Die casting, just as much as any manufacturing operation will surely involve some manner of heat generation, part movement, cooling and ejection. Because of how intense die casting can be, it is almost impossible to imagine a smooth operation without the use of lubricants.
Lubricants aid the die casting process by minimizing the risk of part damage, easing part ejection and heat dissipation. What lubricants are suitable for die casting, and what type of lubrication options exist? Here are some basic information on the importance and types of die casting lubricants that can be used in casting end use parts.
Types of Lubricants
Die lubricants and plunger lubricants are the two major types of lubricants engaged in the die casting process. The main difference between these categories of lubricants lies in their mode of action.
Die Lubricants serve the function of decreasing stress on casting systems. This is achieved by increasing film forming at wetting at higher temperatures. It also improves solder protection, surface adhesion and reduces gas generation. The die lubricant essentially works as a releasing agent that helps produce parts with lesser chances of corrosion and cleaner, brighter casting appearance.
Plunger lubricants, on the other hand, are used to ensure that the operations of the shot sleeve and injection plunger remain smooth and consistent. Plunger lubricants may come in their dry or wet forms, but dry forms are often preferred due to the lower risk of contaminating water supply and reduced environmental impacts.
Plunger lubricants help to better the castability of the metal, prevent porosity and extend the life cycle of the shot sleeves and plungers.
The Importance of Lubricants
Die-casting lubricants are important as they:
1. Aid the removal of completed parts safely
This is done through the use of die lubricants or die sprays that prevent the damaging of the completed part on ejection. Applying the right amount of die lubricant is very critical. This is because using insufficient amounts can result in the part sticking to the mold, resulting in defects that may be cosmetic or functional.
Similarly, using too much die lubricants can result in poor surface finish or part porosity as a result of the inability of the lubricant to evaporate in time.
2. Eases the entire die casting process
As important die casting parameters like temperature, pressure and heat capacity gets higher and higher, the chances of failure and safety risks also increase. Lubricants perform the function of easing the moving parts in high-pressure die casting machine, enhancing heat dissipation arising from thermal stress and hotter die surface adhesion. Die casting lubricants also improve the overall efficiency of the die casting system and decreases production cost.
3. Die Casting defects
Lubricants can also prevent several die casting defects such as “fish eye”, “cold shut” and “in-cavity build-ups”. For instance, using quality lubricants can help create an environment with more uniform heat transfer that prevents solidification of casting before the mold becomes completely filled.
Die casting lubricants also help to prevent in-cavity build up by reducing the avenues for build-up of unwanted matter within the die cavity.
Firstpart Die Casting Manufacturing Services
Firstpart can help you optimize your production, design, budget and supply chain to choose what is best for you.Our experience in metal die casting makes us one of the most competent metal casters, using a wide array of methods to ensure high-quality, defect-free parts every time. Please click here to get in touch with one of our experts and determine the best process for you.
Firstpart will also provide you with free quotes, design and finish suggestions on your next project right away! Work with us and allow us to manage your die casting production needs and help you transition from rock solid prototypes to excellently finished die-casted products.