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High pressure die casting continues to be the most efficient and lowest cost, large throughput manufacturing process for casting parts from non-ferrous metals, such as aluminum, magnesium, zinc, copper, brass, and lead alloys.
Quaker Houghton proposed switching to the boron-free CERFA-KLEEN® 5281, a biostable non-nitrited, high pressure spray cleaner with short-term in-plant rust inhibition.
Based on laboratory analysis and thermal imagery results the soldering and build up problems were identified and Quaker Houghton recommended DIE SLICK® 2015, a subset of the DIE SLICK® 2050 A series.
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.
A large automotive diesel engine manufacturer in Indiana was having boron issues with a competitor’s cleaner on their engine blocks. Quaker Houghton proposed switching to the boron-free CERFA-KLEEN® 5281, a biostable non-nitrited, high pressure spray cleaner with short-term in-plant rust inhibition.
HOCUT® 4940 provides superior cutting performance and reduced tool wear enabling the customer to better execute titanium machining with both lower cost of operation and higher productivity.
Competitive die and plunger lubricants were tested on the same machines where the current Quaker Houghton DIE SLICK® 1548 C and POLY SLICK™ 31 plunger beads were being used. This substitution resulted in an increased amount of porosity after x-ray analysis on the castings so the customer immediately halted use of the competitive products.
Since using QUAKERTEK™ AX 2502-EP in their operations, the company has saved over $11,000 per year plus increased service level and laboratory support at their mill.
HOCUT® 795 B is a versatile, heavy duty, chlorine-free, soluble metal removal fluid specially formulated to machine Aerospace grade aluminum alloys.
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.
Quaker Houghton, analyzed the customer’s process and developed PLUNGER SLICK® 202; a premium low viscosity plunger lubricant formulated for high pressure die casting.
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.
The DIE SLICK® 1850 Series is designed for excellent release and a bright cosmetic casting finish. These synthetic, petroleum-free formulations are blended specifically to meet customers’ production environments.
From the start of the trial, QUAKERTEK™ UX 4615-EP did not melt away and remained at the application point on the roll neck. Due to the positive results on the roll neck the grease was also applied to the output tables and swivel.
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QUAKERCOOL® 770 is a high-performance mineral oil free micro-emulsion ideally suited to all operations demanding premium surface finish quality and consistent lubrication.
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.
The DIE SLICK® 2050 Series is designed for excellent release and a bright cosmetic casting finish. These semi-synthetic, wax-free formulations are blended specifically to meet customers’ production environments.
Quaker Houghton worked with maintenance personnel and conducted a trial for the metal spinning operation utilizing approximately 10% HOUGHTO-DRAW® 7060.
One of the most difficult but important jobs in hydraulic fluid maintenance is taking a proper and representative sample. The best way to do this is to always take the sample at the same place in the hydraulic system.
QUAKERCLEAN® 8820 is a foam-inhibited workshop floor cleaner for the removal of oil, grease and pigment soiling from industrial floor coverings in production and storage areas.
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.
Padded reamers are utilized throughout the manufacturing industry to generate the final hole geometry and meet demanding surface finish tolerances. Some examples of padded reamer applications are automatic transmission valve channels, engine valve guides and engine crankbore/cambores.
After 3,000 hours of operation (approximately 6 months) the bearings were checked. The QUAKERTEK™ CS 4602- EP bearing had no obvious damage on the raceway or roller surface, while the current grease had a large flaking zone on the raceway of the outer ring.
Aerospace Components Machining: Reduced Cycle Time and Tooling Costs at UK Ejector Seat Manufacturer
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.
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.
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.
From the increasing demands for specialty cans and improved aesthetics to stringent compliance regulations and environmental concerns to ongoing requirements for sustainability and beverage taste protection, these companies must operate more efficiently and safely than ever.
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 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.
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: superior lubrication properties, reduced fluid maintenance, environmentally friendly.
Quaker Houghton’s distributor proposed CERFA-KLEEN® 300 – a concentrated, non-slip, mildly alkaline, general maintenance and floor cleaner that effectively removes machining fluids, grease, rubber tire marks and more. CERFA-KLEEN® 300 is also NPE-free, which can help with waste water disposal concerns.
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.
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.
Quaker Houghton introduced QUAKERCOOL® 7200 HBFF after performing compatibility tests with different polish pastes, cleaners, electroplating, etc.
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.
This document contains procedure guidelines for the conversion from both water free and water based hydraulic fluids to QUINTOLUBRIC® 888.
Heat treating and quenching are arguably the most critical operations in the manufacture of gears. It is these processes that provide a gear with the proper mechanical and wear properties to withstand high contact stresses and have high longevity.
Due to the complexities of the die casting production process, proper die lubricant selection can be a laborious task.
Quaker Houghton recommended replacing the competitive coolant with QUAKERCOOL® 8013, a heavy duty metalworking fluid which is known for superior foam control. This product has eliminated the customer’s foam issue providing a cleaner work environment and lowering the chance for slips and falls.
Under growing pressure to increase productivity and throughput, reduce environmental impact, aerospace companies are also dealing with new highly engineered materials creating new requirements in manufacturing processes and metalworking fluids.