Identifying Organic Contaminants in Sub Tier Castings Using FTIR Fingerprinting
Attenuated total reflectance FTIR identifies organic parting agents on raw castings before expensive coating processes fail on customer lines.
Mold Release Emulsion
Meaning
Lubricating liquid consisting of oil or wax droplets dispersed in water used to prevent cast parts from sticking to the mold surface. Applied by automated spray systems, mold release emulsion creates a heat resistant barrier that facilitates the clean ejection of the finished part. The water phase evaporates upon contact with the hot die, leaving a thin film of active lubricant.
Thermal Regulation
Evaporation of the water content provides a cooling effect that helps maintain the die temperature within the target range. This prevents the mold steel from overheating, which would shorten its service life and cause soldering of the aluminum. If the temperature is too low, the emulsion may not dry properly, leading to gas porosity in the metal.
Modern formulations use synthetic oils that withstand higher temperatures without smoking or degradation.
Surface Quality
Film thickness determines the smoothness of the cast part and the ease of subsequent finishing. An excessive amount of lubricant can cause staining or dark marks on the surface of the component. These residues must be removed before the part can be painted or plated.
Dilution ratios are carefully monitored to balance the release performance with the cleanliness of the part.
Environmental Control
Water based systems have replaced solvent based alternatives to reduce the emission of volatile organic compounds in the factory. The runoff from the spraying process is collected and treated in an oil-water separator before disposal. This reduces the environmental impact of the foundry operations and improves the air quality for the workers.