Die release agents, also known as die lubricants, are essential in the die casting process. Many solutions have been developed to cater to diverse industry applications. These encompass water-based options, water-based MQL (Minimum Quantity Lubrication), oil-based MQL, and electrostatic-based lubricants.
Each solution is meticulously designed for precise and consistent application, contributing to improved process efficiency and component quality. Achieving controlled and repeatable application is paramount for optimal performance. Accurate and consistent dilution is an additional consideration when working with water-based products.
Failing to optimize these aspects can lead to challenges, including porosity, staining, and soldering, where components adhere to the die. Such issues can compromise product quality in the short term and, if not addressed, may result in downstream consequences such as production inefficiency, reduced equipment lifespan, or even equipment downtime.
So, what obstacles prevent the consistent, accurate, and repeatable application of die lubricants?
The causes of inconsistency - water-based release agents
For water-based release agents specifically, mixing and bacteria can present significant challenges. Most water-based die lubricants are purchased in concentrated form and mixed to the desired concentration. Poor control of dilution concentration will lead to inconsistencies in the process.
For this type of lubricant, it’s common to use large central stores of diluted lubricant to feed the casting lines, which inevitably leads to fungal and bacterial growth which, left unchecked, can clog lines, affect flow rates, and pose both process problems and potential health hazards. While this can be treated with heavily regulated biocides, it adds an additional layer of complexity.
However, for water-based and other lubricants, the critical barrier to the consistent, repeatable delivery of die lubricant dosing is inadequate or incorrectly specified equipment that fails to offer the required level of controlled lubricant dilution and/or spray volume.