TECHNOLOGY #05

Water-based Release Agents

Water-based release agents have recently been introduced in aluminum extrusion processes. These lubricants are known for their minimal environmental impact and clean application process.

Their effectiveness in aluminum extrusion is influenced by automated application methods and consistency. Moreover, worker safety and health considerations can also significantly improved due to the absence of toxic fumes.

How it works

Water-based release agents are formulated to provide a thin, lubricating layer on the die surface. These agents work by evaporating the water content during the extrusion process, leaving behind a uniform, lubricating film that reduces friction and prevents sticking or galling of the aluminum.

These lubricants maintain their performance at the high temperatures that are typical in the extrusion process, ensuring consistent lubrication and protection for the dies.

Product application:

Water-based release agents are usually applied to the die surface through automated spraying systems.

This allows for easy and uniform application, ensuring consistent coverage across complex die geometries.

The water content evaporates quickly upon contact with the hot die, forming a stable, adherent lubricating layer.

Both manual and automated systems can be used to apply these lubricants, offering flexibility and efficiency in various production environments.

Disclosure:

*Disclosure: Interlub designed, manufactures and sells Interforge KI and Interforge KI-C, our own water-based release agents. The knowledge and data presented on this technology is informed by our experience with this products. The effects can vary from solution to solution.

Strengths & Weaknesses

Let´s explore the strengths and weaknesses of using Water-based Release Agentsin a common aluminum extrusion process.

Strengths	Weaknesses
Application Consistency: Automated spraying systems ensure a consistent and uniform application, reducing variability and enhancing lubrication performance.	Equipmet calibration: While automated systems improve consistency, achieving uniform coverage can still require precision and regular calibration of equipment.
Increased Workplace Safety: No toxic fumes and reduced particle exposure improve worker health and safety. The non-flammable nature of water-based agents further enhances workplace safety.	Storage Conditions: Proper storage conditions are necessary to prevent freezing or contamination of water-based lubricants, which can affect their performance.
Low Environmental Impact: Minimal environmental impact due to the absence of harmful chemicals and easy compliance with environmental regulations.	Initial Setup Costs: Automated systems for applying water-based release agents require an upfront investment, although the long-term gains in productivity and reduced labor costs can provide a favorable return on investment.
Labor Efficiency: Automated application reduces manual labor, enhancing efficiency and freeing up operators for other tasks.
Residue Management: Typically leave minimal residue, reducing the need for extensive post-processing and cleaning steps.

Disclosure:

Interlub designeds manufactures and commercializes water-based release agents such as Interforge KI and Interforge KI-C. The knowledge and data presented on this part is informed by our experience with our products in Aluminum Extrusion plants in North-America and Europe. The effects may vary from solution to solution and by the operating conditions and practices in each plant.

Strengths & Weaknesses

Let´s explore the strengths and weaknesses of using Water-based Release Agents in a common aluminum extrusion process.

Strengths

Application Consistency:

Automated spraying systems ensure a consistent and uniform application, reducing variability and enhancing lubrication performance.

Increased Workplace Safety:

No toxic fumes and reduced particle exposure improve worker health and safety. The non-flammable nature of water-based agents further enhances workplace safety.

Low Environmental Impact:

Minimal environmental impact due to the absence of harmful chemicals and easy compliance with environmental regulations.

Labor Efficiency:

Automated application reduces manual labor, enhancing efficiency and freeing up operators for other tasks.

Residue Management:

Typically leave minimal residue, reducing the need for extensive post-processing and cleaning steps.

Weaknesses

Initial Setup Costs:

Automated systems for applying water-based release agents require an upfront investment, although the long-term gains in productivity and reduced labor costs can provide a favorable return on investment.

Equipmet calibration:

While automated systems improve consistency, achieving uniform coverage can still require precision and regular calibration of equipment.

Storage Conditions:

Proper storage conditions are necessary to prevent freezing or contamination of water-based lubricants, which can affect their performance.

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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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