A Wide Range of Process Enhancing Products to Improve Operational Efficiency
Die casting is a complex process with intricate machines and a number of processing steps. Since all of these can have an impact on the quality of the product and the overall productivity of the plant, Chem-Trend has developed a complete range of offerings to serve the specialized needs of some of these stages.
Solder is a perennial problem in die casting† operations and removing it is a difficult task. Chem-Trend anti-solder pastes provide an easy way to remove solder. Just brush a small amount on top of the soldered area in the die and make a shot†. The paste loosens the solder and allows it to be removed with the shot. Repeated application may be required to remove severe cases of solder.
Hot Spot Greases
While our die lubricants are designed to give good solder protection throughout the die, the presence of localized hot spots, may be economically addressed through the use of our hot spot greases. Just brush a small amount on the hot spot and make a shot as usual.
Smooth travel of ejector pins, core pins and slides, is essential for trouble free operations on a die cast machine. The normal application of die lubricant is usually adequate to provide lubrication of these moving parts. In special cases, some additional lubrication may be required. Chem-Trend pin lubricants are engineered to form a lubricious film even on very hot surfaces without creating build-up that may accumulate in the slide path.
Some die casting operations will quench the castings in a tank of water as soon as it is ejected from the die cast machine. This is done to rapidly cool the part. The presence of water, oxygen, heat and metal can create a potential for corrosion on the casting surface. Chem-Trend quench compounds are designed to be added into the quench water tank to prevent this.
Trim Press Lubricants
As a casting is ejected from a die, it contains various extraneous pieces such as the gate†, runners, overflows etc. that have to be removed to produce the desired part shape. In some cases this is done with special equipment called the trim press. Designed for the specific part, the trim press applies pressure on the extraneous parts while holding the main casting in a fixed position. The resulting shear force causes the extraneous parts to break off. The shearing blades of the press occasionally need lubrication that can be ably provided by Chem-Trend trim lubricants.
Die casters usually have a number of dies that are used as dictated by the production schedule. These dies need to be protected against corrosion while in storage. Chem-Trend corrosion preventers are designed to be used with steel dies and do not require cleaning before being put back into service.
The pouring of molten metal into the shot sleeve† is usually done through the use of a cast iron ladle. In some cases the metal enters the sleeve through an open launder. In addition transfer of molten metal from the melting furnaces to the holding furnaces near the machine may also be done through transfer buckets. In all these cases it is necessary to coat the surfaces in contact with the molten metal, to prevent soldering†, contamination of the alloy and promote easy transfer. Chem-Trend ladle coatings have been proven to significantly extend the life of these consumable elements, saving costs and down time.
The act of assembling the various components of a die: the insert, slides, chill plates etc. can be a laborious and tiring process. Use of the correct lubricants in the building of the die can reduce labor and time taken, without interfering with the heat transfer during operations. Chem-Trend assembly lubricants are designed to resist washing out and water ingress by the sprays during normal operation and promote good heat exchange, while still being easy to use in the tool room.
Proper maintenance of the die lubrication system is essential for smooth operations and the consistent production of quality parts. The dilution tanks and spray heads can get coated with dried die lubricant residue which can easily be removed through the use of special cleaners provided by Chem-Trend. These may also be used for general maintenance on the shop floor. Special low alkalinity products are also available for magnesium casting applications.
Hydraulic systems are the main motive force in a die cast machine. The high clamping forces needed to keep the dies together, and the need to push large quantities of molten metal through a narrow orifice at high speed, make these the obvious choice to power this equipment. While there are a wide variety of hydraulic fluids available, the tough operating environment in a die casting shop make it imperative that fire resistant fluids capable of operating at system pressures of 170 bar/2500 psi are recommended. The intense economic pressures on die casting have made water-glycol fluids the preferred alternative for this application. Chem-Trend hydraulic fluid has been independently certified to provide the best wear† performance on the Vickers vane pump test for many years. Our large customer base has also verified this. Our hydraulic fluids are not available in all markets, so please contact your local Chem-Trend representatives to confirm availability in your area.
The die cast machine has many moving parts that are subject to intense loads and good lubrication is critical to the smooth running of the machine. Increased friction can cause a significant increase in power consumption and in extreme cases lead to failure of the machine. Chem-Trend’s engineered toggle lubricant has established very high benchmarks on a wide range of tests used to predict performance under such severe conditions.
Our work with die casting operations around the world for over fifty years has provided us with the type of knowledge and experience that can benefit you. Contact us to see how our products and expertise can help impact the efficiency of your operation.