Addressing galling and sticking to the mold requires more than just uniform spraying—it demands deeper intervention across three dimensions: film quality, mold condition, and alloy composition.
The core function of a release agent is to form a continuous, robust, and high-temperature-resistant barrier on the mold surface. If the release agent lacks sufficient lubricity, thermal stability, or adhesion— mismatched with process conditions (e.g., mold temperature, molten aluminum temperature, cooling efficiency)—this film may crack under high-pressure, high-speed metal flow. This exposes bare mold steel to molten metal, causing welding and subsequent sticking/galling. Thus, selecting a high-quality release agent matched to the alloy is foundational.
Aluminum alloys with iron content <0.6% are prone to sticking. When mold cavities have poor surface roughness or microscopic damage, release agent adhesion weakens—even with uniform spraying, the film easily fractures at imperfections. Regular mold maintenance (polishing, removing sintered layers) and surface treatments (e.g., nitriding) enhance the release agent’s effectiveness. A smooth, hard cavity surface reduces reliance on the release film.
Performance Validation: Field-test release agents for film-forming ability, abrasion resistance, and final demolding force.
Mold Health Management: Implement routine inspections and maintenance to keep cavity surfaces in optimal condition.
Alloy Formulation Review: For aluminum alloys, maintain iron content within the 0.6%–0.8% process window to inherently reduce chemical sticking tendency.
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