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Lubricants uesd in Die Casting process
Lubricants uesd in Die Casting process
Lubricants
Water-based lubricants, called emulsions, are the most commonly used type of lubricant, because of health, environmental, and safety reasons. Unlike solvent-based lubricants, if water is properly treated to remove all minerals from it, it will not leave any by-product in the dies. If the water is not properly treated, then the minerals can cause surface defects and discontinuities. There are four types of water-based lubricants: oil in water, water in oil, semi-synthetic, and synthetic. Oil in water is the best, because when the lubricant is applied, the water cools the die surface by evaporating while depositing the oil, which helps release the shot. A common mixture for this type of lubricants is thirty parts water to one part oil, however in extreme cases a ratio of 100:1 is used.

Oils that are used include heavy residual oil (HRO), animal fats, vegetable fats, and synthetic fats. HROs are gelatinous at room temperature, but at the high temperatures found in die casting, they form a thin film. Other substances are added to control the emulsions viscosity and thermal properties; these include graphite, aluminium, and mica. Other chemical additives are used to inhibit rusting and oxidation. Emulsifiers are added to water-based lubricants, so that oil based additives can be mixed into the water; these include soap, alcohol esters, and ethylene oxides.
Historically, solvent-based lubricants, such as diesel fuel and kerosene, were commonly used. These were good at releasing the part from the dies, but a small explosion occurred during each shot, which led to a build-up of carbon on the mold cavity walls. However, they were easier to apply evenly than water-based lubricants.
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