Die Casting : 60% Consumption Reduction Die Casting Aluminum

CASE STUDY Die Casting :

60% Consumption Reduction Die Casting Aluminum PLUNGER SLICK® 5210 The Challenge

The Benefits

A large aluminum die caster of automotive, industrial and appliance components needed a new plunger lubricant for their high pressure casting operation. The competitive fluid required a high spray volume making it very costly and the customer wanted to:

PLUNGER SLICK® 5210 was trialed and passed all of the customer’s lubricity requirements. In addition to saving on plunger lubricant cost, the customer benefitted from the following improvements:

• Reduce consumption • Minimize smoke • Decrease costs

• 60% Reduction in usage • Lower smoke emissions • Decrease in residue • Savings on lubricant cost

The Solution

Spray Volume

Quaker Houghton reviewed the customers objectives and developed a new invert emulsion plunger lubricant to meet their needs. Quaker Houghton’s invert emulsion technology consists of water based plunger lubricants with oil; the water burns off leaving only the amount of oil needed for optimum lubrication.

5 4.5 4

CC Per Cycle

3.5

60% Decrease

3 2.5 2 1.5 1 0.5 0

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Competitive Product

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PLUNGER SLICK® 5210

Competitive plunger lubricant 4cc application – Some excessive material

PLUNGER SLICK® 5210 2cc application – Optimum lubrication

Process and Equipment

Creating Sustainable Value

Part(s)

Custom Al parts

Material

Aluminum

Machine

800-1800 Ton

Plunger Dosage

4” Beryllium copper tip and 4.5” Steel ring tips Competitor: 4-5 cc per cycle PLUNGER SLICK® 5210: 2 cc per cycle

Application

Spray for 1.5 seconds during retract

Orifice

8 mm diameter orifice through the rod

Pressure

90 PSI

The Product PLUNGER SLICK® 5210 is an invert emulsion plunger lubricant designed for aluminum die casting operations.

Quaker Houghton’s invert emulsion technology consists of water based plunger lubricants with oil; the water burns off leaving only the amount of oil needed for optimum lubrication. This product is formulated to combine the benefits of a water-based lubricant with the superior lubrication of an oil-based lubricant. Engineered chemistries provide excellent boundary protection for plunger tips and shot sleeves.

©2020 Quaker Houghton. All rights reserved.

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.

Quaker Houghton was able to reduce the customers usage by 60% through a decrease from an average of 4.5 cc/cycle with the competitive product to 2 cc/cycle using PLUNGER SLICK® 5210. This reduces the cost per part produced and saves the customer money on waste treatment costs. PLUNGER SLICK® 5210 showed a drastic decrease in residue on the part and machine, decreasing the customer’s fire risk and downtime for cleaning maintenance.

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. The talc containing competitive fluid had the Health Hazard GHS warning, switching to PLUNGER SLICK® 5210 helped to decrease the customer’s smoke emissions and improve operator acceptance. PLUNGER SLICK® 5210 is also available in totes, eliminating the need to dispose of drums which was necessary using the competitive product. The customer also experienced a 60% consumption reduction lowering chemical and water usage.

quakerhoughton.com | info@quakerhoughton.com

V001.19.03.EN.GL