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When die casting precision metal components, it is important to incorporate a release agent to ensure the part ejects from the die effortlessly and free of defects. At Dynacast, there are many steps we take during the design and production of your metal component to ensure a successful project—mold release being one of them.
The Function of Mold Release in Die Casting
Mold release, die spray, die lubricant—however you wish to call it—is a requirement of the die casting process. A precise amount of mold release is sprayed onto the steel mold before each shot. The liquid evaporates when it comes in contact with the hot steel leaving just the right amount of lubricated coating. If there is too much lubricant, it cannot evaporate fast enough when the molten metal is injected causing porosity. This can also happen if the tool cools too quickly and lubricant builds up on the surface. Vice versa, if there is not enough, the component can stick in the die and cause defects in the part. The more design friendly you are with the allowance of draft; the less mold release you have to use and the more freely molten metal will flow into the die.
To ensure a successful project, include our design engineers early on during the design phase of your component. Our team can help you create a precise component that is successful in mass production. Contact one of our engineers today!
Types of Mold Release Lubricants
There are many different types of mold sprays to choose from depending on the type of material used in casting and its application. Most lubricants are geared towards base materials such as zinc, aluminum, and magnesium. Each lubricant is then broken down by overall function and the complexity of the part.
Water-based lubricants are the most popular sprays used for standard casting because they provide a release agent and work as a cooling medium. If you are going to paint or plate the component, an oil-based mold spray may be used as an alternative. An oil based lubricant provides a necessary release agent but doesn’t provide the same level of cooling which water based does. This difference allows for an increased die surface temperature, which lends itself to high-quality cosmetic finishes and increased production yields where water based lubricants fail.
Mold Release Concerns
When designing a part for die casting, customers typically have two concerns, “Will mold release cause porosity?” And “Is mold release safe for medical and surgical applications?”
Porosity is inherent to the die casting process, so no matter what die casting manufacturer you use, you will have porosity, it is just a matter of how much. Dynacast works to minimize porosity on many levels, starting with the component design. Our engineers and tool makers design proper overflows and venting to minimize porosity. Then they will test, sample, and optimize for the best possible production process to ensure porosity is minimized—this includes the type of mold release we use and how much.
If your part is used within a bio-compatible application and has to get approved by the FDA, there are several steps to take to ensure complete compatibility. For example, an electroless nickel plating can be used to safeguard your component from mold release leaking. Dynacast works with today’s leading medical device and wearables companies to ensure that our mold release sprays can pass the most stringent tests and requirements.
ISO 13485 Certified Die Casting Manufacturer
While an additional step to the die casting process, mold release is required to ensure parts maintain their shape and complexity when discharged from the die cavity. The amount and type of mold release needed is customer and application driven. Contact our team today and speak with one of our highly-trained and experienced engineers to get the conversation started about your next metal component. Involving our engineers early on during the design phase will ensure your part is designed to succeed in mass production.
If you are looking for a partnership to help you apply new tools and technologies, or help you fully realize your design vision, let us help you move your business forward, contact our team today to get the conversation started.