Inorganic core coating

Inorganic cores are increasingly used in gravity and low-pressure processes as they do not produce gas in the casting.

They are also breathable and this allows the air in the mould to come out during the casting process.

These two characteristics must be preserved. However, you must also pay special attention to reducing sintering effects.

In this regard, Altea has designed a specific powder that, applied electrostatically to the cores using the Dry Lub system, maintains the characteristics of the cores. This way, it prevents alloy penetration and improves earthwork, while leaving the surfaces cleaner and smoother.

The benefits are particularly visible in narrow cavities, which require meticulous and very expensive cleaning operations (specific steps for oil and water in vehicle engines, turbine parts, etc.) to ensure the absence of residues when the piece is complete.

The inorganic core coating process is the result of extensive research, which involved different companies to manufacture parts of the vehicle chassis with walls 2.5 mm thick.

As it often happens, it has found its ideal development in the production of vehicle engine blocks.

Strengths

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Unaltered core permeability

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Improved smoothness

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Easy earthwork

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No core alteration

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Reduced sintering effect

HOW THE DRY LUB SYSTEM WORKS

The product is electrostatically applied to a dielectric chamber, which allows it to spread evenly along the core without altering its breathable properties.

The amount of product required to obtain good results is extremely small, i.e. 1 g  per core to manufacture a 4-cylinder engine block.

Watch it in action

Live videos shot during the clients’ production cycle.

Any doubts?

Check out our FAQ section. Contact us if you don’t find the answer you were looking for.
Can the powder change the melting quality?
This powder is made up of talc and synthetic graphite processed with nano-technologies. These products are highly compatible with aluminium.
How does it keep permeability unaltered?
The product applied is dry and melts above 1200 °C. The micro particles deposit on the surface without altering breathability.
Does the powder fall off when the core is placed in the mould?
Powder does not fall off because it is applied to the surface electrostatically. However, you need to pay special attention when you blow air into the mould to remove the sand that falls from the core.
How is the product applied electrostatically?
This operation occurs in a dielectric chamber, in which the electrostatically charged powder is sprayed. As the core is a conductor, it makes the product stick to it.
Is this process expensive?
It’s an added cost in the melting stage. The ROI is obtained during the processing and cleaning stages of the various pipes.

 

Isn’t powder dispersed into the environment?
A minimum amount of the dry product is applied electrostatically to the surfaces. A light suction is required to remove the fumes that result from the melting process.

 

Is the powder toxic?

The products we use are not toxic and meet all EC parameters.

 

How will the work environment be on board the die-casting machine?

By eliminating the water-based release agent we have eliminated oil mist and waste water as well as subsequent depurations. Moreover, we have reduced suction-related consumption.

What criticality can we find if we want to integrate the Dry Lub System into our production cycle?

Technically none, because the lubrication head of the Dry Lub System is made specifically for the die casting machine in which it is mounted. Consider that the powder is almost invisible and the application is really fast.

 

Is it possible to test all this?
Our procedure includes manual tests on the moulds being used by our clients. We also check the temperatures using a thermographic camera and analyse the results. The possibility to continue the automated tests is an option we’ll consider at a later stage.

This first stage is totally free of charge for the client.

Are you interested in our DRY LUB SYSTEM?

Dry Lub System technology for inorganic cores