Field Trials with NOVOTEC® CR800 for die casting
in China and Germany, Matthias Reihmann
Performance of GELITA
NOVOTEC® CR800
in cooling release agents (CRA)
distributed by:
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Applications for the New Protein Layer Technology
2
Cleaning Metalworking
© 2018 GELITA AG. Any copies need to be authorized by GELITA
Die-Casting
CRA are needed in machining
for cooling and reduction of wear
3© 2018 GELITA AG. Any copies need to be authorized by GELITA
Typical ingredients for CRA
• Oil, Silicone or Wax
• Water
• Emulsifiers• Other additives (e.g. Corrosion
Inhibitors, Detergents, Lubricants, Biocides/Fungicides etc.)
Oil works very good for lubrication
but limits cooling properties
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Typical issues caused by weak cooling
• Increased Consumption
• Less Productivity
• Surface Damage• More effort for cleaning due to cracked
oil residues, difficulties in further processing steps (e.g. painting, bonding, phosphating)
© 2018 GELITA AG. Any copies need to be authorized by GELITA
Without
NOVOTEC®
With
NOVOTEC®
Second Skin instead of a Raincoat:
Hydrophilic Protein Layers attract water
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Advantages of Protein Layer Technology
• Changed surface wetting
• Improved cooling
• Better Surface quality
• Protein can be added as additive to any existing water-miscible product
• NOVOTEC® CR800 is safe for food contact, skin contact and derived from sustainable resources
© 2018 GELITA AG. Any copies need to be authorized by GELITA
6
Scheme of Protein Layer Formation on a Surface
Substrate
Surface
Van-der-
Waals
Interaction
Hydrogen
Bonding
Protein
(from Collagen)
Water
molecules
1. Absorbtion
on Surface
2. Interaction
between Proteins
3. Water binding
by Proteins
4. Hydrophilic Layer
EEquilibrium
Moisture
Content
~10%
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7
Making protein films visible by Fluorescein-Markers
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Microscope image of Fluorescein-marked NOVOTEC®
protein molecules (green) bound on a steel surface
Fluorescein isothiocyanate (FITC)
• Under normal conditions the protein layers are fully transparent and not visible for the human eye
• To make them visible under the microscope the Proteins are marked with FITC
Changed Surface Wetting Behaviour by Protein Layers
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without NOVOTEC® 1% NOVOTEC®
1 s
3 s
5 s
7 s
Water on Steel surfaces treated with Protein
Water on Glass surfaces treated with Protein
without NOVOTEC® 1% NOVOTEC®
1 s
4 s
8 s
12 s
0
10
20
30
40
50
60
70
80
0 5 10 15 20
con
tact
an
gle
[°]
time [sec.]
untreatedsteel
treated with1% NOVOTEC
0
10
20
30
0 10 20
con
tact
an
gle
[°]
time [sec.]
untreatedglass
treated with1% NOVOTEC
© 2018 GELITA AG. Any copies need to be authorized by GELITA
®
®
Residue free release of the protein formulationTGA of NOVOTEC® CR00 under Nitrogen atmosphere
NOVOTEC® CR800 is stable up to more than 300 °C.
The first peak at 100 °C represents the evaporation of water.
The second peak at 320 °C represents degradation of protein.© 2018 GELITA AG. Any copies need to be authorized by GELITA
Benefits of Protein Layers for Metalworking
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SURFACE INTEGRITY
COOLING
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directly before spray
directly before spray
directly after spray
directly after spray
27.4 Liter
conventional cooling
release agent
20.0 Liter NOVOTEC®
CR800 based cooling
release agent
LESS CONSUMPTION
CLEAN SURFACES
Conventional
cooling release
agent
NOVOTEC® CR800
based cooling release
agent
11© 2018 GELITA AG. Any copies need to be authorized by GELITA
Conditions:
Müller-Weingarten 1.800 t Coldbox, 30 parts of a crankcase, AlSi9Cu3
10 Liters “release agent concentrate” made by diluting NOVOTEC® CR800 by factor 8 with water were dissolved in front of the
machine in a 1000 liter container with tapwater (corresponding to a 1:800 dilution NOVOTEC® CR800)
The NOVOTEC® CR800 dilution was directly sucked by the high-pressure pump of the spray robot bypassing
the normal release agent flow cycle. This resulted in a flow of 13.7 Liter instead of 27.4 Liter per cast.
Increased spray time by 20s (to reach 20 Liter per cast) by reduction of robot speed.
Thermal images have been done directly before and after spray.
Written temperature indicates temperature at crosshair,
which may vary
Field trial at KS HUAYU AluTech GmbHNOVOTEC CR800® - 1:800 aqueous dilution
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Field trial at KS HUAYU AluTech GmbHNOVOTEC CR800® - 1:800 aqueous dilution
Production with conventional cooling release agent: 27.4 Liter per shot
Production with NOVOTEC® CR800: 20.0 Liter per shot
directly before spray
directly before spray directly after spray
directly after spray
© 2018 GELITA AG. Any copies need to be authorized by GELITA
13
Field trial at KS HUAYU AluTech GmbHNOVOTEC CR800® - 1:800 aqueous dilution
Production with conventional cooling release agent: 27.4 Liter per shot
Production with NOVOTEC® CR800: 20.0 Liter per shot
directly before spray
directly before spray directly after spray
directly after spray
© 2018 GELITA AG. Any copies need to be authorized by GELITA
14© 2018 GELITA AG. Any copies need to be authorized by GELITA
Field trial at KS HUAYU AluTech GmbHNOVOTEC CR800® - 1:800 aqueous dilution
Tested: high pressure casting of AlSi crankcasesPositive: cooling water demand reduced by 30%
chemistry reduced by 30%production time reduction by 20% possible (based on reduced spray amount)very clean castings, cleaning not mandatory for further processingall parts passed regular QA (X-Ray)
Negative: spray needs to be fine and nozzles adjusted accordinglysimple 1:1 replacement failed due to increased cooling- 30% spray volume reduction mandatoryimproved lubrication on injectors necessary to increase process security
15© 2018 GELITA AG. Any copies need to be authorized by GELITA
Field trial at Shanghai, ChinaNOVOTEC CR800® - in MWF Guideline Formulation G18V1
Tested: AlSi12 automotive structural partPositive: cooling water demand reduced by 30%
chemistry reduced by 30%very clean castingsmore than 30 parts without problems
Negative: part blocked in the machine after approx. 35 cycles!
16© 2018 GELITA AG. Any copies need to be authorized by GELITA
Field trial at Shanghai, ChinaNOVOTEC CR800® - in MWF Guideline Formulation G18V1
Tested: aluminum rotor casePositive: cooling water demand reduced by 30%
chemistry reduced by 30%safe release of ultra soft alloysvery clean castings, before almost black
Negative: nothing within a 1 month trial
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Industry Trends Manufacturer (B2B) Consumer (B2C)
Regulatory
(Product Safety)
✓ No REACH
✓ Natural polymer
✓ Natural product with high
performance
Performance
(Efficiency)
✓ New Additive/ Base Stock(can be incorporated in most water-
miscible or fully synthetic mold release
agents)
✓ Improved cooling
✓ Faster production
✓ Less consumption
✓ Less residues
Eco-friendly
(free-from claims)✓ Clean Label
✓ Less waste
✓ Less water usage
✓ No or only very low allergenic
potential
Benefits of adding Proteins to CRAsfor NOVOTEC® CR800
© 2018 GELITA AG. Any copies need to be authorized by GELITA
Field Trials with NOVOTEC® CR800 for die casting
in China and Germany, Matthias ReihmannAustralia
Beaudesert
Phone: +61 (7) 55 41 - 35 44
Brazil
Cotia São Paulo
Phone: +55 11 2163-8000
USA
Sioux City, IA
Phone: +1 712 943 5516
South Africa
West Krugersdorp
Phone: +27 11 662 5300
China
Shanghai
Phone: +86 21 6335 3099
Mexico
Lerma
Phone: +52 7 28 285 0101
Germany
Eberbach
Phone: +49 62 71 84-01
New Zealand
Christchurch
Phone: +64 33 84 30 93
Sweden
Stidsvig
Phone: +46 4 35 265 - 00
France
Aix-en-Provence
Phone: +33 4 42 63 28 40
UK
Holmes Chapel
Phone: +44 14 77 53 69 00
www.GELITA.com
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