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Chemicals Innovative Spraying System Ensures Optimal Control

| Editor: Nicole Kareta

Release agents have to meet various requirements in order to maintain the quality of the castings and to guarantee a sustainable and economic use. This involves continuous control processes. In this context, Ultraseal International presented an electrostatic spray system designed for die casting as well as water-free die release agents at EUROGUSS 2020.

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The control units of the spray systems have been equipped with additional pneumatics to regulate air flow during spraying.
The control units of the spray systems have been equipped with additional pneumatics to regulate air flow during spraying.
(Source: Ultraseal International)

Ultraseal International, a manufacturer of impregnation chemicals, impregnation systems and die release spray technology, presented Lubrolene, a new series of water-free die release agents and a specially developed, turnkey, spray system, at this year's EUROGUSS. In combination with the electrostatic spray technology, an optimal release for die cast parts of engines, drive trains and structural vehicle components is made possible with this solution. The new technologies are designed in particular for higher temperature die casting associated with larger, more complex structural components and where precise control of the spraying process is essential.

Pneumatic Control Ensures Optimum Spraying Quantity

“The complexity of large structural parts makes it difficult to design internal cooling to adequately cool all parts of the die uniformly. This leads to the development of localised hot spots which, in turn, create solder problems. Lubrolene negates the need for die cooling by lubricant. The lubricant is designed to work at a wide range of temperatures and delivers a high adhesion efficiency for thicker and more effective film formation.” says Tim Butler, Head of Special Projects at Ultraseal International.

In addition, the control units of spray systems have been equipped with additional pneumatics to regulate air flow during spraying. “This allows difficult areas of the die to be treated individually — sometimes faster, sometimes slower or with lower quantities — so that the spray rate can be calibrated accurately. The new technology is capable of measuring film thickness during process control and beyond the laboratory context immediately. In this way even the finest spraying is possible,” continues Butler.

The electrostatic spray process enables an optimal release for die cast parts of engines, drive trains and structural vehicle components.
The electrostatic spray process enables an optimal release for die cast parts of engines, drive trains and structural vehicle components.
(Source: Ultraseal International)

Electrostatic Properties

Another difference to the conventional air spray method is that the negatively charged particles of the die release agent are attracted to the grounded die, resulting in an even coverage over the entire surface. This reduces the need to position the nozzle at different angles. The electrostatic process also provides excellent adhesion, faster cycle times and requires less maintenance, as the cleaning effort for molds and spray nozzles is significantly reduced.

Further characteristics of Lubrolene die release agents:

  • lowest quantity die release agent per cycle
  • significant reduction of operating and die maintenance costs
  • effective operation at temperatures above 300 °C
  • increased service life of the casting tool
  • non flammable

“Lubrolene is used in a wide range of applications including powertrain, transmissions, shock towers, rails and torque boxes in ICE, hybrid and battery electric vehicles. We supply many global plants of well-known OEMs, providing a turnkey installation of the spray system on site at each plant,” explains Butler.

Progress for the Environment

Butler: “For a chemical company, environmental protection is a serious issue. I don't consider the increasing requirements in this area as competition to technological progress, but rather as an opportunity to provide our products with additional advantages. Of course, in die casting there is a long way to go. But with Lubrolene the process does not produce waste water. In addition, we have independently taken many air measurements in European plants and the values have all been good. So we have found that we are releasing fewer pollutants into the air and have good control over these emissions. Therefore the use of Lubrolene also helps to improve environmental performance and working conditions in the plant.”

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