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DIE CASTING

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REDUCED BLISTERING AND SPRAY TIME DIE CASTING AUTOMOTIVE STRUCTURAL CASTINGS DIE SLICK® N450

THE SOLUTION

Quaker Chemical reviewed the customers concerns and performed lubricant testing including FTIR spectroscopy, a visual residue comparison, Thermogravimetric analysis (TGA) and solids content testing. Quaker utilizes these four standard laboratory tests to accurately predict die lubricant performance in the customer’s production environment. Quaker tested DIE SLICK® N450 against the competitive product and found that while it contained slightly less solids content than the competitive product, DIE SLICK® N450 has a significantly higher thermal stability between 400°C and 800°C which will improve production issues (shown in Figure 1). The visual comparison of the dried products in Figure 4 that DIE SLICK® N450 burns cleaner than the competitor, translating to lower residue, cleaner machines, and decreased tendency for staining. By switching to DIE SLICK® N450 the customer was able to realize the following improvements:

» 44% Decrease in blistering from 36% to less than 20%

» 26% Spray time reduction from 9.5 seconds to 7 seconds

» Improved production time due to the reduction in re-manufacturing scrapped parts

» Reduced water use and waste treatment costs » Able to produce more good parts/hour with better

machine capacity, extending the die life

CHALLENGESA major global supplier of lightweight conventional and structural die cast parts to the automotive and industrial industries was experiencing production issues. The customer was facing an average scrap rate of 36% due to blistering on structural castings with the competitive product. They were looking for a new die casting lubricant with the following improvements:

» Reduction in scrap rate due to blistering

» Maintain a good cosmetic appearance

» Eliminate issues with castings sticking to the dies

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DIE CASTING

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PROCESS AND EQUIPMENT

Part Automotive Structural Castings

Material AURAL 2 Aluminum

Machine 2500 Ton HPM

Ratio DIE SLICK® N450 90:1Competitive product 45:1

Operation High Pressure Die Casting

THE PRODUCT

DIE SLICK® N450 is a synthetic lubricant which contains a blend of reactive polymeric lubricants. DIE SLICK® N450 exhibits excellent emulsion stability when diluted and forms a tough die film that resists soldering and promotes good metal flow. The formulation incorporates Smart Polymer technology and high molecular weight alkane cross-linking agents. Smart Polymer technology is a thermodynamically reactive polymer blend which forms a tough barrier on hot areas of the die, while lightly coating cooler, less demanding areas. This unique property translates to reduced solder, enhanced release and wetting characteristics while producing bright and clean castings.

THE EXPERTISE

The Quaker DIE SLICK® family of die lubricants provide excellent emulsion stability and exceptional solder resistance at aggressive temperatures, increasing your performance and production. The Die Casting product line offers a complete package of value-added fluids including plunger lubricants, quenchents, fire-resistant hydraulic fluids, ladle coatings, trimming lubricants, cleaners and machining fluids. This case illustrates the importance of supplier relationship, support and correct fluid selection. Proper selection and application of the die lubricant can result in substantial cost benefits. That is why Quaker focuses on developing solutions with the highest performance without compromise, fluids that sharpen your competitive edge.

REDUCED BLISTERING AND SPRAY TIME DIE CASTING AUTOMOTIVE STRUCTURAL CASTINGS DIE SLICK® N450

Figure 4: Visual Comparison DIE SLICK® N450 vs. Competitive product

DIE SLICK® N450 Competitive product