Die Release Agents For Aluminium Pressure Die Casting
A die release agent in high-pressure die casting has to do three things at once: release the casting cleanly, cool and protect the die, and leave a surface that can be painted, powder-coated or welded. Pyroflux India makes the Alucoat range of water-dispersible die release agents in Noida for aluminium, zinc and magnesium die casting, from economical mineral-oil grades for general work to high-solids fully synthetic grades for complex castings that must be free of flow marks. Dilution ratios run from 50 litres of water per litre of concentrate to 500, so the cost per shot drops as the grade goes up. The same works supplies plunger lubricant and boron nitride die coatings for cores, inserts and soldering-prone areas. The selection table below is the short answer; the data sheets have the rest.
The Alucoat Range At a Glance
| Grade | Base | Dilution (litres of water per litre) | Best for |
|---|---|---|---|
| Alucoat 736 | Mineral oil | 50–60 | General-purpose, economical, good finish on all kinds of parts |
| Alucoat 936 | Mineral oil plus additives | 80–100 | Good finish on all kinds of parts at a lower cost per shot |
| Alucoat 2044 | Semi-synthetic | 80–120 | Superior finish without flow marks; works with old dies with cracks; dimensionally accurate castings |
| Alucoat 4044 | Fully synthetic, German-origin technology | 100–120 | Excellent finish, no flow marks; castings can be welded, powder-coated and painted |
| Alucoat 6044 | Fully synthetic, high solids | 120–150 | As 4044 with higher solids for demanding castings |
| Alucoat 8044 | Fully synthetic, high solids | 400–500 | Economical high-performance grade for all kinds of complex castings |
Plunger Lubricant And BN Die Coatings
Plunger Lubricant
Lubricant for the shot sleeve and plunger tip in aluminium HPDC, supplied in drums; consistent shot-to-shot friction, less tip wear.
Boron Nitride Die Coatings
A white, non-wetting h-BN film on cores, inserts and soldering-prone areas, from the aerosol for touch-ups or the suspension for a bonded coat.
BN aerosol →Ladle And Holding-Furnace Coatings
Non-wetting coatings for dosing ladles, launders and furnace hardware feeding the cell.
Casthouse coatings →Getting The Dilution Right
- Start at the lower end of the grade’s dilution range and open the ratio in steps while watching release, soldering and surface finish.
- Keep the mixing tank agitated and the water clean; hard water and contamination shorten the life of any emulsion.
- Spray to coat, not to flood: a thin, even film on a die at the right temperature releases better than a wet die.
- Check die temperature. Too cold and the agent runs off before it films; too hot and it flashes before it spreads.
- Review the ratio when the die, the alloy or the casting changes; a 2044-class grade often lets you open the ratio further than a mineral-oil grade.
Plunger Lubricants And Die Putty
| Plunger lubricant M8500 | Graphite plunger lubricant for aluminium pressure die casting |
|---|---|
| Plunger lubricant, graphite-free | Graphite-free plunger lubricant for clean shot sleeves |
| Mastic powder (putty) | High-temperature putty for sealing and repair around the die |
| Refcote | Launder coating and paste for the metal path to the machine |
Together with the Alucoat die release range these cover the shot sleeve, the plunger, the die and the launder on one line.
Common Questions
Which Alucoat grade should I start with?
For general aluminium castings, Alucoat 936 at 80–100:1. For castings that will be painted, powder-coated or welded, or that show flow marks, Alucoat 2044 or 4044. For high-volume complex castings where cost per shot matters most, Alucoat 8044 at 400–500:1.
Are the agents safe for zinc and magnesium die casting?
Yes. The range is formulated for aluminium, zinc and magnesium alloys; tell us the alloy and we confirm the grade.
Can castings be powder-coated and welded after release?
With the fully synthetic grades (4044, 6044, 8044) and the semi-synthetic 2044, yes; that is one of the reasons to move up from the mineral-oil grades.
Do you supply ready-to-use or concentrate?
Both forms are available. Concentrates are the economical choice for most cells; ready-to-use is useful for small shops without mixing equipment.
Do you supply a technical data sheet and SDS?
Yes, per grade, by email within one working day of a request.
Tell Us The Process; We Will Recommend The Grade
Substrate, process temperature, atmosphere and how you prefer to apply it. That is everything we need to point you at the right product, send a sample, or quote.
- Phone
- +91 98181 87838
- sales@pyroflux.in
- Office
- G-5, Sector 63, Noida 201301, Uttar Pradesh, India
- Factory
- G-15, Sector 63, Noida 201301, Uttar Pradesh, India
- Hours
- Monday to Saturday, 9 am to 6 pm IST