Equipment Solutions
Lubricant Layer Thickness
For an effective lubrication of the die surface a certain coverage with (solid) lubricants is necessary. The lubricant must give full coverage of the surface and also cover the roughness of the surface. A layer of (solid) lubricant has to insure that there will be no direct metal contact during the process step between the (hot) metal and the die. Different approaches are possible with or w/o conversion layers, pigmented or non pigmented. Basically, a layer of 1 to 3 μm of a dense lubricant layer with good adhesion to the surface will do the lubrication or release job for a one time contact.
Thermal Die Management
Casting and forging processes require a proper thermal management and lubrication of the die. After the die is opened and the forged or casted part is removed, the spraying process is started.
There are two different process strategies:
Selective Spraying
Spray cooling and lube application are separated into two steps;
- Cooling with water only,
- Application of lubricant.
Here the highest concentration possible should be selected (depending on media rheology) for the most effective process.
Combined Spraying
A relatively highly diluted lubricant dispersion or emulsion is used for spray cooling and lube application in one spraying step. This kind of process is mainly used in pressure die casting or fast running forging processes. In order to be able to apply the lubricant, the surface temperature has to be lowered to a level which is allowing proper film building. The typical temperature range is 150 to 250 °C; some lubricants are allowing temperatures up to 400 °C .
Perfect castings - best cycle times - power and control - whatever your targets are, our casting line will have the solution for your needs. Standardized or tailor made; our range of linear, robotized or gantry solutions allows us to adapt to almost any requirement. State of the art spraying tools offer perfect atomization, spraying power and of course effective control. Accurate and reliable dosing, mixing and supply systems are standing. for comfortable handling of the process chemicals. Die cooling and lubrication are imperative parts of the overall forging process. PTC Technic develops advanced spray systems for best results in terms of parts quality and production efficiency.
Our company also offers different solutions for foundries, such as Jet Cooling (Coe Cooling System), degassing and dross removal device, Density Index Measurement, piston lubrication systems.