F C T h y Water Free Die Casting Technology

Water Free
F
Die C
Casting T
Technology
h
y
Do you think
we do not want to use
any die lubricant
Why do we spray such a lot?
I hate “greasy” and “wet” and
“slippery” floor…
Too much maintenance…
We are wasting die lube…
Clothes always get so dirty…
Shall we look for something new?
Open
Let us change from
“unnecessary”
to “necessary”
We want to further decrease the die lubricant …
We do not want to waste any die lube…
We want to spray behind the slide core properly…
We want to spray easily…
We do not want soldering due to die lubricant
Let us create something new
the door
Water Free Releasing agent
WFR Series
An effective film is formed under high die temperatures
WFR can effectively form a thick film by suppressing the influence of Leidenfrost phenomenon compared with water based lubricant even over 300°C (572°F) die temperature.
Water based
die lubricant
(Dilution ratio 80:1)
0.000 sec
0.005 sec
0.010 sec
0.030 sec
0.060 sec
0.160 sec
Water Free Releasing agent
WFR-3R
Test Condition: 350℃ (662°
F), 0.05ml droplet
Effective and efficient adhesion makes a small amount spray possible.
Even with 1/30 less spray amount, WFR adhered 5 times more than water based die
lubricant.
■Spray time and adhesion amount
Adhesion 20
amount
(mg)
■Film thickness data with Laser Scanning Microscope
A-201 / 10ml X 1time
A-201 / 10ml X 3times
WFR-3R / 0.3ml X 1time
WFR-3R / 0.3ml X 1time
15
A-201
（10ml）
Less than 1µm
(immeasurable level)
10
Plate temperature
5
WFR-3R
(0.3ml)
0
250
300
350
Plate temperature(°C)
Less than 1µm
(immeasurable level)
Less than 1µm
(immeasurable level)
250℃
300℃
350℃
Average film thickness :
2.9µm
Average film thickness :
2.8µm
Average film thickness :
2.3µm
To make an equal active ingredients amount between water based die lubricant and WFR-3R, Water
based die lube / 1:80 dilution ratio, Spray quantity：10 ml, WFR / Concentrated, Spray quantity：0.3 ml
Even with small amount WFR provides a very low frictional resistance force.
Only a small amount of spray with
excellent adhesion is needed for good
die release. Too much spray and adhesion has a negative effect on costs and
product quality.
Frictional 14
resistance
force
(kgf) 12
■Adhesion amount and
Frictional resistance force
Test Condition:
250°
C (482°
F)
Area with soldering
10
8
6
WFR-3R
4
2
0
5
10
15
20
Adhesion amount (mg)
High performance, environmentally-friendly,
quality improvement, cost reduction
We would like to provide solutions to various problems
which are related with die lubricant.
Even a small spray amount gives an excellent anti-soldering performance.
WFR has an excellent adhesion performance and low
frictional resistance force, therefore it can preserve
higher lubricity and releasing ability over 300°C
(572°F) range, and prevent soldering problems.
■Die temperature and Frictional resistance force
14
Frictional
resistance
force
(kgf) 12
Area with soldering
10
A-201 (Dilution ratio 80:1)/10ml
8
6
WFR-3R/0.3ml
4
2
0
200
250
300
350
400
Plate temperature(°C)
Less thermal shock gives extended die life
WFR does not have any cooling capability and the die surface temperature is not
cooled, therefore it prevents heat cracks and extends die life.
250
Die dimension variation (×10-6)
Temp (°C)
260
■Die temperature changes
after die lubricant spray
Spray start
240
230
WFR-3R/4ml
220
210
200
Spray finish
190
180
3
6
9
12
15
18
21
Sec
■Picture of heat crack
WFR-3R/4ml
0
-50
-100
-150
-200
-250
Water based die lubricant (4ml)
-300
Water based die lubricant (4ml)
0
50
■Die dimension variation
after die lubricant spray
-350
0
3
6
9
12
15
18
21
Sec
Not only the releasing performance but also safety is pursued.
We simulated the possible causes of fire with die lubricants in a die casting factory,
and proved that WFR has a very low fire risk.
Hydraulic fluid
VG46
Water Free Releasing agent
WFR-3R
WFR + Electrostatic spray provides
a revolutionary step in die casting
WFR for Electrostatic spray
application
WFR-EC Series
What is “Electrostatic spray”?
What is “WFR for electrostatic spray”?
Spray particle
Existing WFR
WFR-EC Series
Base oil
Active
ingredients
Auxiliary
agent for
electrostatic
Negatively charged die lubricant
adheres to the grounded die
Normally it is not possible to use electrostatic application with oil
based die lubricant as the oil is an insulator. However, WFR contains the auxiliary agent for electrostatic spray. This enables electrostatic spray and creates a new possibility for die lubricant spray
application.
Fine spray mist adheres to the die
through invisible electrostatic power.
Effects of Electrostatic spray application for Die casting
With ordinary air spray gun…
With Electrostatic spray gun…
Need to spray from many different angles to adhere properly.
With electrostatic, can adhere
to a wide area from a single
spray direction
Without
Electrostatic
Front
Side
Behind
With
Electrostatic
■Die lubricant adhesion efficiency to dies
Adhesion efficiency increases with electrostatic
spray application, therefore
A-201 + Air spray gun
3%
● Minimum number of spray nozzle
● Simple spray setting
● Easy maintenance
WFR + Air spray gun
33%
WFR-3EC + electrostatic spray gun
78%
0
10
20
30
40
50
60
70
80
90
100
Adhesion efficiency (%)
There are various benefits for using electrostatic
application with WFR.
The 4th generation new die lubricant
NPL Series
Our concept is a no-soldering, less gas-producing die lubricant
WFR series high adhesion efficiency can now be combined
into a product incorporating inorganic powder
Uniform film thickness and heat insulating effect
WFR-3R
NPL-H10
WFR forms a consistent smooth film
regardless of die
surface roughness.
Die Temperature fluctuates
from point to
point.
NPL forms a film
despite die roughness
and unevenness,
creates a consistent
film.
Die temperature
fluctuation is
smaller.
Heat insulating and retaining properties
20.0
Frictional
resistance
force 17.5
(kgf)
■Die temperature and Frictional resistance force
Spray volume : 0.3ml
Molten Aluminum temperature : 670°C (1238°F)
Molten aluminum volume : 90 ml
440
15.0
430
No die lubricant
420
WFR-3EC
12.5
Area with soldering
10.0
410
400
7.5
390
WFR-5AP
380
5.0
NPL-H10
2.5
0
250
■Die temperature rises after pouring molten aluminum
Temp 460
(°C)
450
370
NPL-H10
360
350
300
350
400
450
Plate temperature(°C)
Inorganic powdered NPL series shows low
frictional resistance force under high die temperature, and improves soldering problems.
0
1.0
2.0
3.0
4.0
5.0
Elapsed time (sec.)
The heat transmission from molten aluminum to
the die is delayed with inorganic powder.
Smooth casting surface
WFR-5AP
NPL-H10
NPL series containing inorganic powder gives an excellent surface finish compared
with ordinary die lubricants
due to heat insulation and less
gas formation.
To utilize the old and historical die coating technology and WFR technology for high
pressure die casting process. It is suitable for squeeze casting and Magnesium or Zinc
casting which need better metal flow.
WFR
Water Free Die Casting Technology
■Product line-up
Die temperature
Model No.
Maximum
die temperature
Features
Applicable
die temperature
WFR series
Water Free Releasing agent
WFR-5AP
430°C
200 – 350°C
High die temperature type (over 380°C (716°F) range), excellent high temperature
adhesion and lubricity performance and suitable for thick wall and pressure proof
castings.
WFR-53S
400°C
180 – 330°C
Low density type of WFR-5AP, to reduce the adhesion overage for controlling oil
marks and flow lines.
WFR-3R
380°C
150 – 300°C
Standard type of WFR series, well balanced formulation to cover from low
temperature to high temperature, and good for thin to complex casting parts.
WFR-33W
330°C
130 – 280°C
Improved adhesion efficiency of WFR-33, suitable for small, precision part and
casings etc.
WFR-33
300°C
130 – 240°C
Low density type of WFR-3R, well balanced formulation to cover from low
temperature to high temperature, and suitable for small and precision parts and
casings etc.
WFR-0
280°C
110 – 230°C
Non-Silicon type of WFR-3R, high lubricity and good for big and thick wall castings
which require excellent paintability and concern the electromagnetic shield.
WFR-03
250°C
110 – 200°C
Low density type of WFR-0. Suitable for low die temperature and good for small
precision zinc or magnesium parts as computer parts or electrical components etc.
WFR-M5
300°C
150 – 250°C
High performance WFR for magnesium casting, better metal flow and high
releasing performance for big magnesium parts.
WFR-M3
220°C
100 – 180°C
Low density type, developed and designed for small and thin Magnesium parts
with excellent surface finish.
WFR for Electrostatic spray application
WFR-EC series
WFR-5EC
430°C
200 – 350°C
Electrostatic spray application spec. of WFR-5AP
WFR-53EC
400°C
180 – 330°C
Electrostatic spray application spec. of WFR-53S
WFR-3EC
380°C
150 – 300°C
Electrostatic spray application spec. of WFR-3R
WFR-33EC
300°C
130 – 240°C
Electrostatic spray application spec. of WFR-33
WFR-0EC
280°C
110 – 230°C
Electrostatic spray application spec. of WFR-0
The 4th generation new die lubricant
NPL series
NPL-H10
450°C
100°C –
Contained inorganic powder and has an excellent performance of heat insulating
and retaining properties
NPL-G15
450°C –
100°C –
Repairing agent of water based coating film for Gravity and Low pressure casting.
Excellent high temperature adhesion and can apply in operation.
Special start-up liquid for WFR series. Excellent adhesion and form a strong film
under low temperature and reducing number of warm-up shots.
For warm-up purpose
Start-up liquids series
WFR-LR
-
Room temperature –
NPL-AERO
-
110°C –
NPL-ZERO
-
Room temperature
– 100°C
■Contact us about WFR series, WFR-EC series and NPL series.
Inorganic powder contains aerosol for repairing die coating film. Anti-soldering
and improve metal flow purposes for high pressure die casting.
Inorganic powder contains start –up aerosol
Aoki Science Institute Co., Ltd.
Main office:
Roppongi Hills Mori Tower 18F, 6-10-1 Roppongi, Minato-ku Tokyo 106-6118, Japan
TEL +81-3-3403-4301 FAX +81-3-3403-4304
URL http://www.lubrolene.co.jp/english/
Branch office:
34-1 Soraike, Wakabayashinishimachi, Toyota-city Aichi 473-0917, Japan
TEL +81-565-41-3830 FAX +81-565-53-1055