PECM Issue 38 2019 | Page 59

OVERCOMING CHALLENGES To avoid compromising quality and increasing costs in the creation of large, complex components, specifying the correct die-casting lubricant is essential to ensure an adequate release lubricant film is formed over the die surface. However, the surface temperature of the die makes this difficult with water-based lubricants. To ensure the oil film is successfully formed on the die surface some water-based lubricant will remain in the die cavities. This may cause porosity problems and water stain on the casting surface. Whilst residual water on the die surface can be dried using compressed air, this extends cycle times and is a costly consumer of electrical energy, increasing processing costs. For an industry looking to cast larger components with higher process temperatures and also meet the challenges of maintaining product quality, improving productivity and reducing costs, Lubrolene WFR provides the best solution. Significantly reducing the quantities of lubricant required, Lubrolene negates the need for die cooling by lubricant and delivers a high adhesion efficiency for thicker and more effective film formation. Quality is improved through better molten metal flow and reduction of the quantity of trapped gases due to no external water-cool, as well as the fact that WFR can be applied at higher temperatures than conventional water-based lubricants, meaning there is less thermal stress on dies. The avoidance of heat cracks extends the service life of the dies significantly – the major source of savings. With cavities increasingly present in complex pieces, Lubrolene WFR-EC – which features an electrostatic charge – ensures an effective and efficient release. Creating a wrap-around effect, the electrostatic charge delivers consistent, uniform coverage, irrespective of die complexity. Using a specially-developed electrostatic spray gun, the application of Lubrolene WFR further reduces soldering problems, providing full, unrivalled coverage. Once the practicalities of complex, one- piece die casting are resolved through the implementation of new technologies and solutions, the benefits for automotive manufacturers begin to emerge fully. Reduced spray time, increased die life and a low reject rate all lead to enhanced benefits and cost savings for manufacturers. Combine that with zero wastewater from the process and reduced CO2 emissions, as a result of reduced air blow, and the environmental impacts of utilising an efficient casting die release lubricant cannot be ignored. To learn more about Lubrolene die release lubricant, or to discover more about the improvements it could have on your processes, call the Ultraseal team on 024 7625 8444 or visit www.ultraseal- impregnation.com. Issue 38 PECM 59