Henkel is a global leader in the manufacture of lubricant products for the casting industry. High-pressure die casting relies on best-in-class lubricants like BONDERITE® to reduce costs and improve productivity.
What is High-Pressure Die Casting?
High-pressure die casting (HPDC) is a manufacturing process where molten metal is injected into a steel mold cavity at high pressure. Pressures for HPDC are typically between 10,000 to 30,000 psi. High-pressure die casting is advantageous over other casting methods as it allows for the efficient manufacture of intricate parts with high dimensional accuracy. High-pressure casting has rapid cycle times. The entire process, from the injection of the molten metal in the mold to cooling and releasing the final part, is finished within seconds. The fast production time makes HPDC well suited for large-scale manufacturing, where efficiency and productivity are critical.
High-pressure aluminum die casting is increasingly common in industries, such as the automotive market, that need to produce a large quantity of parts with tight tolerances and aesthetic appeal, and value the benefits of a lighter, malleable, and more cost-effective metal. Aluminum gigacasting, an extremely high-pressure form of die casting, is widely being adopted by automakers to make large aluminum castings, thereby decreasing the number of pieces needed to make the car body. Reducing the number of castings simplifies and lowers the cost of production, as well as reduces the vehicle weight.
While high-pressure die casting offers manufacturers several advantages, the process relies on technology and quality materials to work correctly. Innovations in mold design and simulation software are enhancing the effectiveness of HPDC. Specific lubricants are also necessary to ensure the quality and integrity of cast parts.
Why are HPDC Lubricants Important?
High-pressure die casting lubricants serve several purposes in the die casting process. These specialized lubricants, also called release agents or die sprays, enhance the efficiency, quality, and longevity of the process, mold, and cast parts.
Reduce Friction
A basic function of casting lubricants is to reduce friction and improve lubricity between the molten metal and the walls of the die cavity. Before molten metal is injected into the mold, high-pressure die casting lubricants form a thin film to protect the mold surface. This film acts as a barrier to prevent defects, such as cold shuts and drag marks, leading to higher-quality castings.
Facilitate Flow of Molten Metal
The protective lubricant film on the mold surface also allows for smoother metal flow. Improved metal flow facilitates die fill, which is especially critical in the casting of intricate, complex parts. The right lubricant will help prevent short fill during high-pressure casting and reduce scrap.
Prevent Soldering and Sticking
Soldering and sticking is when molten metal solidifies and adheres to the mold surface. Proper die casting lubricants form a protective barrier in the mold cavity to discourage metal adhesion, making it easier to release the finished part free of damage.
Henkel BONDERITE® HPDC Lubricants
Henkel has engineered a portfolio of lubricant solutions for high-pressure die casting to ensure your casting process runs as smoothly as possible. Below are some of the key high-pressure BONDERITE® casting lubricants.
Grade
Function
Key Benefits
Application Method
BONDERITE® L-CA CP 579N
Water-based release agent
Superior release properties, excellent cleanliness, and high wetting performance at high temperatures
Spray
BONDERITE® L-CA CP 799
Water-based release agent
High-solid, silicone-free emulsion with excellent release properties and allows for unhindered downstream processes like painting and plating
Spray
BONDERITE® L-CA CP 1002N
Water-based release agent
Wax-free release agent with superior release properties and excellent wetting characteristics at high temperatures
Also referred to as DELTACAST 696, protects ladles from molten metal
Brush
BONDERITE® L-CA CP 786
Hot spot lubricant
Used as a start-up coating and applied to hot spots on the die
Spray or brush
How to Choose the Best HPDC Lubricant
Many factors need to be considered when choosing the right high-pressure die casting lubricant, including the type of metal alloy being cast, operating pressure and temperature, and the desired surface finish. Casting lubricants are formulated for specific applications and process requirements so that the manufacturer can choose a product that best meets their requirements.
How the high-pressure die casting lubricant is applied is also very important and can affect the effectiveness of the lubricant. Automated spray systems are generally the best option as spraying applies a precise and uniform coating on the mold surface between cycles. Spray systems provide consistent lubrication, prevent build-up, and minimize waste.
Contact us to today to speak with a technical representative and find a lubricant that is best for your casting operation.
