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A die casting company producing parts for a variety of industries, including for computers, telecommunications, and automotives, was facing a significant challenge with product quality. Approximately 10% of their casted parts were rejected because of dull appearances, which was unacceptable in the highly competitive industrial manufacturing sector. This issue not only increased production costs but also reduced the company’s efficiency in delivering high-quality die cast products.
The dull finish of the parts was attributed to inconsistencies in the release process, which affected the visual quality of the aluminum parts. Since appearance is often a key indicator of quality in metal casting, the company needed a reliable solution to improve both the appearance and overall production efficiency of their aluminum die cast parts.
Our Solutions
Fluid Solutions’ team of lubrication experts conducted a comprehensive assessment of the company’s die casting process. After evaluating the situation, we recommended switching to Quaker Die Slick 4513, a high-performance synthetic lubricant specifically designed for aluminum die casting. This product features Smart Polymer Technology, which significantly improves the casting process.
Smart Polymer Technology uses a reactive polymer blend that forms a tough barrier on the hot areas of the die while lightly coating cooler, less demanding areas. This ensures reduced soldering, enhanced release properties, and excellent wetting characteristics. As a result, the company could produce brighter and cleaner die cast products, with fewer defects. The improved release properties also reduced the amount of lubricant required during production, further optimizing the process.
Impact
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By switching to Quaker Die Slick 4513, the die casting company achieved several key improvements in their operations:
- Higher-quality castings: The company saw a dramatic improvement in the appearance of their diecast parts, with a reduction in rejected products from 10% to just 3%. The castings were noticeably shinier and brighter, meeting the aesthetic demands of their customers in industries such as automotive and electronics.
- Reduced lubricant consumption: The switch to this synthetic lubricant also led to significant cost savings in terms of lubricant usage. The dilution ratio increased from 1:40 to 1:100, meaning less concentrated die lubricant was needed to prepare the die lube, further reducing operational expenses.
- Improved production efficiency: The reduction in product defects and the decreased need for die lubes allowed the company to streamline their production process, cutting down on waste and reducing overall maintenance requirements.
These results highlight the benefits of using advanced metal forming fluids and synthetic lubricants in high-demand industrial settings like aluminum die casting. By addressing the issue with a tailored lubrication solution, Fluid Solutions enabled the company to increase product quality, reduce costs, and improve overall operational efficiency.
Product Information
Quaker Die Slick 4513 is a synthetic, polymer-containing die lubricant that is specifically planned for industries such as automotive, heavy equipment, electronics, and consumer goods. Its unique Smart Polymer Technology allows die casters to produce cleaner and brighter die cast products by enhancing release properties and reducing solder buildup in die casting operations. Quaker Die Slick 4513 is an ideal solution for companies looking to improve their metal casting processes while minimizing lubricant usage and increasing production efficiency.
Industry Expertise in Lubricant Solutions
Fluid Solutions specializes in lubrication for the aluminum die casting industry and other metalworking applications. Our team thoroughly investigates lubrication challenges and delivers customized solutions that enhance operational efficiency. Whether you need metalworking fluids, synthetic lubricants, or die casting solutions, we provide expertise and high-performance products to optimize your production.
Achieve Brighter, High-Quality Castings with Our Advanced Lubricants
Improve your die cast products while minimizing operational costs with our advanced lubrication solutions. As a leading manufacturer of metalworking fluids, we offer tailored products designed to meet your specific needs: brighter, high-quality castings and improved efficiency.
Reach out to us today at (02) 8370 5928 / (0917) 894 9156 or email inquiry@fluidsolutions.com.ph to get a consultation on how we can enhance your metal casting operations.
