Do you think we do not want to use any die lubricant

Transcription

1 Water Free F Die C Casting T Technology h y

2 Do you think we do not want to use any die lubricant Why do we spray such a lot? I hate greasy and wet and slippery floor Too much maintenance We are wasting die lube Clothes always get so dirty Shall we look for something new? Open

3 Let us change from unnecessary to necessary We want to further decrease the die lubricant We do not want to waste any die lube We want to spray behind the slide core properly We want to spray easily We do not want soldering due to die lubricant Let us create something new the door

4 Water Free Releasing agent WFR Series An effective film is formed under high die temperatures WFR can effectively form a thick film by suppressing the influence of Leidenfrost phenomenon compared with water based lubricant even over 3 C (572 F) die temperature. Water based die lubricant (Dilution ratio 8:1). sec.5 sec.1 sec.3 sec.6 sec.16 sec Water Free Releasing agent Test Condition: 35 (662 F),.5ml droplet Effective and efficient adhesion makes a small amount spray possible. Even with 1/3 less spray amount, WFR adhered 5 times more than water based die lubricant. Spray time and adhesion amount Adhesion 2 amount (mg) Film thickness data with Laser Scanning Microscope A-21 / 1ml X 1time A-21 / 1ml X 3times /.3ml X 1time /.3ml X 1time 15 A-21 1ml Less than 1µm (immeasurable level) 1 Plate temperature 5 (.3ml) Plate temperature( C) Less than 1µm (immeasurable level) Less than 1µm (immeasurable level) Average film thickness : 2.9µm Average film thickness : 2.8µm Average film thickness : 2.3µm To make an equal active ingredients amount between water based die lubricant and, Water based die lube / 1:8 dilution ratio, Spray quantity 1 ml, WFR / Concentrated, Spray quantity.3 ml Even with small amount WFR provides a very low frictional resistance force. Only a small amount of spray with excellent adhesion is needed for good die release. Too much spray and adhesion has a negative effect on costs and product quality. Frictional 14 resistance force (kgf) 12 Adhesion amount and Frictional resistance force Test Condition: 25 C (482 F) Area with soldering Adhesion amount (mg)

5 High performance, environmentally-friendly, quality improvement, cost reduction We would like to provide solutions to various problems which are related with die lubricant. Even a small spray amount gives an excellent anti-soldering performance. WFR has an excellent adhesion performance and low frictional resistance force, therefore it can preserve higher lubricity and releasing ability over 3 C (572 F) range, and prevent soldering problems. Die temperature and Frictional resistance force 14 Frictional resistance force (kgf) 12 Area with soldering 1 A-21 (Dilution ratio 8:1)/1ml 8 6 /.3ml Plate temperature( C) Less thermal shock gives extended die life WFR does not have any cooling capability and the die surface temperature is not cooled, therefore it prevents heat cracks and extends die life. Die dimension variation ( 1-6) Temp ( C) Die temperature changes after die lubricant spray Spray start /4ml Spray finish Sec Picture of heat crack /4ml Water based die lubricant (4ml) -3 Water based die lubricant (4ml) Die dimension variation after die lubricant spray Sec Not only the releasing performance but also safety is pursued. We simulated the possible causes of fire with die lubricants in a die casting factory, and proved that WFR has a very low fire risk. Hydraulic fluid VG46 Water Free Releasing agent

6 WFR + Electrostatic spray provides a revolutionary step in die casting WFR for Electrostatic spray application WFR-EC Series What is Electrostatic spray? What is WFR for electrostatic spray? Spray particle Existing WFR WFR-EC Series Base oil Active ingredients Auxiliary agent for electrostatic Negatively charged die lubricant adheres to the grounded die Normally it is not possible to use electrostatic application with oil based die lubricant as the oil is an insulator. However, WFR contains the auxiliary agent for electrostatic spray. This enables electrostatic spray and creates a new possibility for die lubricant spray application. Fine spray mist adheres to the die through invisible electrostatic power. Effects of Electrostatic spray application for Die casting With ordinary air spray gun With Electrostatic spray gun Need to spray from many different angles to adhere properly. With electrostatic, can adhere to a wide area from a single spray direction Without Electrostatic Front Side Behind With Electrostatic Die lubricant adhesion efficiency to dies Adhesion efficiency increases with electrostatic spray application, therefore A-21 + Air spray gun 3% Minimum number of spray nozzle Simple spray setting Easy maintenance WFR + Air spray gun 33% WFR-3EC + electrostatic spray gun 78% Adhesion efficiency (%) There are various benefits for using electrostatic application with WFR.

7 The 4 th generation new die lubricant NPL Series Our concept is a no-soldering, less gas-producing die lubricant WFR series high adhesion efficiency can now be combined into a product incorporating inorganic powder Uniform film thickness and heat insulating effect WFR forms a consistent smooth film regardless of die surface roughness. Die Temperature fluctuates from point to point. NPL-H1 NPL forms a film despite die roughness and unevenness, creates a consistent film. Die temperature fluctuation is smaller. Heat insulating and retaining properties Frictional resistance force (kgf) Die temperature and Frictional resistance force Area with soldering NPL-H1 Plate temperature( C) Inorganic powdered NPL series shows low frictional resistance force under high die temperature, and improves soldering problems. Temp ( C) Die temperature rises after pouring molten aluminum Spray volume :.3ml Molten Aluminum temperature : 67 C (1238 F) Molten aluminum volume : 9 ml NPL-H1 Elapsed time (sec.) The heat transmission from molten aluminum to the die is delayed with inorganic powder. Smooth casting surface WFR-5AP NPL-H1 NPL series containing inorganic powder gives an excellent surface finish compared with ordinary die lubricants due to heat insulation and less gas formation. To utilize the old and historical die coating technology and WFR technology for high pressure die casting process. It is suitable for squeeze casting and Magnesium or Zinc casting which need better metal flow.

8 Product line-up WFR Water Free Die Casting Technology Model No. Maximum die temperature Die temperature Applicable die temperature Features Water Free Releasing agent WFR-5AP 43 C 2 35 C WFRseries High die temperature type (over 38 C (716 F) range), excellent high temperature adhesion and lubricity performance and suitable for thick wall and pressure proof castings. WFR-53S WFR-33W WFR-33 WFR- WFR-3 WFR-M5 WFR-M3 4 C C 38 C 15 3 C 33 C C 3 C C 28 C C 25 C 11 2 C 3 C C 22 C 1 18 C Low density type of WFR-5AP, to reduce the adhesion overage for controlling oil marks and flow lines. Standard type of WFR series, well balanced formulation to cover from low temperature to high temperature, and good for thin to complex casting parts. Improved adhesion efficiency of WFR-33, suitable for small, precision part and casings etc. Low density type of, well balanced formulation to cover from low temperature to high temperature, and suitable for small and precision parts and casings etc. Non-Silicon type of, high lubricity and good for big and thick wall castings which require excellent paintability and concern the electromagnetic shield. Low density type of WFR-. Suitable for low die temperature and good for small precision zinc or magnesium parts as computer parts or electrical components etc. High performance WFR for magnesium casting, better metal flow and high releasing performance for big magnesium parts. Low density type, developed and designed for small and thin Magnesium parts with excellent surface finish. WFR for Electrostatic spray application WFR-ECseries WFR-5EC 43 C 2 35 C Electrostatic spray application spec. of WFR-5AP WFR-53EC 4 C C Electrostatic spray application spec. of WFR-53S WFR-3EC 38 C 15 3 C Electrostatic spray application spec. of WFR-33EC 3 C C Electrostatic spray application spec. of WFR-33 WFR-EC 28 C C Electrostatic spray application spec. of WFR- The 4 th generation new die lubricant NPLseries NPL-H1 NPL-G15 45 C 1 C 45 C 1 C Contained inorganic powder and has an excellent performance of heat insulating and retaining properties Repairing agent of water based coating film for Gravity and Low pressure casting. Excellent high temperature adhesion and can apply in operation. For warm-up purpose Start-up liquids series WFR-LR Room temperature Special start-up liquid for WFR series. Excellent adhesion and form a strong film under low temperature and reducing number of warm-up shots. NPL-AERO 11 C Inorganic powder contains aerosol for repairing die coating film. Anti-soldering and improve metal flow purposes for high pressure die casting. NPL-ZERO Room temperature 1 C Inorganic powder contains start up aerosol Aoki Science Institute Co., Ltd. Main office: Roppongi Hills Mori Tower 18F, Roppongi, Minato-ku Tokyo , Japan TEL FAX URL Branch office: 34-1 Soraike, Wakabayashinishimachi, Toyota-city Aichi , Japan TEL FAX