To create even more value for its customer, Henkel as leading producer of industrial adhesives developed an efficiency-boosting strategy that has reduced costs considerably in Trimet’s processes. The key element of the full product and service package is a highly efficient lubricant concentrate of the Bonderite brand that cuts cycle times in production by an impressive 5 percent.
Jun 25, 2014 Düsseldorf / Germany
Know-how Wins Out
With his highly efficient lubricant concentrate of the Bonderite brand and a technical service Henkel offers tailored, integrated solutions for pressure die-casting processes to companies from the metal processing industry. By offering this full package Henkel convinced Trimet, one of Europe’s leading aluminum casting producers, that has switched all its production lines to Henkel technologies.
At Trimet’s plant in Harzgerode, Germany, alone, huge quantities of aluminum are heated to almost 700 degrees Celsius (1292 degrees Fahrenheit), injected into the die-casting molds and pressed noiselessly but with huge forces. Each year, the plant processes thousands of metric tons of the expensive light metal that is in such big demand in the automotive industry.
On the production line, Bonderite not only accelerates the process, but also brings a new level of quality to the homogeneous sealing of die-cast components. Under the microscope, engine blocks used to reveal slightly porous surfaces on piston and cylinder cavities resulting from gas released by organic lubricant components bursting during the hardening process. Since Bonderite L-CA CP 791 contains only minimal amounts of organic constituents, the product releases much less gas, leaving a more homogeneous surface.
Despite the shortened cycle times and improved surface quality, the castings can be removed easily from the mold residue-free. Overall, Bonderite L-CA CP 791 has significantly improved the process and cut costs appreciably at the same time.
What ultimately convinced Trimet, however, was the full package including technical service. “We have application engineers familiar with all the ins and outs of the die-casting process,” explains Edmund Hinkel, Henkel Sales Engineer. “Every application engineer sent to the customer site has comprehensive knowledge either of the die-casting process or of the chemistry involved. With this depth of expertise, we can significantly enhance customer processes. We can modify cycle times, for instance, optimize lubricant and release agent spraying behavior, and assure uniform heat distribution.”
“Our ability to deliver both a high-performance product and the necessary process know-how saved our business with Trimet,” says Björn Lorenz, Regional Sales Manager Metal Forming in the Transport & Metal business. “It makes us unique in the die-casting sector, giving us a competitive edge that we will continue to exploit.”
The lubricant concentrate Bonderite L-CA CP 791 makes it possible to remove light metal castings such as aluminum engine blocks from the die-casting mold easily and without residue.