As lightweight automotive design fuels more diecasting applications, faster die-spraying is cutting cycle times, and more uniform adhesion is improving process reliability.
Excerpt from the June 2020 article from Foundry Management & Technology
Cost optimization and improved productivity and product quality are driving die casting strategies, particularly in the face of global competition and the need to produce more complex components. Automotive design and manufacturing are prompting to die casters to take on more complex, lightweight, components for powertrain, chassis, and structural parts. In turn, this has guided investments in larger high-pressure die casting machines and more expensive tooling, which has manufacturers seeking to improve productivity, process reliability, and product quality, and to extend die service.
The main purpose of a die-release agent is to allow clean part release and provide a release film that minimizes die soldering, and uniform coverage is critical to both process reliability and the finished product quality. Standard water-based lubricants evaporate in contact with a hot steel die, leaving a lubricant coating. This is a critical stage, because too much lubricant means liquid cannot evaporate quickly enough when molten metal is injected; and too little lubricant may result in poor material flow (i.e., "die soldering"), and then causing surface defects and porosity that reduce finished product quality.Read More