Polymer-based die release lubricants – The superior alternative to water-based die lubrication?

As die casting technology has progressed, so has the reliance on lubrication to deliver an effective protective coating. New dies are becoming more complex each year and the variation in parts has grown significantly over the past decade. Intricate die casting, using highly accurate and detailed dies, is fast being adopted in automotive manufacturing where one complex part can replace a similar unit manufactured expensively from dozens of individual components.

Wide variances in die design, size and complexity impact the flow of the alloy through the die and gives each system a unique thermodynamic profile, leading to significant temperature variation where there are both hot and cold areas on the die’s surface. Hot areas are a cause for concern for manufacturers, as higher temperatures can cause defects in the final cast of the alloy, impacting both the quality and efficiency of production. To address this broad temperature range, the application manifolds for traditional siloxane lubricants are often complex, and spray cycles are detailed and lengthy. 

As a result, the cooler areas of the die are often over-sprayed. The excess lubricant increases the need for maintenance and creates costly downtime in production.

Intelligence is key - the right die release lubricant for every job

As manufacturers’ requirements get ever more complex, the die casting process must become more intelligent. This is where innovative products in the die casting value chain really matter. In this case, an adaptive release lubricant is required to improve the efficiency of the process.

To meet this need, Quaker Houghton introduced a new Smart Polymer die release lubricant, specifically for intricate die casting applications. It differentiates itself from traditional siloxane lubricants by incorporating thermodynamic reactive polymers which actively adapt to variations in die temperature. When exposed to high heat areas, the lubricant’s polymers react via a crosslinking mechanism, ensuring that the lubricant is appropriately distributed across the die and avoiding the need to spray excessive release coating.

Breaking down the chemistry behind the technology, special polymers within the lubricant contain reactive sites which, when exposed to high heat on the surface of the die, allow for the formation of chemical bonds between neighboring polymers. In application, the lubricant can adapt to specific temperature changes throughout the die casting process:

• When exposed to low temperatures from 110?C-220?C, the lubricant polymers will remain inactive, offering standard protection from molten alloys

• At medium temperatures ranging from 220?C to 330?C, the polymer will begin to react, forming a stronger, more heat-resistant coating
• Once the die temperature exceeds 330?C, the smart polymer will react quickly and adhere more effectively to the die, providing the best protection and strongest coating

Improved efficiencies through intelligent solutions 

Inevitably, die casting maintenance is time-consuming and labor-intensive, and often the only solution to solder or die build-up is manual abrasion of the alloy or residue from the die. Failure to do so is detrimental to the long-term performance of the die, causing staining, ejector pin failures and imperfections on the finished alloy castings.

With improved chemistry, Quaker Houghton’s reactive polymer-based die release lubricant comprehensively outperforms conventional siloxane lubricants while enhancing efficiency. For example, a die coated with a standard siloxane lubricant produced between 2,500 and 3,000 castings before needing essential maintenance. The same die treated with Smart Polymer lubrication lasted far longer, achieving between 7,000 and 9,000 castings before maintenance was required. Furthermore, the polymer-based lubricant solution requires far less application per casting, reducing lubricant consumption and costs.

For manufacturers open to smarter, more intelligent, and more innovative die release lubricants, there are multiple advantages. These include reduced cycle times, fewer maintenance intervals and less or no soldering. This prevents considerable expense in the long-term, and improves both productivity and efficiency, with the financial benefits that brings.

Tailored solutions to maximize capabilities

When challenged to provide a lubrication solution for a leading Japanese die casting and precision machining manufacturer, Quaker Houghton proposed its Smart Polymer die release lubricant which resulted in increased efficiencies well beyond the customer’s expectations.

The manufacturer wanted to achieve optimal conditions for casting, eliminate soldering time and reduce cycle times, and sought a complete lubricant solution. Analyzing the customer’s specific challenges, Quaker Houghton tailored a polymer-based solution – the DIE SLICK 45 series - to meet the demands of the customer perfectly. The benefits were striking – productivity increased by 10%, soldering was virtually eliminated, and both lubricant consumption and wastewater were decreased by 45%.

Providing the market with adaptative solutions

As modern die casting capabilities grow in complexity, it’s imperative that die casting lubrication continues to evolve to serve the needs of manufacturers. Smart Polymer technology enables reactive solutions previously impossible with traditional water-based lubrication, reducing downtime, cost and improving die capabilities.

To better serve the demands of the modern die casting market, Quaker Houghton has introduced a new offering, DieCast iQ, bringing together class-leading lubricants alongside the highest quality equipment and technologies currently within the market - providing a ‘one-stop’ package for die casting excellence.