A renowned Japanese manufacturer specialising in high-quality automotive components, including aluminium die-cast products such as engine and transmission parts. Their operations also cover manual transmissions, differentials, and critical suspension parts like knuckle assemblies and hubs.
The Challenge
The customer faced several critical issues related to die temperature imbalance and inadequate lubrication during the die casting process. On the fixed die side, incomplete water evaporation caused by the limited time between spray and metal injection led to poor die lube film formation. This resulted in gas porosity (pinholes) and shrinkage due to improper flow and compaction of the molten alloy. Additionally, temperature distribution was uneven, with the runners on the sides of the die significantly colder than the central runners, worsening the material flow.
On the moving die side, similar issues were observed including uneven solidification. In particular, a localized hot spot was detected, with a peak temperature. Although not extremely high, this was the hottest point on the die and resulted in delayed solidification, increasing the risk of shrinkage defects.
MotulTech's Solution
MotulTech recommended CASTING 650 K, an advanced aqueous emulsion formulated with fully synthetic lubricants, polymers, and specialised additives. Designed specifically for high-pressure die casting of aluminium and magnesium alloys. CASTING 650 K offers superior thermal stability and exceptional film-forming capabilities. Its high-performance formulation ensures consistent and uniform lubrication, even under demanding conditions, improving metal flow, minimizing defects such as porosity and shrinkage, and supporting optimal die temperature control across both fixed and moving die surfaces.
The Outcome
• The total cycle time was reduced by 38%, contributing to significantly higher productivity.
• Water consumption dropped substantially leading to a 52% reduction in annual water costs.
• Despite the higher investments into the new release agent, the customer realized total annual savings of approximately $200,000 USD, driven by improved casting quality, reduced defects, lower operational costs and improved productivity.
