Disadvantages with Water Based Die-Release Agents
Around 50 years ago, water-based die release agents began to replace oil-based products in High Pressure Die Casting due to their advantages in terms of health and working environment.
However, problems in the usage of water-based lubricants are well-known:
- As the water-based product needs temperatures below 250 degrees to adhere, the repeated heating and cooling cycles thermally stress the die leading to cracking and therefore repairs and expensive die replacement
- Typical spray cycles are lengthy, including water cooling, water-based lubricant spray, and drying through compressed air blow
- Water-based products based on wax emulsions have a tendency to deposit in spray nozzles leading to bacterial growth and down-time
- Residual water and cooled dies lead to porosity and soldering problems
- Large spray volumes cause a dirty working environment and high water treatment costs
In short, the casting conditions have been designed around the die lubricant capabilities, rather than the optimum casting process.