10/24/2023 Technology & Processes Quality assurance Expert voices

Optimizing fluids and equipment for consistent die casting performance

To achieve consistent product quality and maintain process performance in die casting, controlled, stable die release lubricant application to the die face is essential. Yet, many manufacturers struggle to achieve this level of consistency. Examining the challenges and exploring effective solutions is crucial to ensure quality and optimize performance. Mark Cross, the Global Business Development Director for Die Casting at Quaker Houghton, delves into these matters.

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.

A case for universal consistency

Accuracy, repeatability, and consistency: These are what matter in the application of die lubricants. Only then can constant flow rates, volumes, and pressures be achieved, ensuring the desired result, regardless of the number of machines used or the scale of the wider operation.

All of this emphasizes the quality of the die release lubricant delivery equipment – itself a complex and multifaceted part of the overall process.

Equipped for the task

Each lubricant has different properties. Equally, each application is unique. The solution, therefore, needs to be fully customized to each challenge.

One obvious way to build quality assurance into even the most intricate parts of the die casting process is to invest in equipment that accurately mixes concentrated die lubricants to pre-determined levels and delivers consistent, repeatable quantities to the die face.

There is a wide range of requirements, from operations with mixed schedules that require agile or mobile solutions to fixed central systems capable of supporting various lines. While some operations require water-based agents, others involve new water-free (oil-based) Minimum Quantity Lubrication (MQLs) or hybrid systems.

Technology exists to meet these varied needs. But whatever the configuration of equipment and delivery system, there’s one area where both meet to deliver exceptional advantage - digital.

Digitalization – the future for fluids

The arrival of Industry 4.0 has changed manufacturing forever, giving even greater control and data and putting users firmly in command of their operations. Digital has obvious applications in the die casting industry, helping automate complex functions while using sensors and other technologies (including thermal cameras to identify hotspots, for example) to monitor performance and efficiency.

Gathering live, real-world information from equipment and relaying instructions back to the hardware enables system managers to fine-tune improvements on live die casting lines while also gathering actionable insights that will allow businesses to use lubricants and die casting fluids more effectively. By optimizing the use of time, labor and resources, the benefits include improved processes, productivity, and machine performance, along with reduced cost, cycle times, and downtime.

Consistency through consultancy

Consistency is the key to protecting the quality and integrity of any given die casting operation, and it is something that can be designed and engineered. However, balancing the different commercial and technical needs requires a detailed understanding of objectives, a thorough evaluation of operating conditions, and a considered recommendation.
In arriving at the optimal solution, equipment and lubricant are key. But there’s one final piece of the puzzle that’s mission-critical: namely, expertise. Therefore, it’s advisable to seek advice from a specialist such as Quaker Houghton, who can configure a complete, turnkey package of equipment and lubricants, hardware, and software to ensure that desired outcomes can be replicated repeatedly. Accurately. Repeatably. Consistently.