The Hill and Griffith Company
1085 Summer Street - Cincinnati, OH 45204
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Die Casting News

Die Casting Machine Lubrication Tips

Posted by Hill and Griffith Company on Oct 18, 2017 3:04:45 PM

NADCA Video News Update - Mechanical Maintenance & Evaluation of Die Cast Machines: DCM Primary Mechanical Structures - Highlight

The material presented in this video are some highlights from NADCA’s online webinar - Mechanical Maintenance & Evaluation of Die Cast Machines: Die Casting Machine Primary Mechanical Structures - presented by Jerald Brevick. The first in the Mechanical Maintenance & Evaluation of Die Cast Machines series covers topics related to the major mechanical support structures of die casting machines; the machine base, rails, platen supports, wear pads, die carriers, tie bars and bushings.

Click here to view the sample of the complete video.

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Tags: Die Casting, Metal Casting, diecast, diecasting, Aluminum Die Casting Process, die casting release agent, die casting lubricant, Die Casting Technical Support

Die Lubricant Biofilms -  How They Impact the Die Casting Process

Posted by Hill and Griffith Company on Oct 11, 2017 4:56:31 PM

Presentation by Tim Cowell, Technical Director Die Casting & Metal Working Fluids, The Hill and Griffith Company.

In the picture above Tim Cowell is presenting this Formal Presentation, "Die Lubricant Biofilms -  How They Impact the Die Casting Process," at the XVI Simposium 2017 in Queretara, Mexico

Die Lubricants

Within the die casting process, where molten metal is injected into a steel die, a release/lubricant agent is applied to the die to allow for proper release. These release agents are often referred to as die lubricants.

Die Lubricants provide three major functions that are vital to the die casting process.

  • Release of the Casting
  • Lubrication of the moving parts of the Die
  • Surface cooling of the Die

Die Lubricant Central Systems

These products are typically water dilutable and are diluted between the range of 50:1 to 100:1 in a central mixing system.  

The die lubricant is delivered through a network of piping connected to the die cast machines and ultimately to the die surface by spray nozzles. Below is a simple diagram of this type of set up.

Die Lubricant Spray Nozzles

An important key to assuring that the die is evenly coated with the die lubricant is to make sure that all spray nozzles are working and there is nothing that would obstruct the flow to and from these nozzles.

Filtration

To insure this, a series of filters are placed at various locations in the die lubricant supply system.

An example of a steel reinforced wire mesh filter used in Die Lubrication supply systems. Often steel reinforced filters are used to keep the filters from collapsing.

The purpose of these filters is to keep the fluid clean so that foreign materials will not plug up the spray nozzles.

Biofilms: Filters

Inline filters are used to keep the lubricant flow clean and protect the Spray nozzles from clogging up.

Biofilms often clog these filters reducing the amount of release agent being supplied to the spray nozzle and reducing the effectiveness of the atomization.

An example of an inline screen filter just pulled out of the line. This screen filter was given to the die lubricant manufacturer for further evaluation.

However, these filters often become contaminated with a slime (biofilms) resulting in a reduction of die lubricant flow to the spray nozzles and sometimes completely shut off.

Biofilms

All water dilutable die release formulations share the common problem of susceptibility to microbial attack.

This is not all bad news since we need the used dilute fluid to be biodegradable for waste treatment purposes. 

The challenge for both formulators and die casters using water-based release agents is to minimize the adverse economic impact of uncontrolled microbial contamination in the die casting operations.

Biofilms are a real problem in maintaining a clean die lubricant system.

In order to address this problem, the following questions need to be answered:

What are Biofilms?
  • How do Biofilms Form and Reproduce?
  • What can be done to remove Biofilms?
  • What can be done to prevent Biofilms?

What are Biofilms?

Biofilms are collections of microorganisms and the extracellular polymers they secrete, attached to either inert or living substrata.

Two types of microorganisms contaminate die release fluids: bacteria and fungi. Four factors predominate in controlling microbial life:
  • Energy Source – Obtained by breakdown of organic compounds
  • Nutrients – Water Source (minerals)
  • Warm Thermal Conditions
  • pH conditions – between 7-9.0

Microorganisms create "micro-environments“ called Biofilms in which conditions may be very different than they are in the bulk fluid.

A biofilm is an aggregate of microorganisms in which cells adhere to each other on a surface. These adherent cells are frequently embedded within a self-produced matrix of extracellular polymeric substance (EPS). Biofilm EPS, which is also referred to as slime

These Biofilms are protected from changes in diluted release agent temperature, chemistry and pH by the slime that the microbial population produces.

In terms of pH, this means that even though a diluted release agent may be maintained at pH 8.5-9.0, the pH within the microenvironment may be below 7.0. PH control often affects symptoms rather than the underlying problem of microbial growth.

Biofilms: Central Systems and Piping

Die Casting Systems and Biofilms

What can be done to remove Biofilms?

Biofilms are difficult to remove, especially the mature colonies. Typically, removal involves a two-step process.

  • Chemical Treatment
  • Physical Removal

Biofilms: Treatment

Chemical Treatment

A residual level of biocide is essential to help control biofilms, but biocide alone cannot penetrate or dissolve a biofilm mass. Incorporating the use of specially formulated cleaners/disinfectants assist in dissolving the EPS allowing the biocide to effective kill the microbes. It also removes byproducts, such as Nitrogen (Ammonia) that promote the growth of the bacteria in the biofilm.

Normally, the system being cleaned is filled with the cleaner/disinfectant and allowed to sit for a period of 8 to 24 hours before being flushed with water (preferably hot). This allows for plenty of contact time for the surfactants of the cleaner to break down the EPS and allow the disinfectant to do its work.

Physical Removal

Physical methods can be effective, especially in addressing “mature,” well-developed biofilms.  Flushing hot water through pipes at high velocities, for example, can help remove biofilms from smooth pipe interiors, such as PVC. 

Biofilms may be more difficult to address in pipes with rough interior surfaces.  In those cases more aggressive physical methods are used to scour pipe interiors.  Pushing a flexible swab with an abrasive outer coating through a pipe by means of hydraulic pressure is one of the most common methods employed to physically remove scale and biofilm.

If the buildup is too much, then the pipe should be replaced with PVC if possible.

Biofilms: Prevention

What can be done to prevent Biofilms?

Biofilms are heterogeneous, inherently patchy, and colonized with diverse microbial communities — qualities that make biofilm control challenging for any die lubricant supply system. The keys are a monitoring system, a treatment system, and a preventative maintenance program. 

A. Monitor the Microbes within the System

With the understanding that the microbes (bacteria and fungi) are present where water and food sources are present, it is unrealistic to think that the microbes can be eradicated. However, monitoring the number of microbes within the bulk fluid allows for a die caster / fluid manager to determine when hit the system with a kill dosage of biocide / fungicide.

The simplest way of monitoring them is by bio dip slides.

These slides allow for the both the die caster / fluid manager to determine the concentration of microbes present in the bulk fluid.

If the bacteria are greater than 104 in the bulk fluid, then the system should be treated with a dose of biocide.

If fungus shows up in greater amounts of two colonies, then a fungicide should be added. These are typically added to the diluted die lubricant reservoir.

B. Reduce the free number of bacteria by using small dosages of biocide / fungicide

There are products that keep the number of both bacteria and fungi minimal by introducing low maintenance dosages into the system throughout the week. The focus is keeping the number of microbes minimal before they begin to create biofilms.

C. Perform Preventative Maintenance every six months.

Every six months, the system should be shut down and cleaned using the specially formulated cleaner / disinfectant.

This will keep the bacteria and biofilms to a minimum before they create problems for production.

Summary

Die lubricant spray is vital to the successful production of castings within the die casting industry.

Biofilms, without the proper treatment program, can create a real problem in this area.

Die casters must have a monitoring system and a scheduled preventative program in place to assure a clean and consistent source of die lubricant supply to the die.


Hill and Griffith Customer Service

We're known for our hands on approach. Let us visit your plant, offer die casting technical support and recommend release agents, lubricants, plunger lubricants and permanent mold lubricants that suit your needs. Products that represent the latest in technology and ongoing research that enhance competitiveness and increase productivity. 

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Tags: Die Casting, Metal Casting, diecast, diecasting, Aluminum Die Casting Process, die casting release agent, die casting lubricant, Die Casting Technical Support

Our Ten Most Popular Die Casting Lubricant News Posts

Posted by Hill and Griffith Company on Oct 4, 2017 9:17:45 PM

The following are our ten most popular news posts about die casting lubricants. Enjoy!

#1 2016 Die Casting Award Competition Winners

#2 Global Die Casting Release Agent Market - Trends, and Forecasts

#3 Gas Porosity And Surface Die Casting Defects

#4 Die Casting Machine Safety

 

#5 High Pressure Die Casting Release Agent Spray Manifold

#6 Is 2017 The Year for 5S - Die Casting Process Improvement?

#7 CONCOTE™ Permanent Mold Coatings

#8 Die Casting Surface Defect Prevention - NADCA Course highlights

#9 Pushing for Larger-Dimension Diecastings

#10 NADCA Die Casting Soldering Mitigation Video Offered

 


Hill and Griffith Customer Service

We're known for our hands on approach. Let us visit your plant, offer die casting technical support and recommend release agents, lubricants, plunger lubricants and permanent mold lubricants that suit your needs. Products that represent the latest in technology and ongoing research that enhance competitiveness and increase productivity. 

Read More

Tags: Die Casting, Metal Casting, diecast, diecasting, Aluminum Die Casting Process, die casting release agent, die casting defects, die casting lubricant, Plunger Lubricants, Die Casting Technical Support

It's Not Your Father's Die Lube Anymore

Posted by Hill and Griffith Company on Sep 27, 2017 8:38:41 PM

Introduction

In recent years, die cast lubricants have changed greatly! Die casters who have been around long enough will remember "traditional oil-based die lube products" (1). Subsequent generations have seen a conversion to "water-based prod­ucts" and in some limited applications a "dry powder."

With every generation, a better, faster, different prod­uct has been developed by the various manufacturers of die lubricants. The good news is that all of these manufacturers and universities have dedicated a great deal of time, money and effort into the pursuit of better products.

For the benefit of this discussion, the informa­tion contained will review advances in technology without reviewing the "traditional oil-based products" or the "dry powder" products. The discussion will review advances that have occurred in the "water-based technology". The "water-based technology" appears to be the predominately used product for applications where the die lubricant contributes to the external cooling of a die (2) Water has proven to be a great benefit to the characteristics of die coolant (3,4). Therefore, it is not necessary to review that aspect of die lubricant technology, as significant work has been completed at universities (such as Ohio State) and various manufacturers.

Die Casting Engineer Magazine, November 2003
Victor S. Lafay, Vice President Research and Technical Development
Stephen L. Neltner, Manager Product Development
Hill & Griffith Company
Cincinnati, Ohio

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Tags: Die Casting, Metal Casting, diecast, diecasting, Aluminum Die Casting Process, die casting release agent, die casting defects, die casting lubricant, Plunger Lubricants, Die Casting Technical Support

News from Sales & Operations - Die Casting Technical Support

Posted by Hill and Griffith Company on Sep 19, 2017 2:26:19 PM

New Technical Representatives and Mike Lawry's appointment to Vice President of Sales and Operations


Dear customers and friends of The Hill and Griffith Company,

It's been a busy year here at The Hill and Griffith Company. We've had successful foundry and concrete industry shows and you'll find us this week at the North American Die Casting Association's Die Casting Congress & TabletopSeptember 18-20, 2017 in Atlanta, GA, Booth #225. If you get the chance, please stop by and meet these new employees.



I’m pleased to announce the hiring of Doug Schwall for the Northern Indiana territory for sales. Doug comes to us with 20+ years of machining, die casting and maintenance experience as a hands-on manager. His duties will include die casting, foundry, concrete and machining with an emphasis on new customers and growth to existing accounts in the area. Doug’s understanding of the area and key personnel will be a tremendous asset with growing this territory to its fullest potential. Doug’s contact info:  

Doug Schwall
The Hill and Griffith Company
Technical Representative
317-313-4059
dschwall@hillandgriffith.com

 



And I’m pleased to announce the hiring of Angela Cox for the Northern Illinois/Wisconsin territory for sales.  Angela comes to us with 15+ years of die casting, machining and industrial chemical sales experience. Angela’s contact info:

Angela Cox
The Hill and Griffith Company
Technical Representative
931-216-2026 Mobile
acox@hillandgriffith.com
 
 



Also, I’m pleased to announce the hiring of Rodney Schisler for the Southwest Ohio territory for sales. Rodney comes to us with 28 years of die casting and low-pressure casting experience as a hands-on manager. His duties will include die casting, foundry, concrete and machining with an emphasis on new customers and growth to existing accounts in the area.  Rodney’s past experiences will be a tremendous benefit with his process knowledge and will be utilized in other territories as needs arise. Rodney’s contact info:
 
Rodney Schisler
The Hill and Griffith Company
Technical Representative
513-503-3314
rschisler@hillandgriffith.com


One last thing, my new title is VP of Sales & Operation. After 26 years with The Hill and Griffith Company, I look forward to improving our sales and service even more in our core markets as well as new ones. My door is always open, so contact me at any time with any concern or a new idea to help make your job easier. My contact info:

Mike Lawry
The Hill and Griffith Company
VP of Sales & Operation
317-727-8276
mlawry@hillandgriffith.com

Sincerely,

Mike Lawry


Hill and Griffith Customer Service

We're known for our hands on approach. Let us visit your plant, offer die casting technical support and recommend release agents, lubricants, plunger lubricants and permanent mold lubricants that suit your needs. Products that represent the latest in technology and ongoing research that enhance competitiveness and increase productivity. 

Read More

Tags: Die Casting, Metal Casting, diecast, diecasting, Aluminum Die Casting Process, die casting release agent, die casting defects, die casting lubricant, Plunger Lubricants, Die Casting Technical Support

Die Casting Plunger Lubricants & Porosity: How they interrelate

Posted by Hill and Griffith Company on Sep 13, 2017 3:52:41 PM

NADCA Congress Session Spotlight - Tim Cowell, Technical Director at The Hill and Griffith Company to present at the Die Casting Congress & Tabletop 

In the weeks leading up to the 2017 Die Casting Congress & Tabletop NADCA highlights information on papers that will be presented during the congress sessions. The following paper is scheduled to be presented on Wednesday, September 20: Computer Modeling II - 8:00-9:30 AM, Session Chair: Charles Monroe

Plunger Lubricants and Porosity: How they interrelate within the Die Casting Process
Timothy Cowell, Technical Director, Hill and Griffith Company

High Pressure Die Casting is a manufacturing process in which molten metal is injected, with a die casting machine using applied force and high pressure, into a steel die to form various products (castings). Within this process, there are large numbers of variables that need to be controlled to make an acceptable casting. If these variables are not controlled then defects within the castings (parts) occur making them unusable.
 
 
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Tags: Die Casting, Metal Casting, diecast, diecasting, Aluminum Die Casting Process, die casting release agent, die casting defects, die casting lubricant, Plunger Lubricants

Kamtek's New Alabama Plant Offers High Tech Die Casting Jobs

Posted by Hill and Griffith Company on Sep 13, 2017 1:44:16 PM

Kamtek opens $60 million Birmingham expansion

Kamtek officially opened its $60 million aluminum casting plant today, bringing a new capability that is in high demand as the automotive industry seeks to make lighter cars while retaining strength and safety.

Kamtek, an operation of international automotive supplier giant Magna, added high-pressure vacuum die-casting to its existing stamping and assembly operations in Birmingham’s Pinson Valley. The nearly 150,000-square-foot plant will eventually employ more than 100 workers.

“It allows us to produce aluminum castings at a much faster and higher-quality rate,” said John Hackett, general manager of Kamtek’s Birmingham operations. “They help to lightweight the vehicles of the future to reach better fuel economy, but it also gives them a much safer vehicle and a stronger structure to the aluminum. Typically, what we’re making here will replace maybe an 11- or 12-piece component with one part.” Hackett pointed to one such recent automotive success due to the process. “If you look at the Cadillac CT6 released last year, it has 13 casting components all produced by Magna that replaced 35 previous components,” Hacket said. “It helped contribute to the 200-pound weight savings on the vehicle.” 

Alabama Gov. Kay Ivey toured Kamtek's new aluminum casting plant in Birmingham. (Michael Tomberlin / Alabama NewsCenter)

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Tags: Die Casting, Metal Casting, diecast, diecasting, Aluminum Die Casting Process, die casting release agent, die casting defects, die casting lubricant, High Tech Die Casting Jobs

How to Reduce Die Casting Lubricant Build Up

Posted by Hill and Griffith Company on Sep 6, 2017 4:01:33 PM

NADCA EC-515 Die Casting Defects Course Review, Basics for controlling die casting defects - By Dr. Steve Midson

  • A die casting lubricant build up usually comes from lubricant that was not evaporated from the die
  • If it is darker in color, it is often referred to as carbon
  • Review the die temperatures with the die spray supplier to get the proper lubricant - keep ratio under control
  • Use of hard water in the die lubricant can sometimes cause build up
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Tags: Die Casting, Metal Casting, diecast, diecasting, Aluminum Die Casting Process, die casting release agent, die casting defects, die casting lubricant

Reducing Die Soldering by Proper Use of Lubricants

Posted by Hill and Griffith Company on Aug 30, 2017 4:10:24 PM

NADCA EC-515 Die Casting Defects Course Review, Basics for controlling die casting defects - By Dr. Steve Midson

  • Soldering phenomenon occurs when the molten aluminum enters the die and contacts directly on steel die cavity
  • The molten aluminum stream removes the applied surface lubricant film and the iron oxide layer or other coatings then erodes grain boundaries and pits the die surface
  • At a high enough temperature and pressure a reaction takes place that causes the formation of an aluminum-iron intermetallic and a direct fusion between the die and the casting
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Tags: Die Casting, Metal Casting, diecast, diecasting, Aluminum Die Casting Process, die casting release agent, die casting defects

Reduce Die Casting Cracks by Proper Use of Lubricants

Posted by Hill and Griffith Company on Aug 23, 2017 1:45:28 PM

NADCA EC-515 Die Casting Defects Course Review, Basics for controlling die casting defects - By Dr. Steve Midson

  • Reduce Die Casting Cracks, or tears, or hot cracks have many causes, but usually are at least partially caused by shrinkage cracks on the surface
  • Most often, the casting is stretched in the die as it cools because the die doesn’t change dimensions while the casting is cooling and contracting. The stretching causes cracks at the weak point (the last point to solidify)
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Tags: Die Casting, Metal Casting, diecast, diecasting, Aluminum Die Casting Process, die casting release agent, die casting defects

 


Hill and Griffith Customer Service

We're known for our hands on approach. Let us visit your plant and recommend release agents, lubricants, plunger lubricants and permanent mold lubricants that suit your needs. Products that represent the latest in technology and ongoing research that enhance competitiveness and increase productivity. 

Hill and Griffith Samples

Product Samples

We are pleased to provide samples in quantities large enough to allow you to "try before you buy." Die Casting and Squeeze Lubricants- Diluco®, Permanent Mold Coatings- Concote™, Plunger Lube™- Graphite and non-graphite oils and pastes with excellent anti-wear properties, Casting Operations Products: Start-up lubes, Ladle coatings, Anti-soldering pastes, Water glycol, Trim press lubricants, Surface protection for casting storage, Corrosion protection for die storage, Cleaners for machines and dies, Corrosion protection for machines, Heat treatment quenchants, and Heat-transfer fluids. Also, Industrial Lubricants Griflube®, Hydraulic fluids with fire-resistant and anti-wear properties, Bio-Syn natural ester-based hydraulic fluid, Way oil knuckle lubes and Metalworking Fluids- Grifcut™

Contact us for Product Samples

Hill and Griffith Customer Service

Technical Services & Support

On-site process surveys, Casting defect investigations, Product testing, Tooling start-ups and Statistical process controls and much more. Also, lab facilities are available to provide testing upon request. 

Contact us to Arrange a Visit

Bulletins and Technical Papers for Die Casting Products

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