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DIE CASTING

© 2017 Quaker Chemical Corporation. All Rights Reserved.

INCREASING PLUNGER TIP AND SHOT SLEEVE LIFE POLY SLICK™ 76-P

THE SOLUTION

Quaker Chemical Corporation (“Quaker”) 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 installed the POLY SLICK™ Bead Dispenser equipment, a custom designed applicator compatible with Quaker’s line of wax bead plunger lubricants. By switching their plunger lubricant to POLY SLICK™ 76-P, the customer achieved the following results:

» 50% Average reduction of plunger tip usage saving $9,000 per month

» 20% Average increase in shot sleeve life resulting in a savings of $8,000 per month

» Improved cleanliness and reduction of oil being released into the sump

Aver

age

Tips

Rep

lace

d/ M

onth

Previous Product0

70

POLY SLICK™ 76-P

50

60

PLUNGER TIP USAGE REDUCTION

30

40

20

10

» 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

CHALLENGESA 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:

» Increased plunger tip and shot sleeve life

» Improved cleanliness

quakerchem.com | 1.800.523.7010

DIE CASTING

© 2017 Quaker Chemical Corporation. All Rights Reserved. 05.17-V001-EN

PROCESS AND EQUIPMENT

Machine 1,800 Tons

Operation High pressure die casting

Parts Engine blocks, transmission and structural components

Material Aluminum 380 & 383

Plunger Tip Material Beryllium copper

Plunger Tip Diameter 4 to 5 Inches

THE PRODUCT

POLY SLICK™ 76-P is a beaded, dry-form plunger lubricant designed as a high performance substitute to oil-based lubricants. This product is formulated with a unique blend of the highest quality waxes and additives for rapid wetting and excellent boundary lubrication, allowing for increased shot velocities and extended tip and sleeve life. POLY SLICK™ 76-P plunger beads create less carbon build-up than traditional oil-based plunger lubricants, resulting in cleaner die cavities and machines, along with less porosity. POLY SLICK™ 76-P contains graphite for enhanced lubrication and thermal resistance to meet the demands of your process. The amount of POLY SLICK™ 76-P applied is dependent on the size of the plunger tip and the weight of the casting produced.

THE EXPERTISE

The Quaker POLY SLICK™ family of plunger lubricants exhibit strong adherence and reduced residue extending your tip and sleeve life and production cycles. The Die Casting product line offers a complete package of value-added fluids including die casting lubricants, quenchents, fire-resistant hydraulic fluids, ladle coatings, trimming lubricants, cleaners and machining fluids. This case illustrates the importance of supplier relationship, support and correct fluid selection. Proper selection and application of the fluid can result in substantial cost benefits. That is why Quaker focuses on developing solutions with the highest performance without compromise, fluids that sharpen your competitive edge.

INCREASING PLUNGER TIP AND SHOT SLEEVE LIFE POLY SLICK™ 76-P