Ester-Based Lubricant and Anti-Leidenfrost Additive Solutions on Aluminum High-Pressure Die-Casting Applications
The high-pressure die-casting process is growing since it is a cost-effective solution in the production of lightweight parts for a variety of industries. Nevertheless, the harsh working conditions of the die lead to premature failing and poor quality of the produced parts. Lubricants are applied to...
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MDPI AG
2025-01-01
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| Series: | Lubricants |
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| Online Access: | https://www.mdpi.com/2075-4442/13/1/32 |
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| author | Nuria Cuadrado Eduard Vidales Manel da Silva Wadi Wajana Leandre Muntada Angel Navarro Lluis Beltran Montserrat Vilaseca |
| author_facet | Nuria Cuadrado Eduard Vidales Manel da Silva Wadi Wajana Leandre Muntada Angel Navarro Lluis Beltran Montserrat Vilaseca |
| author_sort | Nuria Cuadrado |
| collection | DOAJ |
| description | The high-pressure die-casting process is growing since it is a cost-effective solution in the production of lightweight parts for a variety of industries. Nevertheless, the harsh working conditions of the die lead to premature failing and poor quality of the produced parts. Lubricants are applied to cooling the die surface and create a protective film to minimize die wear. However, the high temperature of the die during the casting production makes it difficult for the lubricant to reach the die surface due to the Leidenfrost effect. In this study, the effectiveness of newly developed ester-based lubricants designed to address Leidenfrost phenomenon in high-pressure die-casting is evaluated at laboratory and pilot plant scale. The new lubricants are based on the same ester solution; however, one of them includes a specially formulated anti-Leidenfrost additive to optimize performance at the temperature ranges typically encountered in industrial aluminum high-pressure die-casting processes. The results show a correlation between lubricant heat-transfer capability and aluminum adhesion. Additionally, a pilot plant methodology for testing newly formulated lubricants has been established while the experimental methodology developed for assessing heat-transfer capability is validated as a rapid and cost-effective approach for evaluating lubrication alternatives for high-pressure die-casting applications. Finally, the efficiency of environmentally friendly ester-based lubricants for high-temperature applications has been demonstrated. |
| format | Article |
| id | doaj-art-91b1a899180949adaf7f7e7cdc5b6c64 |
| institution | Kabale University |
| issn | 2075-4442 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Lubricants |
| spelling | doaj-art-91b1a899180949adaf7f7e7cdc5b6c642025-01-24T13:39:03ZengMDPI AGLubricants2075-44422025-01-011313210.3390/lubricants13010032Ester-Based Lubricant and Anti-Leidenfrost Additive Solutions on Aluminum High-Pressure Die-Casting ApplicationsNuria Cuadrado0Eduard Vidales1Manel da Silva2Wadi Wajana3Leandre Muntada4Angel Navarro5Lluis Beltran6Montserrat Vilaseca7Eurecat, Technological Center of Catalonia, Unit of Metallic and Ceramic Materials, 08243 Manresa, SpainEurecat, Technological Center of Catalonia, Unit of Metallic and Ceramic Materials, 08243 Manresa, SpainEurecat, Technological Center of Catalonia, Unit of Metallic and Ceramic Materials, 08243 Manresa, SpainBrugarolas S.A., Camí de la Riera 36-44, Polígon Industrial Cova Solera, 08191 Rubí, SpainBrugarolas S.A., Camí de la Riera 36-44, Polígon Industrial Cova Solera, 08191 Rubí, SpainIndustrial Química Lasem, S.A.U., Pol. Ind. Pla del Camí-Av. De la Indústria, 7, 08297 Castellgalí, SpainIndustrial Química Lasem, S.A.U., Pol. Ind. Pla del Camí-Av. De la Indústria, 7, 08297 Castellgalí, SpainEurecat, Technological Center of Catalonia, Unit of Metallic and Ceramic Materials, 08243 Manresa, SpainThe high-pressure die-casting process is growing since it is a cost-effective solution in the production of lightweight parts for a variety of industries. Nevertheless, the harsh working conditions of the die lead to premature failing and poor quality of the produced parts. Lubricants are applied to cooling the die surface and create a protective film to minimize die wear. However, the high temperature of the die during the casting production makes it difficult for the lubricant to reach the die surface due to the Leidenfrost effect. In this study, the effectiveness of newly developed ester-based lubricants designed to address Leidenfrost phenomenon in high-pressure die-casting is evaluated at laboratory and pilot plant scale. The new lubricants are based on the same ester solution; however, one of them includes a specially formulated anti-Leidenfrost additive to optimize performance at the temperature ranges typically encountered in industrial aluminum high-pressure die-casting processes. The results show a correlation between lubricant heat-transfer capability and aluminum adhesion. Additionally, a pilot plant methodology for testing newly formulated lubricants has been established while the experimental methodology developed for assessing heat-transfer capability is validated as a rapid and cost-effective approach for evaluating lubrication alternatives for high-pressure die-casting applications. Finally, the efficiency of environmentally friendly ester-based lubricants for high-temperature applications has been demonstrated.https://www.mdpi.com/2075-4442/13/1/32adhesion wear mechanismLeidenfrost pointaluminum high-pressure die-castingadditive lubricants |
| spellingShingle | Nuria Cuadrado Eduard Vidales Manel da Silva Wadi Wajana Leandre Muntada Angel Navarro Lluis Beltran Montserrat Vilaseca Ester-Based Lubricant and Anti-Leidenfrost Additive Solutions on Aluminum High-Pressure Die-Casting Applications Lubricants adhesion wear mechanism Leidenfrost point aluminum high-pressure die-casting additive lubricants |
| title | Ester-Based Lubricant and Anti-Leidenfrost Additive Solutions on Aluminum High-Pressure Die-Casting Applications |
| title_full | Ester-Based Lubricant and Anti-Leidenfrost Additive Solutions on Aluminum High-Pressure Die-Casting Applications |
| title_fullStr | Ester-Based Lubricant and Anti-Leidenfrost Additive Solutions on Aluminum High-Pressure Die-Casting Applications |
| title_full_unstemmed | Ester-Based Lubricant and Anti-Leidenfrost Additive Solutions on Aluminum High-Pressure Die-Casting Applications |
| title_short | Ester-Based Lubricant and Anti-Leidenfrost Additive Solutions on Aluminum High-Pressure Die-Casting Applications |
| title_sort | ester based lubricant and anti leidenfrost additive solutions on aluminum high pressure die casting applications |
| topic | adhesion wear mechanism Leidenfrost point aluminum high-pressure die-casting additive lubricants |
| url | https://www.mdpi.com/2075-4442/13/1/32 |
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