TECHNOLOGY #03

Graphite and Boron Sticks

Graphite suspensions are used as release agents in aluminum extrusion. These materials are known for their high-temperature stability and excellent lubricating properties.

Their effectiveness is influenced by application methods and process consistency, as well as worker health and safety considerations.

How it works

Graphite and Boron sticks are solid lubricants that, when applied to the die surface, form a thin, lubricating layer. This layer reduces friction and prevents sticking or galling of the aluminum as it is extruded.

Both materials maintain their lubricating properties at high temperatures, typical in the extrusion process, ensuring consistent performance.

Product application:

Graphite and Boron sticks are typically applied by manually rubbing them onto the die surface, though this method can present challenges in achieving uniform coverage.

Ensuring a consistent layer is crucial for optimal performance, as uneven application can lead to variable lubrication and increased wear.

For improved consistency and efficiency, automated systems can be employed to apply the lubricant uniformly across the die surface.

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 Graphite and Boron Stick lubricants in a common aluminum extrusion process.

Strengths	Weaknesses
Effective Lubrication: Graphite and Boron sticks provide excellent lubrication, reducing wear on the dies and extending their lifespan.	Application Consistency: Achieving a uniform layer can be difficult. Manual application relies on the skill and diligence of the operator, which can lead to variability in the thickness and evenness of the lubricant layer.
Relative Chemical Stability: Graphite and Boron are relatively stable under the conditions present in aluminum extrusion, with minimal interaction with aluminum, thereby preserving the quality of the extruded product.	Performance Variability: Inconsistent application can result in areas with insufficient lubrication, leading to increased wear and potential defects in the extruded product.
Long shelf life: Both materials remain effective at high temperatures, ensuring consistent lubrication throughout the extrusion process.	Labor Intensive: Manually rubbing sticks onto die surfaces is time-consuming and labor-intensive, especially for large or complex dies.
	Production Downtime: Manual lubrication method can contribute to longer downtimes between extrusion runs, reducing overall productivity. Automated systems, while improving consistency, can add to the initial setup costs.
	Residue Management Although generally minimal, some residue may remain on the extruded aluminum, which might require additional cleaning steps, potentially adding to post-processing time and costs.

Strengths & Weaknesses

Let´s explore the strengths and weaknesses of using Graphite and Boron Stick lubricants in a common aluminum extrusion process.

Strengths

Effective Lubrication:

Graphite and Boron sticks provide excellent lubrication, reducing wear on the dies and extending their lifespan.

Thermal Stability:

Both materials remain effective at high temperatures, ensuring consistent lubrication throughout the extrusion process.

Relative Chemical Stability:

Graphite and Boron are relatively stable under the conditions present in aluminum extrusion, with minimal interaction with aluminum, thereby preserving the quality of the extruded product.

Long shelf life:

Both materials remain effective at high temperatures, ensuring consistent lubrication throughout the extrusion process.

Weaknesses

Application Consistency:

Achieving a uniform layer can be difficult. Manual application relies on the skill and diligence of the operator, which can lead to variability in the thickness and evenness of the lubricant layer.

Performance Variability:

Inconsistent application can result in areas with insufficient lubrication, leading to increased wear and potential defects in the extruded product.

Labor Intensive:

Manually rubbing sticks onto die surfaces is time-consuming and labor-intensive, especially for large or complex dies.

Production Downtime:

Manual lubrication method can contribute to longer downtimes between extrusion runs, reducing overall productivity. Automated systems, while improving consistency, can add to the initial setup costs.

Residue Management

Although generally minimal, some residue may remain on the extruded aluminum, which might require additional cleaning steps, potentially adding to post-processing time and costs.

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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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