CASE STUDY Die Casting: 70% Increase in Parts Produced DIE SLICK® AD 32 The Challenge
The Benefits
A large Japanese die casting company that produces electric power steering systems for the automotive industry was experiencing problems with their die casting release agent. The competitive product was causing issues clogging the die spray nozzles which caused excessive downtime. The customer turned to Quaker Houghton for a new die release lubricant with the following requirements:
The customer has experienced the following improvements by switching to DIE SLICK® AD 32:
• Eliminate nozzle clogging • Increase productivity • Decrease consumption and save money
the dilution ratio from 1: 80-1: 90 with the • Reduced competitive fluid to 1: 140, saving costs
nozzle clogging, reduced mold and nozzle • Eliminated cleaning time, and further increased production efficiency
number of parts produced per 36 kg of mold • The release agent increased from 24,161 to 41,000, an increase of about 70%
Die Lubricant Spray Volume Reduction per Application
The Solution The Quaker Houghton team worked closely with the customer to better understand their production process and analyze the structure of the casting. Quaker Houghton recommended DIE SLICK® AD 32 as a solution. This product was chosen because it does not contain wax, and has good film-forming performance at high temperatures. The castings produced are bright and clean with great lubrication. By switching to DIE SLICK® AD 32, nozzle clogging has been eliminated, number of parts produced has increased, and consumption has been decreased.
Parts Produced per 36kg of Die Lubricant 45,000
DIE LUBRICANT SPRAY VOLUME (g)
1.6 1.4
41% Reduction
1.2 1 0.8 0.6 0.4 0.2 0
1.49
0.88
Competitive Fluid
DIE SLICK® AD 32
PARTS PRODUCED
40,000 35,000 30,000
70% Increase
25,000 20,000 15,000 10,000 5,000 0
24,161
41,000
Competitive Fluid
DIE SLICK® AD 32
©2020 Quaker Houghton. All rights reserved.
quakerhoughton.com | info@quakerhoughton.com
Creating Sustainable Value
The Product
Quaker Houghton focuses on providing customer solutions that reduce waste, energy, water usage and chemical consumption, while improving operational processes, tool life and the health and safety of workers. We are committed to creating a positive social, environmental and economic impact on our world. By converting to DIE SLICK® AD 32, the customer was able to reduce chemical consumption by increasing the dilution ratio. No more nozzle clogging means less downtime, and the product boosted production by 70% giving them the ability to produce more parts, increasing profits.
DIE SLICK® AD-32 is a high performance synthetic die lubricant formulated for more difficult die casting operations. DIE SLICK® AD-32 incorporates state of the art polymers that enhance its wetting and release capabilities while producing bright and clean castings. Typical operating temperature range is 175°C to 285°C. Process and Equipment Part
Electric power steering systems
Material
Aluminum Alloy
Dilution Ratio Operation
©2020 Quaker Houghton. All rights reserved.
Competitive Product- 1:80 to 1:90 DIE SLICK® AD 32 – 1:140 High Pressure Die Casting
quakerhoughton.com | info@quakerhoughton.com
V001.20.01.EN.GL