TECHNOLOGY #01

Acetylene Flames

Acetylene flames are still frequently used as a release agent in aluminum extrusion. This method is known for its ability to produce a carbonaceous film that provides effective lubrication and reduces friction.

Its adoption is influenced by specific process requirements such as die complexity, extrusion speed, product surface finish quality, and worker health considerations due to the use of flammable gases.

How it works

How it works

Acetylene flames produce a flame rich in carbon particles when acetylene is burned.

These carbon particles form a thin, lubricating layer on the surface of the die, reducing friction and preventing sticking or galling of the aluminum as it is extruded.

The carbonaceous film maintains its lubricating properties at high temperatures, typical in the extrusion process, ensuring consistent performance.

Product Application:

Acetylene flames are applied using a torch, which is directed onto the die surface.

The flame covers all areas of the die where the aluminum will contact, depositing a uniform carbon layer.

The application process is straightforward and can be performed manually or using automated systems to ensure consistent coverage.

References:

Boron Nitride – Solutions for Aluminum Extrusion - Christiane Klöpfer, ESK Ceramics GmbH & Co. KG, A Ceradyne Company, Kempten, Germany (here).

Strengths & Weaknesses

Let´s explore the strengths and weaknesses of using Acetylene Flame lubricants in a common aluminum extrusion process.

Strengths
Weaknesses

Rapid Application:

The use of acetylene flames allows for quick application of the lubricating layer, which can enhance production efficiency.

Safety Precautions:

The use of acetylene, a highly flammable gas, requires stringent safety measures to prevent accidents.

Effective Lubrication:

Acetylene flames produce a carbon film that provides excellent lubrication, reducing wear on the dies and extending their lifespan.

Consistent Application:

Ensuring uniform application of the carbon film is crucial to avoid defects and ensure smooth operation.

Temperature Stability:

The carbon film remains effective at high temperatures, ensuring consistent lubrication throughout the extrusion process.

Health and Safety:

Proper ventilation is necessary to manage combustion byproducts and ensure a safe working environment for operators.

Minimal Residue:

Properly applied, the carbon film leaves minimal residue on the extruded aluminum, maintaining surface quality.

Environmental Concerns: The use of acetylene flames produces combustion byproducts that need to be managed to comply with environmental regulations.
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Equipment Maintenance:
Regular maintenance of torches and gas supply systems is required to ensure reliable performance and safety.

Strengths & Weaknesses

Let´s explore the strengths and weaknesses of using Acetylene Flame lubricants in a common aluminum extrusion process.

Strengths
Rapid Application:
The use of acetylene flames allows for quick application of the lubricating layer, which can enhance production efficiency.
Effective Lubrication:
Etylene flames produce a carbon film that provides excellent lubrication, reducing wear on the dies and extending their lifespan.
Temperature Stability:
The carbon film remains effective at high temperatures, ensuring consistent lubrication throughout the extrusion process.
Minimal Residue:
Properly applied, the carbon film leaves minimal residue on the extruded aluminum, maintaining surface quality.
Weaknesses
Safety Precautions:
The use of acetylene, a highly flammable gas, requires stringent safety measures to prevent accidents.
Consistent Application:
Ensuring uniform application of the carbon film is crucial to avoid defects and ensure smooth operation.
Health and Safety:
Proper ventilation is necessary to manage combustion byproducts and ensure a safe working environment for operators.
Environmental Concerns:
The use of acetylene flames produces combustion byproducts that need to be managed to comply with environmental regulations.
Equipment Maintenance:
Regular maintenance of torches and gas supply systems is required to ensure reliable performance and safety.

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DISTINGUISH TECHNOLOGIES

1. Acetylene Flames

2. Boron Nitride

3. Graphite Sticks

4. Graphite Suspensions

5. Water-Based Lubricants

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