SOLID FILM LUBRICANTS - FUCHS LUBRITECH GmbH

SOLID FILM
LUBRICANTS
THE DRY LUBRICATION

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CONTENTS
INTRODUCTION...................................................................................................................... 3
STRUCTURE AND FUNCTION OF SOLID FILM LUBRICANTS...................................................... 4
PERFORMANCE RANGE OF SOLID FILM LUBRICANTS.............................................................. 6
PRE-TREATMENT AND APPLICATION....................................................................................... 7
TYPICAL TEST METHODS FOR SOLID FILM LUBRICANTS.........................................................10
SELECTION AND USE OF SOLID FILM LUBRICANTS.................................................................12
USING SOLID FILM LUBRICANTS ON VARIOUS AUTOMOTIVE APPLICATIONS......................... 13
FUCHS LUBRITECH'S SOLID FILM LUBRICANT CONCEPT.........................................................14
APPENDIX
APPLICATIONS.......................................................................................................................16
CHARACTERISTIC DATA........................................................................................................ 17
CHECK-LIST – SOLID FILM LUBRICANT COATING...................................................................18
2 SOLID FILM LUBRICANTS - THE DRY LUBRICATION
FUCHS LUBRITECH GMBH

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NTRODUCTION
INTRODUCTION
In many instances, if it's a question of dry film
lubrication, solid film lubricants are the optimum
choice. Solid lubricant coating has proved its
worth many times over and today provides a reliable
and indispensable design element.
Increases in automated production and assembly makes
solid film lubricants ever more important. They make it
possible to provide many structural components with
dry, efficient lubrication and, compared with conventional
lubricants, permit designs to be simpler. They
improve the running-in of highly-stressed machinery
components, simplify installation processes and,
in many instances, guarantee maintenance-free
lifetime lubrication.
Solid film lubricants manufactured by FUCHS LUBRITECH
are "state-of-the-art" and meet the increasing technical
demands made by diverse sectors such as industrial and
plant technology, metal-processing industry, machinery
construction and the commodity goods and automotive
industries.
In addition to their outstanding technical properties, the
solid film lubricants made by FUCHS LUBRITECH also
comply with the ever-increasing demands to address
environmental issues.
FUCHS LUBRITECH GMBH
INTRODUCTION
SOLID FILM LUBRICANTS - THE DRY LUBRICATION 3
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STRUCTURE AND FUNCTION OF SOLID FILM LUBRICANTS .......................................................................
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TRUCTURE
STRUCTURE AND FUNCTION
AND OF SOLID FUNCTION
FILM LUBRICANTS
Solid film lubricants are carefully selected solid lubricants combined
with organic or inorganic binders dispersed in solvents.
The fundamental difference compared with normal industrial varnishes
is that they contain solid lubricants instead of colour pigments.
Apart from the main components – binders, solid lubricants and
solvents – solid film lubricants may also contain functional additives
such as corrosion inhibitors or UV active components.
COMPOSITION OF SOLID FILM LUBRICANTS
Solid Lubricants
MoS 2, graphite, PTFE ...
Binders
Epoxy-, polyurethane-, amide-imide-, silicone resin …
Solvents
Organic solvents, water
Additives
Corrosion protection, wetting, preservatives, UV additive ...
4 SOLID FILM LUBRICANTS - THE DRY LUBRICATION FUCHS LUBRITECH GMBH

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30 μm
10 μm
10-15 μm
Coefficient of Friction μ
INDUSTRIAL VARNISH
SOLID FILM LUBRICANT
SOLID FILM LUBRICANT
ON PHOSPHATED METAL
STRIBECK DIAGRAM: MODEL OF THE FRICTION AREAS
DURING FLUID LUBRICATION
FUCHS LUBRITECH GMBH
Binder Colour pigment
Metal
Solid lubricant
deposited on
surface
Solid lubricant
FUNCTION OF A SOLID FILM LUBRICANT
Opposing surface
1) Partial separation of
the solid lubricant
from the coating
Boundary friction
Static friction
Mixed friction
Hydrodynamic friction
(Fluid lubrication)
Solid lubricant impregnated
into surface
Phosphate layer
Opposing surface Opposing surface
2) Transfer of the solid
lubricant onto the
opposing surface
Rotational speed n
3) Formation of the
transfer film
Boundary friction
Mixed friction
Hydrodynamic
friction
Solid film lubricant
Oil
STRUCTURE AND FUNCTION OF SOLID FILM LUBRICANTS
After drying and curing, solid film lubricants form a
strong dry coating several microns thick, by adhering
firmly to the substrate. The film reduces both
wear and friction as well as acting as a parting
agent and provides lubrication between the opposing
surfaces.
10μm
Scanning electron micrograph of the surface of a MoS 2 solid film lubricant layer
before applying frictional load.
10μm
Scanning electron micrograph of the surface of a MoS 2 solid film lubricant layer
after frictional loading – smoothing of the surface of the solid film lubricant.
Initial smoothing of the surface of the solid film
lubricant takes place as a result of the relative
movement of the opposing surfaces.
A partial discharge of material from the solid film
lubricant layer creates a "transfer" film on the
opposite surface. The build-up of lubricating film
between the two surfaces leads to a reduction in
the coefficient of friction.
The solid film lubricant provides the dual advantage
of dry and clean lubrication and in many instances
can replace the use of greases and fluid lubricants,
particularly where slow sliding movements are
involved. In addition solid film lubricants can be
used in combination with fluid or pastes. Solid film
lubricants enhance the lubrication of components
in the boundary friction region, when there is
no hydrodynamic lubrication and direct contact
between the surfaces occurs.
SOLID FILM LUBRICANTS - THE DRY LUBRICATION 5
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PERFORMANCE RANGE OF SOLID FILM LUBRICANTS ............................................................................
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ERFORMANCE RANGE
PERFORMANCE RANGE OF SOLID FILM LUBRICANTS
Solid film lubricants enable to pre-treat and store lubricated parts ready for assembly.
They are characterised by extremely high resistance to pressure and to temperatures; they neither age nor become
resinous and at the same time are clean to handle. FUCHS LUBRITECH's solid film lubricants possess outstanding
lubricating and protective properties:
ADVANTAGES FIELDS OF APPLICATION
SOLID FILM LUBRICANTS
make dry and clean lubrication possible
are resistant to contamination
protect against corrosion
lubricate under extreme conditions
(high and low temperatures, vacuum, radiation)
are suitable for the surface refinement of a number
of materials (metals, plastics, elastomers, ceramics,
glass etc.)
SOLID FILM LUBRICANTS
make assembly and dismantling of fitted parts simpler
optimise the running-in performance of highly-stressed components
make maintenance-free lifetime lubrication possible
prevent the occurrence of "stick-slip" and thus reduce noise
attain precise coefficients of friction with low variables for fasteners
when combined with oil and grease lubrication guarantee additional
safety through emergency lubrication.
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PRE-TREATMENT
Surface preparation of the parts to be coated plays an
important role during solid film lubricant coating.
Good adhesion and therefore long lifetime can only be
achieved with a pre-treatment which is customised for
the particular part and solid film lubricant. Thorough
removal of all grease residues, dust, dirt, rust and scale is
a fundamental part of the pre-treatment of the work
piece surface.
PLASTIC PARTS:
De-greasing of plastics and elastomers can be achieved
with aqueous cleaners or solvents. When using solvents,
however, attention should be paid to compatibility with
the plastics to be cleaned.
The adhesion of the solid film lubricants can be improved
by roughing the surface, for example. Suitable
methods are grinding or blasting with CO2 or sand.
Deformation of the parts or surface damage must be
avoided. Alternatively, physical methods such as plasma
activation, corona or flame treatment can be used for
the pre-treatment of plastics.
FUCHS LUBRITECH GMBH
PRE-TREATMENT AND APPLICATION
RE-TREATMENT
PRE-TREATMENT AND APPLICATION
& APPLICATION
The application of solid film lubricants is a complex subject and should be done by specialists.
Relative service life of solid film lubricants is dependent upon
roughness of the substratum and pre-treatment methods
sandblasted and phosphated
sandblasted
ground
METAL PARTS:
De-greasing can usually be done by using organic
solvents, such as, for example, hydrocarbon, acetone etc.
A more environmentally and user-friendly result can be
achieved by using alkaline or neutral aqueous cleaners.
The effectiveness of the cleaners can usually be intensified
when combined with ultrasound or heat.
Rust and scale can be removed mechanically or chemically.
Grinding or blasting are suitable mechanical
pre-treatment methods. Rust and scale can be removed
chemically through pickling in acids or lyes.
Phosphatising can give significantly improved adhesion
of the solid film lubricant onto the metal surface.
Phosphating improves both the mechanical properties
and corrosion protection of the parts to be coated.
Normally, zinc or manganese phosphating is used.
Relative service life
2 4 6 8 10 12 14 16 18
Surface roughness [μm]
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PRE-TREATMENT AND APPLICATION ............................................................................................
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APPLICATION
Decisive for the application of the solid film lubricant are
primarily the geometric shape of the parts and the technical
application properties of the selected coating.
Application is principally undertaken using traditional
processes found in coating technology, such as, dipping,
tumbling, dip-centrifuging and spraying.
SPRAY-COATING
For most products it has been shown that the "non volatile
part" of the solid film lubricant should be set at
about 26-30% for spray application. The non-volatile
part corresponds to the dry residue, i.e. the dry lubricant
coating after the solvent has evaporated.
Any standard spray gun may be used. HVLP spray guns,
with a circular/spread jet setting and a nozzle diameter
of 0.5-0.8 mm, have proved to be particularly suitable.
The specific design of the HVLP spray technology allows
varnish utilisation of up to 60%.
In many usages pre-heating of the parts to be coated to
60-80°C is an advantage. This also allows the application
of layers with a thickness greater than 20μm
without intermediate ventilation. Spray-coating usually
achieves layer thicknesses of 10-30 μm.
DIP-CENTRIFUGING
During centrifuge coating, it is recommended to set the
non-volatile part to 22-28%, in order to achieve an
optimum coating result. Here, too, it can be an advantage
to pre-heat the parts to be coated to 80-85ºC.
Sand blasting
Chemical pre-treatment
Higher temperatures lead to partial accumulations of
varnish and rough surfaces, lower temperatures only
give rise to very thin layers. The ideal degree of filling of
the centrifuge depends on the plant and usually has to
be determined empirically (guideline: 60-70%). Using
this method of application varnish utilisation can
amount to up to 90%.
It is, however, difficult to achieve homogenous layers
over 10μm thick. With dip-centrifuging there is the danger
that the parts will stick together (particularly parts
with flat surfaces). The parts should, therefore, be
moved continuously during dipping and also when
drying or curing afterwards.
SUMMARY OF THE COATING METHODS
AND AREAS OF APPLICATION
Using robots
Spray coating
Drum coating
Dip Coating
Dip/centrifugal coating
Spray drum coating
8 SOLID FILM LUBRICANTS - THE DRY LUBRICATION FUCHS LUBRITECH GMBH
Drum
Continuous drum
CLEANING PRE-TREATMENT APPL
very suitable
conditionally suitable
Spraying

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DRUM COATING
Coating in drums is particularly suitable for bulk goods,
which have simple shapes (e.g. washers, bolts, pins,
O-rings). An advantage of this process is the surface
smoothing that occurs due to the friction between the
coated parts in the drum and so homogenous layer
surfaces can be achieved. By combining it with a spray
coating in so-called "spraying drums" the thickness of
product deposited can be controlled precisely, thereby
giving an improved coating.
HARDENING
Air-drying solid film lubricants are dried at room temperature
before being subjected to frictional load, while
heat-cured solid film lubricants are cured after coating.
Individual
components
Bulk components
FUCHS LUBRITECH GMBH
Dipping
Eliminate components
sticking
Centrifuge
Rotary cycling table
Drying
Ensure coating
quality
Greater coating
thickness
Reduced consumption
of coating
Complex shapes
Costs
Baking UV light
PRE-TREATMENT AND APPLICATION
Normal curing temperatures are in the region of approx.
100-200ºC. More detailed information about the solid
film lubricants made by FUCHS LUBRITECH can be
obtained from the relevant product information sheets.
QUALITY CONTROL
Layer thickness
testing
ATION HARDENING QUALITY CONTROL PACKING
The general criteria used for the quality control of solid
film lubricant layers are the surface finish, the coating
thickness and adhesion to the surface of the component.
Transparent solid film lubricants usually contain
a special UV indicator which can be made visible with a
UV lamp and allows "Yes/No" control.
Further control parameters are determined by the shape
of the component and the requirements of the coating
applied. Quality control statistical analysis using
appropriate test rigs is rarely required.
SOLID FILM LUBRICANTS - THE DRY LUBRICATION
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TYPICAL TEST METHODS FOR SOLID FILM LUBRICANTS ..........................................................................
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YPICAL TEST METHODS FO
TYPICAL TEST METHODS
FOR SOLID FILM LUBRICANTS
Various methods are used to test the performance of solid film lubricants. The individual characteristics
of a solid film lubricant can be established by selecting the correct test method.
ALMEN WIELAND TEST METHOD
RLV 1) 060
Rotating shaft (coated) fixed in
two bearing shells
Contact geometry: flat surface
Test criteria: fretting load,
coefficient of friction
Measurement at slow
sliding speeds
SRV TEST METHOD
DIN 51834-8
Oscillating counterpart
on a plate (coated)
Contact geometry: line
(alternatively flat surface or point)
Test criteria: coefficient of friction, wear
Service life testing at high sliding speeds
and varying surface pressures
LFW1 TEST METHOD
ASTM D 2714 (RLV 1) 119)
Oscillating ring on block (coated)
Contact geometry: line
Test criteria: coefficient of friction, wear
Service life testing at slow sliding speeds
1) RLV: LUBRITECH Laboratory Specifications
F
F
F
V
F
3500 350
3000 300
2500 250
2000 200
1500 150
1000 100
500 50
0 0
00:00 Time [min] 18:00
0 10 20 30 40 50 60 70 80 90 100 110 120
Time [min]
10 SOLID FILM LUBRICANTS - THE DRY LUBRICATION FUCHS LUBRITECH GMBH
n
Coefficient of Friction, μ
Coefficient of Friction, μ
0,250
0,200
0,150
0,100
0,050
0,20
0,10
0
-0,10
-0,20
0
0 00:30 01:00 01:30 02:00 02:30
Time [h:min]
Temperature T [°C]

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FUCHS LUBRITECH GMBH
TYPICAL TESTING METHODS FOR SOLID FILM LUBRICANTS ........
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R SOLID FILM LUBRICANTS
COEFFICIENT OF FRICTION TESTING ON ELASTOMERS
DIN 52375 (RLV 1) 142)
Oscillating counterpart on a
coated elastomer plate
Contact geometry: flat surface
Test criteria: friction force
Measurement at slow speeds
and under low loads
0
0 10 20
Sliding track [mm]
30 40
SCREW TEST
DIN EN ISO 16047 (DIN 946)
Determination of coefficients
of friction on bolted connections
Contact geometry: flat surface
(thread and bolt head)
Test criteria: coefficient of friction,
clamping force
Measurement of thread friction,
friction under head and total coefficient
of friction
CORROSION TESTS
DIN 50021 (salt spray test),
DIN 50017 (condensed water test),
VDA 621-415 (alternating cycles test)
Determination of the corrosion resistance
of coated test plates or components
1) RLV: LUBRITECH Laboratory Specifications
Tightening torque M A [Nm]
8
7
6
5
4
3
2
1
100
80
60
40
20
uncoated
coated with
solid film lubricant
0
0 10.000 20.000
Clamping force F v [Nm]
30.000 40.000
uncoated
coated with
solid film lubricant
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SELECTION AND USE OF SOLID FILM LUBRICANTS ...............................................................................
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ELECTION & USE
SELECTION AND USE OF SOLID FILM LUBRICANTS
The special demands placed on a solid film lubricant
coating are as numerous as the possible
applications.
The selection of a suitable solid film lubricant requires a
high degree of professional competence and is mainly
determined by these factors: type of component,
purpose of the coating, surrounding conditions and
quality management requirements.
Solid film lubricants manufactured by FUCHS LUBRITECH
have proved themselves in many fields and represent the
optimum solution for dry and clean lubrication. Thus, for
example, they can provide installation-compatible
lubrication for screw connections, fitted parts and
O-rings, help to minimise wear on gear components
and provide lifetime lubrication for components
essential to safety.
SELECTION CRITERIA FOR COATINGS
COMPONENT
Geometry
Weight
Material
Surface
Coating costs
Component testing
Model testing
Statistical process
control
Documentation
QUALITY CONTROL REQUIREMENTS
TYPE
OF COATING
COATING PURPOSE
Running-in lubrication
Assembly
Lifetime lubrication
Corrosion protection
Wear reduction
Decorative appearance
Increase in value
Temperature range
Environmental conditions
Friction conditions
Load
Type of movement
Load cycle
ENVIRONMENTAL CONDITIONS
The assessment as to whether a solid film lubricant is suitable
for providing lifetime lubrication for a component
must usually be proved through trials on suitable test
rigs. Generally solid film lubricants have a limited service
life, which will be indicated in the trial by an increase in
the coefficient of friction and the appearance of wear
phenomena. Thus, it should be noted that load and
sliding speed of the component can have a great
influence on the performance of the solid film lubricant.
Running-in phase
Stationary phase
12 SOLID FILM LUBRICANTS - THE DRY LUBRICATION FUCHS LUBRITECH GMBH
Coefficient of Friction, μ
Coefficient of Friction, μ
0,24
0,21
0,18
0,15
0,12
0,09
0,06
0,03
Service life (relative)
0,15
0,10
0,05
Test duration
Characteristic slope of the coefficient of friction
of a MoS2-based solid film lubricant depending on the test duration.
20 min -1
60 min -1
100 min -1
20 40 60 80
Load [N/mm2 ]
Influence of load and speed on the service life
of a MoS2-based solid film lubricant.
200 400 600 800
Load [N/mm
Influence of load on the coefficient of friction
of a MoS2-based solid film lubricant.
2 ]

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FUCHS LUBRITECH GMBH
USING SOLID FILM LUBRICANTS ON VARIOUS AUTOMOTIVE APPLICATIONS ........
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USING SOLID FILM
USING SOLID FILM LUBRICANTS
LUBRICANTS
ON VARIOUS AUTOMOTIVE APPLICATIONS
5
3
4
2
6 7
Apart from numerous industrial applications, the
versatility of solid film lubrication can be seen
from the automotive applications outlined below.
Solid film lubricants ease the assembly of sealing and
bolting elements, contribute to interior noise reduction,
provide the best possible performance under extreme
conditions (e.g. engine compartment, exhaust system)
and guarantee safe and reliable lubrication of
components.
10
8
1
2
3
4
5
6
7
8
9
10
11
12
9
1
12
11
Source: DaimlerChrysler AG
AREAS OF APPLICATION
Coating of profile gaskets
Various plastic parts in the car interior
Connecting parts in the engine compartment
Elements of the fuel injection system
Reduced coefficient of friction of O-rings
Wear reduction of gaskets
Coating of wheel bolts
High temperature solid film lubricants for exhaust systems
Wear reduction of seat adjustment mechanisms
Closure mechanisms of the safety-belt systems
Sliding components in the boot lid
Sections of the door locking system
Installation lubrication / running-in conditions
Lifetime lubrication
Noise reduction
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THE SOLID FILM LUBRICANT CONCEPT ..........................................................................................
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HE SOLID FILM
THE CUSTOMER IS PARAMOUNT
LUBRICANT CONCEPT
Our professional and experienced lubrication technology team will
help you find solutions to your technical requirements.
With our sample coating service we offer you the
opportunity to test the efficiency of our products on
your components. If necessary we will develop tailormade
solutions especially for your application. In addition
we will assist you with the implementation
of a solid film lubricant coating system up to the
production stage.
Technical advice
on lubricants
Contract coating
in our own coating centre
Sample coating on a laboratory- and
semi commercial scale
Service investigations
by our development division
We offer you the opportunity to have coating work
carried out at one of our coating centres (FLT Surface
Technology).
In addition, through the know-how transfer of the
application technology, we make it possible for
implementation to take place at your own premises or
at those of one of our numerous external partners.
Know-how transfer of the
coating technology
Development
of tailor-made products
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FUCHS LUBRITECH GMBH
APPENDIX ........
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APPLICATIONS AND CHARACTERISTIC DATA
CHECK-LIST
SOLID FILM LUBRICANT COATING
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APPENDIX ......................................................................................................................
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CHECK-LIST SOLID FILM LUBRICANT COATING
Please cross off as appropriate
1. GENERAL CUSTOMER INFORMATION
Company
Contact person Department
Street Postal Code/ Location
Phone Fax
E-Mail Internet
2. INFORMATION ABOUT THE COMPONENT FUNCTION / AREA OF APPLICATION (if possible enclose drawing or sketch)
Description
To what stresses is the component / the system subjected?
Surface pressure
Surrounding media (e.g. dust, salt water, oil, air etc.)
Type of movement (e.g. rolling, sliding)
Operating temperature °C up to °C
3. INFORMATION CONCERNING THE COMPONENT TO BE COATED
Material
Steel
(alloy/description; e.g. St. 37, 100 Chromium 6)
Plastic/elastomers
(e.g. PA, PP… NBR, EPDM)
Surface finish
blank Roughness (e.g. R a value)
4. INFORMATION ABOUT THE UNCOATED MATING SURFACE AT 3.
Material
Steel
(alloy/description; e.g. St. 37, 100 Chromium 6)
Plastic/elastomers
(e.g. PA, PP… NBR, EPDM)
Surface finish
blank
Roughness (e.g. R a value)
Stainless Steel
Miscellaneous
Surface finished
(e.g. phosphatised, galvanised)
Stainless Steel
Miscellaneous
Surface finished
(e.g. phosphatised, galvanised)
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5. REQUIREMENT PROFILE
Coating specified by the customer : (including pre-treatment) Water-based Solvent-based
Coating for assembly aid Durable function lubrication
Running-in lubrication Miscellaneous
Low coefficient of friction [μ] Component testing:
Better wear performance Load cycles (number of cycles):
Corrosion protection [h] Test method Sliding speed in m/s:
Approx. layer thickness in μm: (only give details if absolutely necessary) Sliding track in mm:
Partial coating (please indicate area on the drawing)
Complete coating (standard process)
6. WHAT MUST BE TAKEN INTO ACCOUNT REGARDING THE COMPONENT / ITS USE?
Sand-blasting permissible Yes No
Phosphating permissible Yes No
Avoid temperatures below °C / above °C
Miscellaneous
7. INFORMATION NEEDED FOR JOB COATING
As part of our sample coating service we will suggest one or more coating processes.
In order to be able to select a suitable process for you at the sample stage
we would ask you for the following information:
Number of items per year
Number of items per delivery
Part weight, if applicable
Other requirements
SEND IN THE CHECK-LIST
Please forward this check-list and supplementary information to:
FUCHS LUBRITECH GMBH
Product Management, Dry Film and Coatings
Werner-Heisenberg-Straße 1
67661 Kaiserslautern/Germany
E-mail: gleitlacke@fuchs-lubritech.de
NOTE:
This and other check-lists are also available for downloading on the
Internet from www.fuchs-lubritech.com.
FUCHS LUBRITECH GMBH
APPENDIX ........
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SOLID FILM LUBRICANTS - THE DRY LUBRICATION 19

Lubrication Technology
FUCHS LUBRITECH GMBH
Werner-Heisenberg-Straße 1
67661 Kaiserslautern/Germany
www.fuchs-lubritech.com
Phone: +49 (0) 6301 3206-0
Fax: +49 (0) 6301 3206-940
E-Mail: info@fuchs-lubritech.de
1' PP 03/07 0601787