Think nozzle clogging in die casting is due to poor release agent quality? The truth may be harsher—your carefully purchased aluminum/magnesium die casting release agent might be "cooked to death" in high-temperature workshops. The culprit? Improper storage details most factories overlook.
Emulsion System Collapse—"Oil-Water Separation":
Release agents are precision-engineered oil-in-water emulsions. Their stability is highly temperature-sensitive.
When ambient temperatures exceed critical thresholds (e.g., prolonged exposure >35℃), emulsifiers lose efficacy rapidly, failing to maintain stable oil-water binding.
Result: Emulsion stratification ("clear upper layer, turbid lower layer"), separating active ingredients. Spraying now forms incomplete, uneven lubrication films—spiking sticking risks and pipe blockages.
Moisture Evaporation—"Chronic Poison" for Concentration Control:
For open or poorly sealed buckets, high temps (>35℃) accelerate water evaporation.
Consequences:
① Abnormal concentration spikes: Actual working solution concentration exceeds targets, altering lubrication (thickening or failure) and weakening mold cooling—compromising part quality and mold life.
② Precipitation/sedimentation: Water loss reduces solubility, causing white flocculent or granular precipitates. These directly clog nozzles, pipes, and filters.
Direct sunlight: Metal buckets act as "heat accelerators." Sunlight raises internal temps far above ambient, worsening emulsion breakdown and evaporation. High heat may also degrade emulsifiers/additives, triggering microbial growth (bacteria) and spoilage.
Deceptive "safe" traps:
• Indoor storage near windows/with strong reflected light? Localized hotspots suffice to cause failure.
• Overly ventilated areas? Accelerates moisture loss and volatile component evaporation.
• Exposed centralized supply systems? Proportioning tanks/pipes under direct sun continuously heat the agent—emulsion breakdown and blockages are inevitable.
Water quality risks: Summer use of groundwater/spring water is high-risk (warm temps, high bacterial loads). Even tap water risks contamination from secondary supply tanks/pipes. Bacterial byproducts destabilize emulsions and accelerate spoilage.
Temperature control is critical:
Ideal storage: 10–25℃. Absolute limit: ≤30℃.
Unopened stock must move to cool, shaded, dedicated storage—workshop temps often exceed 40℃ in summer.
Metal buckets need full light avoidance; protect during transport from prolonged sun exposure.
Block moisture intrusion:
Seal tightly, always. Even during downtime, close bucket lids promptly. In high-humidity environments, splashed water (mixed with oils) may cause hydrolysis and failure.
Seal proportioning tanks in centralized systems.
Manage water quality:
Prefer deionized/purified water: avoids calcium/magnesium ions (reducing carbon buildup) and inhibits bacterial growth.
If using municipal water, monitor tank/pipe cleanliness; clean regularly.
Avoid groundwater/spring water unless filtered, sterilized, and closely monitored.
Clean proportioning systems periodically to prevent biofilms/deposits.
Is storage area temp consistently >30℃? (Place a thermometer!)
Are buckets (esp. metal) exposed to direct sunlight/heat sources?
Are buckets resealed immediately and tightly after use? Is single-bucket use >2 weeks?
Are centralized tanks/pipes exposed outdoors or in high-temp zones?
What’s your water source? Is groundwater/spring water treated? Is tap water system clean?
Do you frequently face unexplained nozzle clogs, white precipitates, or sticking?
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