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