Die casting lubricant: FAQs

Why does sludge (suspended material) form in the dilution tank?
When the mold releasing lubricant emulsification balance in the dilution tank is disrupted, the lower density components separate off as insoluble material and become floating sludge.
What methods are there for removing mold deposits?
A detergent can be used to remove them. Normally a petroleum-based or alkaline detergent is used. Check what substances are accumulating in the mold and select the detergent.
Is it possible to prevent or reduce the mold deposits (stickiness)?
The following three methods can be used.
1. The amount of mold releasing lubricant that attaches to the mold can be reduced by selecting a lubricant that is appropriate for the mold temperature and this can reduce the deposits.
2. The deposits can be reduced by adjusting the dilution factor and changing the amount of mold releasing lubricant applied.
3. We can also supply mold releasing lubricants that only have a small amount of attachment to the mold. Please ask us about this.
What problems occur when the mold releasing lubricant dilution factor is too low?
There may be staining on the product or misrun problems. Also, too much mold releasing lubricant attachment may cause accumulation on the mold and lead to environmental problems.
What should be done to check and manage the dilution factor?
Undiluted mold releasing lubricant is generally around 30% active components and the remainder is water. When the mold releasing lubricant is diluted for use, the active ingredients become 1% or less, so measurement with simple apparatus is difficult.
To measure the dilution ratio accurately, it is best to ask the manufacturer to perform the measurement.
What problems occur when the mold releasing lubricant dilution factor is too high?
The separation of the product from the mold will deteriorate and seizing and galling can occur. Also, a load must be applied to remove the product from the mold, so the product produced may be distorted.
Do you have any mold releasing lubricant appropriate for coated products?
Some mold releasing lubricant will remain attached to the surface of the product after the casting, but this is washed in a cleaning process before the coating is applied, so normally the lubricant has no effect on the coating.
However, if there is too much attachment of mold releasing lubricant, or if the concentration of the detergent is too low, then there may be a problem with the coating adhesion, so it would be necessary to check the processes.