 15 AL, support drawing speeds of up to 20 m/s for aluminum alloys (e.g., 6061-T6). Their extreme pressure additives reduce die wear by 50%, critical for manufacturing lightweight structural components for aircraft.

Maintenance Protocols

1. Concentration Management
   For water-miscible AWDO, maintain a concentration of 8–12% (v/v) in the circulating system. Use refractometers to monitor daily, adjusting with deionized water to prevent bacterial growth (total plate count ≤100 CFU/mL).

2. Filtration and Particle Control
   Install multi-stage filters (50 μm pre-filter + 10 μm main filter) to remove aluminum fines and die debris. For oil-based AWDO, replace filters every 200 operating hours or when pressure drop exceeds 0.5 bar.

3. Temperature Regulation
   Keep the lubricant tank temperature between 35–45°C to optimize viscosity. For water-miscible AWDO, avoid temperatures below 25°C to prevent emulsion separation.

4. Oxidation Monitoring
   Perform monthly tests for total acid number (TAN) and Fourier-transform infrared spectroscopy (FTIR) to detect oxidative degradation. Replace AWDO when TAN exceeds 2.0 mg KOH/g or the carbonyl index rises by ≥30%.

5. Die Cleaning and Storage
   After drawing, clean dies with ultrasonic solvents (e.g., isopropyl alcohol) to remove AWDO residues. Store dies in a humidity-controlled cabinet (≤40% RH) to prevent corrosion.

Conclusion

Aluminum Wire Drawing Oil is a high-performance lubricant essential for achieving precision, efficiency, and quality in aluminum wire manufacturing. By leveraging advanced additives and tailored formulations, it addresses the unique challenges of aluminum’s low hardness (HV ≈25) and high thermal conductivity (237 W/m·K). Proper selection and maintenance of AWDO can reduce production costs by 15–20% while extending equipment lifespan by 3–5 years, making it indispensable in industries ranging from automotive to renewable energy.