A History of Working Hand-in-Hand with Die Casters around the Globe
Die casting is a process that Chem-Trend has been involved with for over fifty years. In Die Casting, molten metal is injected into a precisely dimensioned and reusable steel mold very quickly under high pressure. The pressure is maintained until solidification is achieved. The solidified piece takes on the details of the mold cavity† with high precision. It thus offers a way to obtain dimensionally accurate parts with good surface finish. Most importantly, it makes it possible to incorporate great complexity into the part utilizing a relatively simple production process. Depending on the metal alloys employed, it is possible to obtain a wide variety of physical and mechanical properties over a range of sizes and weights.
Die casting has progressed over the last fifty years from relatively small parts made from lower melting metals and alloys such as zinc, to today’s casting of very large parts, such as engine blocks. Currently, parts are most frequently made from relatively high-melting alloys of aluminum or magnesium and are cast at very high pressures to ensure complete cavity fill and minimum porosity† from entrained gases.
As die casting† conditions grow more severe in temperature, pressure and increased part size, the need arises for lubricants to enhance the process, provided they don’t adversely impact the performance characteristics of the product. This is where Chem-Trend comes in. For over fifty years we have developed innovative solutions to help Die Casters continue to advance their operational efficiency and lower their production costs, even as the industry faced increasing challenges for more part complexity.
A high-pressure die casting† machine has many moving parts that require lubrication and some of these are shown in the diagram below.
In a die casting system unique process aid requirements arise because of the thermal stresses experienced as a result of the exposure to molten metal. These include:
- Die lubricants that are applied to the die to enable production of good castings.
- Plunger lubricants that perform at the interface of the plunger tip† and shot sleeve†.
- Ancillary products that facilitate the smooth operation of the die casting machine and related processes.
All materials must function under the unusually harsh conditions of extreme pressure and molten metal exposure. Since many of the processing aid ingredients decompose rapidly on exposure to molten alloys, it is actually the partially pyrolyzed lubricant that must be functional.
At Chem-Trend, we understand the uniqueness of each of these processes, as well as the diversity of the raw materials utilized. Unique, robust, formulated products have been developed to serve as plunger lubricants and die lubricants that meet the needs of these extremely harsh conditions. In addition, we realize the impact that these agents have both on the efficiency of the process and the quality of products. Our history in the die casting industry started in 1960 when our founder pioneered the development of unique release agents designed to serve the needs of the automotive industry. When we developed water-based release agents that could be spray applied to the molds without risk of fire, it revolutionized the die-casting process and made a significant impact not only on the die casting process, but also on the health, safety and environmental (HSE) aspects of die cast facilities.
Recognizing that the needs of mold release agents were not at the forefront of many chemical suppliers, Chem-Trend embarked upon a program of developing and synthesizing unique molecules designed for use in the stringent environment of high-pressure die casting. This need-based design is the philosophy behind a wide range of mold release agents, die lubricants, plunger lubricants and ancillary products focused on increasing quality and productivity while minimizing any adverse impact on the environment.
To learn more about how we have developed advanced products to address the specific challenges found in die casting operations read more in the Die Lubricants, Plunger Lubricants and Ancillary Products pages available below, or contact us directly. If you don’t see your specific application or need mentioned, then contact us and we can review your process together and determine a custom solution to help improve your operation and reduce your costs.