CASE STUDY Die Casting :
Increasing Plunger Tip and Shot Sleeve Life POLY SLICK™ 76-P The Challenge
The Benefits
A global supplier of complex aluminum powertrain parts to the automotive industry was experiencing issues associated with their plunger lubricant. The customer encountered premature wear on their plunger tips resulting in frequent replacement which also negatively impacted production time. Also, the previous mineral oil based fluid was messy and created a slipping hazard when operators were conducting maintenance. The customer was specifically looking for the following solutions:
By switching their plunger lubricant to POLY SLICK™ 76-P, the customer achieved the following results:
• Increased plunger tip and shot sleeve life • Improved cleanliness
average reduction of plunger tip usage saving • 50% $9,000 per month
average increase in shot sleeve life resulting in a • 20% savings of $8,000 per month cleanliness and reduction of oil being re• Improved leased into the sump Plunger Tip Usage Reduction
The Solution Quaker Houghton reviewed the customers issues and recommended they switch to a dry-form wax plunger bead lubricant, POLY SLICK™ 76-P. This solution was chosen because plunger beads create less carbon build-up than traditional oil-based plunger lubricants, resulting in cleaner die cavities and machines. Also, POLY SLICK™ 76-P was formulated as a high performance substitute to oil-based lubricants, demonstrates strong adherence to the plunger tip, extends tip and sleeve life with excellent boundary lubrication, and reduces cycle times. To offer precise feeding of the plunger beads, Quaker Houghton installed the POLY SLICK™ Bead Dispenser equipment, a custom designed applicator compatible with Quaker Houghton’s line of wax bead plunger lubricants.
PLUNGER TIP USAGE WAS REDUCED BY 50% From 60 replacement tips per month to 30 replacements using POLY SLICK™ 76-P.
Custom designed POLY SLICK™ Bead Dispenser equipment and POLY SLICK™ Plunger Beads
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