The Quaker Houghton team worked closely with the customer to better understand their production process and analyze the structure of the casting. Quaker Houghton recommended DIE SLICK® AD 32 as a solution. This product was chosen because it does not contain wax, and has good film-forming performance at high tempera¬tures.
Quaker Houghton recommended POLY SLICK™ 76-P 1.0 – 1.5 mm plunger beads. This solution was chosen because plunger beads create less carbon build-up than traditional plunger lubricants, resulting in cleaner working environments. Also, POLY SLICK™ 76-P demonstrates strong adherence to the plunger tip, extends tip and sleeve life with excellent boundary lubrication, and reduces cycle times.
First, Quaker Houghton helped the manufacturer to understand the advantages of changing from water glycol (HFC) fluids to polyol ester (HFD-U) fluids. These advantages include
Quaker Houghton’s QUINTOLUBRIC® polyol ester HFD-U fluids are fire-resistant hydraulic fluids that do not contain water. HFD fluids are usually based on synthetic base stocks or esters that combine reasonable to good fire-resistant properties with excellent lubrication performance. HFD fluids are designed to operate in oil hydraulic equipment.
One automotive parts supplier decided to take the necessary actions to stop these events from happening, and engaged different departments within their organization to look for a solution.
Quaker Houghton reviewed the customers objectives and developed a new invert emulsion plunger lubricant to meet their needs. Quaker Houghton’s invert emulsion technology consists of water based plunger lubricants with oil; the water burns off leaving only the amount of oil needed for optimum lubrication.
Quaker Houghton met with management at one of the supplier’s major automotive casting facilities, and secured a production trial. The objectives were to reduce downtime from polishing and overall produc¬tion cost. Initially, the Quaker Houghton team worked closely with the process control department to better understand their casting production utilizing thermal imagery on die surfaces.
Quaker Houghton collaborated with not only the customer, but with the paint supplier, paint vendor, and die manufacturer to get to the root cause. An on-site audit of the existing die caster, powder painting process and materials was conducted. Sample cast¬ings were sent to an alternative powder paint source to test for similar results but the alternative powder painted parts had the same out-gassing results as the original parts.
Trials were initially set up for three products: a local boron amine technology coolant, a leading aerospace competitor coolant and HOCUT® 3450. The latter two products were both high ester EP type products with a very high level of lubricity. A total of 6 milling tools were monitored for tool change frequency during the period of the trial.
After a plant survey of machine tools, processes, materials and water conditions, HOCUT® 795 B was proposed supported by independent performance data on similar operations from other aerospace components manufacturers.
HOCUT® 795 B was proposed for machining trials supported by independent performance data on similar operations from other aerospace component manufacturers. HOCUT® 795 B has consistently shown itself to be the best in class coolant for aerospace alloys.
Quaker Houghton proposed HOCUT® 795 B, dedicated to Aerospace parts machining and well established for its long sump life and good stability. The customer began a trial with HOCUT® 795 B on a Mega 5 (MAG) milling tool machine. After 2 years HOCUT® 795 B was still in use, and there has been no sump clean-out and no anti-foam nor bactericide addition.
Quaker Houghton introduced QUAKERDRAW® 73 XP in one drawing line. After seven months the manufacturer experienced improved lubrication, resulting in
Verkol Lubricants, a Quaker Houghton Company, assessed the mill’s situation, and introduced QUAKERTEK™ LX 4602- EPE, a lithium complex grease, reducing bearing failures to 5-6 a year. After 8 years of using QUAKERTEK™ LX 4602-EPE, the mill wanted to run a trial with the main purpose of optimizing grease consumption without causing wear problems, and also to
The mill was currently using a competitor’s Lithium based grease, and Quaker Houghton suggested converting to QUAKERTEK™ CS 4015-EP, a Calcium Sulfonate Complex grease for the trial. The initial fill of the QUAKERTEK™ CS 4015-EP was reduced 15% compared to the lithium based grease.
Quaker Houghton reviewed the operations at the lumber producer and recommended BIOSAFE CON 46/68 W, a high-performance conveyor oil, based on the following
Quaker Houghton’s team of experts in the product development laboratory performed extensive studies in the development of QUAKERAL® 350, a GEN III, secondary amine free product for the customer. QUAKERAL® 350 met all of the customer’s requirements and their 6 systems were converted to the coolant. Quaker Houghton was able to decrease system usage and eliminate downtime. In the past, the filters would rapidly fail due to high microbiological activity in several of the systems. Partial dumps would be required to get these departments running again. No additives have been required to maintain the systems and the customer has been very happy with the cost and process improvements.
QUAKERCUT® 020 XP is a high performance neat cutting oil based on advanced ester technology from renewable raw materials. It is particularly suited for heavy-duty metalworking operations in ferrous and non ferrous materials. The high polarity gives optimal wetting and lubricating properties ensuring high surface finish quality and improved tool life. Part of the QUAKERCUT® XP series, QUAKERCUT® 020 XP has a proven track record of bringing operational, Health & Safety and environmental benefits to a broad range of customers in the automotive and mechanical industries.
Quaker Houghton ran a trial with selected QUAKERTEK™ CS 2202-EP calcium sulfonate grease to lubricate 12 bearings (22215/22218/32215/32218 +gear) per stand. The grease achieved the desired targets by decreas¬ing maintenance time and relubrication rate as well as allowing for increased water resistance.
Binol, a Quaker Houghton Company, introduced QUAKERCUT® 010 XP, an extra high performance neat cutting and grinding oil to replace the mineral oil in the systems.
Binol, a Quaker Houghton Company, analyzed the customer’s challenges and introduced QUAKERCUT® 010 XP, an extra high performance neat cutting and grinding oil.
Binol, a Quaker Houghton Company, analyzed the customer’s challenges and introduced QUAKERCUT® 005 XP, a low viscosity neat cutting and grinding oil to replace the water-based coolants.
Quaker Houghton reviewed the customers concerns and recommended QUAKERCUT® 005 XP, a low viscosity, high performance neat cutting oil. QUAKERCUT® 005 XP was chosen as a solution to reduce the customer’s environmental footprint due to its advanced ester technology from renewable raw materials, biodegradability, high flashpoint for lower fire risk, and no labelling according to the new CLP regulation (Classification, Labelling and Packaging of chemicals).
Based on regular visits and technical support together with a local distributor, Quaker Houghton was able to analyze challenges the customer faced and presented QUAKERCOOL® 7360 BFF. QUAKERCOOL® 7360 BFF at 8% concentration was introduced into two CNC machines, one machining stainless steel, and the other machining pure copper. Tool life, surface finish, and top-ups (kept at 2%) were closely monitored over a three month period. During the trial period, no operating issues were noticed and the pH stayed very stable at 9.20-9.30.
Based on regular visits and technical support together with a local distributor, Quaker Houghton analyzed the customer’s challenges and introduced QUAKERCOOL® 7350. The competitive product, a modern low TBN, high-pH coolant, had been running at a concentration of 8% with a 3% top-up. After 1 week using QUAKERCOOL® 7350, there was no smell, good lubrication performance was noted by the customer, and no top up was made.
QUAKERCOOL® 7350 BFF is a high performance micro-emulsion ideally suited to all operations where high surface finish quality and high lubrication is needed. QUAKERCOOL® 7350 BFF is ideal for general purpose machining of most engineering materials and is recommended for light to medium metalworking operations on cast iron, steel and aluminum.
After considering the demanding nature of the various operations and materials involved in the customer’s process, Quaker Houghton presented QUAKERCOOL® 7350 BFF as a solution. This product was chosen based on the following benefits
This Case Study and the solutions gained were achieved through cooperation with L.E.S., a Quaker Houghton distributor in France. Quaker Houghton introduced QUAKERCOOL® 3608 HFF into 25% of the machines, and L.E.S. made regular visits to provide technical support, fluid maintenance and concentration monitoring.
Quaker Houghton recommended replacing the competitive coolant with QUAKERCOOL® 8013, a heavy duty metalworking fluid which is known for superior foam control.
Quaker Houghton recommended QUAKERCOOL® 5035 HPT because the customer required a boron free fluid that would machine both aluminum and steel at speeds of up to 300 feet per minute. QUAKERCOOL® 5035 HPT is a high performance, ultra-stable semi-synthetic metalworking coolant designed for medium to heavy duty applications. This recyclable product is also free of chlorine, formalde¬hyde, and nitrites which is beneficial for HSE compliance, improved labeling and operator acceptance.
Quaker Houghton reviewed the issues the customer was facing and recommended QUAKERCOOL® 7450. This high-performance microemulsion was chosen because of its versatility to machine both ferrous and non-ferrous metals, is non-foaming, and has superior biostability. The machining capabilities of this product have been proven extensively in Quaker Houghton’s CNC machining center and endorsed by customers who are benefitting from this field proven technology.
BINOL BAND 20 is a safe and environmentally acceptable, non-emulsifying cleaning oil manufactured from rapeseed oil based synthetic esters designed for cleaning and lubricating applications of band saws, circular saws and molding equipment in sawmills. The product has been tested against different elastomers and paints used by the leading manufacturers.
Considering Quaker Houghton’s excellent service provided at this steel producer’s site and integrated product offerings, a trial opportunity for PRIMECOAT™ Z 838-4, a trivalent chromium passivate, resulted.
Based on the reliability issues experienced with the incumbent fluid, Quaker Houghton recommended a comparative ASTM D7043 pump wear test be conducted. Based on the results of the test data and system survey an evaluation of HOUGHTO-SAFE® 419-R was conducted.
To meet the challenges, Quaker Houghton developed QUAKEROL® DR 20, a customized semi-synthetic rolling oil based on the trial goals. Quaker Houghton utilized its global R&D network and corroborated with the customer management in an effort to meet the performance requirements needed for the product.
Due to Quaker Houghton’s relationship with the steel mill - providing other products and continuous technical assistance, the mill requested a replacement for the current grease.
For the trial, some tapered roller bearings were lubricated with the current grease, including the roll necks, and some bearings were lubricated with QUAKERTEK™ CS 4602-EP, including the roll necks.
The company they chose was Quaker Houghton due confidence in Quaker Houghton’s product, people and performance. The mill decided to replace the incumbent grease product in all their hot rolling applications with QUAKERTEK™ AX 2502-EP.
To help improve operations, QUINTOLUBRIC® 888-46 was introduced as a potential replacement. First, Quaker Houghton helped the account to understand the advantages of changing from water glycol (HFC) fluids to QUINTOLUBRIC® 888-46 (polyol ester based HFD-U). These advantages include
QUINTOLUBRIC® 888 is a synthetic fluid that can be used in equipment designed for traditional mineral oil fluids and provides better performance than fluids containing water. In addition to fire resistance, the product provides excel¬lent biodegradability and low aquatic toxicity, making it ideal for use where better environment protection is required. It is approved by FM Global as a less hazardous hydraulic fluid.
Quaker Houghton visited the most critical plant located in Czech Republic which was never visited by the competitor. As a result of the visit, Quaker Houghton introduced QUAKERCOOL® 7200 HBFF after performing compatibility tests with different polish pastes, cleaners, electroplating, etc.
Quaker Houghton 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.
Quaker Houghton, analyzed the customer’s process and developed PLUNGER SLICK®202; a premium low viscosity plunger lubricant formulated for high pressure die casting. Due to the increased thermal stability of PLUNGER SLICK®202, Quaker Houghton was able to provide several benefits to the customer and obtained unanimous approval by all departments including oper¬ations, engineering, purchasing, and safety, health and environmental.
The Quaker Houghton team developed a new “talc-based technology” tip lubricant. The team made adjustments with viscosity- base oils and water vs. oil lubrication and developed the new PLUNGER SLICK® 200T oil based plunger lube.
Quaker Houghton analyzed the customer’s process and recommended switching their plunger lubricant to PLUNGER SLICK® 130, a product formulated for superior performance and excellent boundary lubrication. PLUNGER SLICK® 130 incorporates the highest quality base stock to ensure consistent performance at high temperatures; this increased thermal stability allows for minimized potential decomposition products that contribute to process defects, such as porosity.
Quaker Houghton analyzed the customer’s challenges to determine the ideal casting conditions and introduced DIE SLICK®4510SYN. During the trial, the customer was very pleased with the casting quality and is now expanding its use at a second plant.
The customer is an automotive Tier II supplier of axles and transmissions in Mexico. Salty residue was occurring with the heat treatment washers due to the cleaner being used. The tank needed to be changed after four weeks and the parts needed to be double-washed to remove the residue, often manually
Quaker Houghton selected the water based coating, QUAKERCOAT® 856 GREEN for evaluation. The formula was customized to match the color tone, appearance, and flexibility; and to work with the limitations of the existing equipment. Additionally, the product properties were modified to be able to comply with downstream process requirements including the forming press.
To meet the specific needs of the tube manufacturer, Quaker Houghton developed QUAKERCOAT® 031 LE UV, a high gloss, UV cured protective coating. The formulation was targeted to work with the limitation of the company’s low energy curing lamps as well as having high flexibility for subsequent bending operations. In addition, a proprietary additive enhanced how the coat¬ing flowed on a galvanized substrate while maintaining the desired flexibility and low cure attributes.
To help reduce the dust generated Quaker Houghton recommended the surface copper mine add, DUSTGRIP® SUPER TAC, a dust suppressant that binds the road together while also penetrating the surface to maintain subsoil moisture content, to their operation. The customer trialed DUSTGRIP® SUPER TAC on their haul roads at a 25% concentration at ½ gallon per square yard.
To mitigate the risks of using a mineral oil based hydraulic fluid a large underground coal mine in southern West Virginia was using QUINTOLUBRIC® 888-68 an MSHA approved fire-resistant hydraulic fluid in their hydraulic systems.
To help mitigate the effects of the local water supply Quaker Houghton recommended the mine convert to QUINTOLUBRIC® 818-02, a full synthetic longwall fluid that can withstand the spikes in water hardness. Additionally, Quaker installed a new mixing station to filter the sediment from the water more effectively, and provide tighter controls on the longwall fluid concentration.
HOUGHTO-DRAW® 7060, a non-chlorinated, non-sulphur¬ized biostable soluble oil type metal forming lubricant, was recommended. Quaker Houghton worked with maintenance personnel and conducted a trial for the metal spinning operation utilizing approximately 10% HOUGHTO-DRAW® 7060. After a successful trial, the metal spinning company has now converted their central system to HOUGHTO-DRAW® 7060.
The company needed to make improvements in their machining oper¬ations. They were losing an average of one hour of productivity for each roughing cycle (4 hours lost machining time/ 24 hours). There were also issues with corrosion on machine tool beds with seals and coatings breaking down.
QUAKERCOOL® 770 is a high-performance mineral oil free micro-emulsion ideally suited to all operations demanding premium surface finish quality and consistent lubrication. Best suited for the machining of ferrous metals including stainless steels and other high-nickel, high-chromium ferrous alloys.
The formulations in this series incorporates Smart Polymer technology and high molecular weight alkane cross-linking agents. Uneven protection caused by temperature variation on a die surface is a long-stand¬ing challenge in the die casting industry. Temperature variation is caused by the wide-range of die size, design, complexity, parts produced, and heat profile of each system. Traditional die lubricants
The formulations in this series incorporate Smart Polymer technology and high molecular weight alkane cross-linking agents. Uneven protection caused by temperature variation on a die surface is a long-stand¬ing challenge in the die casting industry. Temperature variation is caused by the wide-range of die size, design, complexity, parts produced, and heat profile of each system. Traditional die lubricants
The formulations in this series incorporate Smart Polymer technology and high molecular weight alkane cross-linking agents. Uneven protection caused by temperature variation on a die surface is a long-stand¬ing challenge in the die casting industry. Temperature variation is caused by the wide-range of die size, design, complexity, parts produced, and heat profile of each system. Traditional die lubricants
The formulations in this series incorporates Smart Polymer technology and high molecular weight alkane cross-linking agents. Uneven protection caused by temperature variation on a die surface is a long-stand¬ing challenge in the die casting industry.
As specialists in die casting lubrication, our team of experts work closely with clients to evaluate and enhance production processes, preparing them for the future. Composition and consistency of lubricants, temperature, automation, safety, waste treatment requirements and numerous other variables are considered by our specialists, then analyzed in our testing laboratories. Stringent quality measures are an integral part of our procedures and our advanced research facilities enhance our ability to perform analytical testing.
The QUAKERCAST™ 85 and D-925 series of casting fluids are products enabling higher casting speeds, lower fluids consumption, and cleaner molds as compared to traditional products. Developed with the most advanced technology for continuous casting applications, these products are formulated with a special blend of highly refined esters, base oils, and additives contributing to their excellent performance properties.
Our dedicated steel specialists, working closely with our R&D chemists, partner with your team to develop customized solutions based on extensive knowledge of your unique operating environment and business goals. We provide on-site expertise that maximizes quality, performance and safety.
Our highly experienced aluminum experts will work closely with your team to solve complex manufacturing challenges. In an increasingly competitive, cost-conscious industry, we are the partner you can trust to prepare you for the future based on extensive knowledge of your unique operating environment and business goals. We provide on-site expertise that maximizes quality, performance and safety.
The need for dust suppressants in the mining industry continues to increase due to health, safety, and regulatory reasons. Whether on a surface or underground mine, dust and other particulates are a constant safety concern for those working in the mining industry. These hazards can cause a wide range issues including respiratory illnesses, exposure to noxious gases, and operational risks.
Our mining experts work closely with our R&D chemists to bring unique solutions to your operation. We are the partner you can trust to provide extensive knowledge of your unique operating environment and business goals. We offer on-site expertise to maximize efficiency, durability, and safety.
Excellent resistance to water washout, high load carrying capacity,high temperature stability and very good corrosion protection
Our highly experienced can industry experts will work closely with your team to solve complex manufacturing challenges through the entire can production process. We are the partner you can trust to prepare you for the future based on extensive knowledge of your unique operating environment and business goals. We provide on-site and global technical support, customized solutions, a stable and dependable supply chain and a network of experienced resources in can manufacturing.
Our team of industry and technology experts work closely with your team to solve complex manufacturing challenges. In an increasingly competitive industry, we are the partner you can trust to prepare you for the future based on extensive knowledge of your unique operating environment and goals. We provide on-site expertise that maximizes quality, performance and safety.
As the name implies, the padded reamer differs from a fluted reamer in that the padded reamer has a cutting surface and guide pads that ride on the diameter of the hole to put pressure on the cutting surface which generates the hole size and geometry. The guide pads also act as a burnishing tool to help provide a smooth surface finish. Since the pad forces are “riding” on the inside surface of the hole, significant lubrication is necessary in padded reamer operations to eliminate scratches on the hole surface and maintain the required surface finish.
High pressure die casting is a process of forcing molten alloy at high pressure into a die. Common alloys are alumi¬num, zinc and magnesium. The dies can be very complex and the variation of parts produced is extensive. Due to the wide variation in die design, size and complexity, the flow of alloy through the die and the thermodynamic profile of each system is unique. This leads to tempera¬ture variation, hot areas and cold areas on the die sur¬face. Two of the major roles of a die casting lubricant are, protect the die from the molten alloy and provide release of the casting. Therefore the need for a lubricant to be effective in a broad temperature range is preferred.
A key contributor to shortened die life is thermal fatigue. In high pressure die casting, production cycle times typically range from a few seconds to just over a minute. Within this span, the die cavity is being sprayed with die lubricant (the lubricant may be cold, cool, or hot, depending on the environment), then the die is sprayed with compressed air, closed, and finally injected with very hot molten alloy. Throughout this production cycle, the temperature of the die steel sharply rises and falls. As a die is continually cycled, the yield strength of the tool steel is reduced, which causes tensile stresses that lead to cracking of the tool.
TAN merely measures the corrosive acids present in the fluid, and will increase over time as an indication of the deterioration of the fluid. However, different lubricant technologies such as mineral oil-based or polyol-ester-based hydraulic fluids and different additive technologies result in different TAN values
This document contains procedure guidelines for the conversion from both water free and water based hydraulic fluids to QUINTOLUBRIC® 888. The final procedure can change depending on local circumstances, and it is recommended to consult your local Sales Representative prior to starting the conversion.
Monitoring through in-service oil analysis, an important element of predictive maintenance, can provide informa-tion about machine wear, as well as lubricant contamina¬tion and condition.
For properties like acidity, viscosity and moisture it generally doesn’t matter where the sample is taken. However, when it comes to determining the cleanliness of a hydraulic fluid, it makes a big difference at what location the sample is taken.
The resistance to ignition and burning, termed fire-resistance in the hydraulic fluids field, is measured using a variety of methods. The techniques developed include laboratory testing methods, as well as simulations for possible industrial crisis situations.
Since die casting production trials typically require significant equipment and resources, and involve time investments and casting loss, Quaker Houghton has established a 4-part laboratory test method for chemical testing to evaluate die lubricants and generate product recommendations.
Since die casting production trials typically require significant equipment and resources, and involve time investments and casting loss, Quaker Houghton has established a 4-part laboratory test method for chemical testing to evaluate die lubricants and generate product recommendations.
