Improvement Results - Releasing Agent and lubricants for Die Casting

Since 2004, WFR has been used around the world. We would like to show you some of our introduction examples.

1800t Robot spray

Product Name Pan-Oil
DCM size 1800t
Electrostatic spray gun type Single head type x 2
Die lube type WFR-3EC

1650t Robot Spray - Hibino Industry Co., Ltd.

Product Name Transmission case
DCM size 1650t
Electrostatic spray gun type T-type twin head type
Die lube type WFR-3EC
Spray volume 3.9ml/shot
(Before: 3000ml/shot)
Air blow time 9 sec reduction
Cycle time 2 sec increase

530t Vertical spray unit

DCM size 530t
Electrostatic spray gun type Small twin head type x 2
Die lube type WFR-3EC

New die casting process with Toshiba Near Dream process (WFR + Electrostatic spray + Multi injection machine) - TOSHIBA MACINE PLASTICS & DIECAST ENGINEERING CO., LTD.

WFR + Electrostatic spray + Multi injection machine

Product Name Parts for Transmission Product image
DCM size 500t
Material ADC12
  Before Now
Spray Application Vertical Spray unit with copper tube cassette Robot spray (6 axes)
Nos. of Spray nozzle Total 35 pipes Total 2pcs
One electrostatic twin head gun
Cycle time --- 13% reduction
Spray time --- 50% Up
Air blow time 5 sec 0
Die lube type Water soluble type (emulsion) WFR-5EC
Spray quantity 1000 ml 0.6 ml/shot

350t ロボットスプレー

DCM size 350t
Electrostatic spray gun type Small twin head type
Die lube type WFR-M5EC
Spray volume 1ml
(Before: 40ml/shot)
Air blow time 1 sec reduction
Cycle time 2 sec reduction

350t 昇降式スプレー

DCM size 350t
Electrostatic spray gun type Small quattro head type
Die lube type WFR-33WE
Spray volume 1 - 2ml
(Before: 150 - 250ml/shot)
Air blow time 5 sec reduction
Cycle time 6 sec reduction

350t ロボットスプレー

DCM size 350t
Electrostatic spray gun type Single head type
Die lube type WFR-3EC

150t ロボットスプレー

DCM size 150t
Electrostatic spray gun type Small twin head type
Die lube type WFR-3EC

Drastic Increase Productivity! Succeeded the stable production with a die implant spray application - Aisan Industry Co., Ltd.

Reduction of reject rate with a die implant spray application to the long slide core section (L/D = 38, ascent : < 0.5 degree).
Success drastic running cost reduction.

Product Name EGR(Exhaust Gas Recirculation) Chamber Product image
DCM size 800t
Material ADC12
Spray Application Robot spray (6 axes)
Nos. of Spray nozzle Total 4 pcs
Fixed : 2 pcs, Moving : 2 pcs
Cooling Water : 0 pcs
Spray quantity 99% reduction (No waste water)
Product volume 14% increase (product cost reduction)
Die life 800% increase (Extend die life)
Air low quantity (88%) reduction (CO2 reduction)
Die lube type WFR-5AP

Brilliant surface finish! Success mass production for Cr plating Zinc appearance part with WFR - Aisan Industry Co., Ltd.

Reduction of metal flow rejection to achieve high quality demanded Cr plating Zinc appearance part.

Product Name Number Plate Frame Number Plate Frame
DCM size 500t
Material ZDC2
Die lube type WFR-33
Nos. of Spray nozzle 2 pcs
Spray quantity 0.9 ml/shot

World First! Success the brake caliper mass production with RHEO cast process (semi solid casting) - AISIN TAKAOKA CO., LTD.

With WFR, succeeded to produce aluminum brake caliper with RHEO casting process instead of cast iron.
Achieved the clean environment due to change graphited water based die lube to WFR.

Product Name Aluminum Brake Caliper Product image
DCM size 800t RHEO Casting Process (semi solid casting)
Material AC4CH
  Before Now
Spray Application Robot spray (6 axes) Robot spray (6 axes)
Nos. of Spray nozzle Total : 30 pcs Total : 38 pcs
Fixed : 14 pcs
moving : 16 pcs
Fixed : 9 pcs
Moving : 9 pcs
Cooling water : 0 pcs Cooling water : 20 pcs
Cycle time 56sec 56sec
Spray time 15sec Cooling water : 5 sec,
WFR : 7 sec
Air blow time 5 sec 8 sec
Die lube type Graphited water based (dilution ratio : 1:30) WFR-3R
Spray quantity 750 ml/shot Cooling water : 300 ml/shot
WFR : 3 ml/shot

Success of machining less die casting part and drastic extension of die life - Kotobuki Kinzoku Kogyo Co., Ltd.

Cap Oil Filter

Success of machining less die casting part and drastic extension of die life

Product Name Cap Oil Filter
DCM size 350t
Material ADC12
Die lube type WFR-33

World first! Valve body mass production with WFR - Daihatsu Motor Co., Ltd.

Success the valve body mass production with WFR application in the world first.
Success to reduce cycle time, reject rate, water treatment cost etc, significantly.

Product Name Valve body for 660cc automobile CVT transmission
(Daihatsu SONICA / MOVE)
Product image
DCM size 800t
Material ADC12
  Before Now
Spray Application Robot spray (6 axes) Robot spray (6 axes)
Nos. of Spray nozzle Total 6 pcs Total 3 pcs
Fixed : 3 pcs
Moving : 3 pcs
Fixed : 1 pcs
Moving : 2 pcs
Cooling Water : 2 pc Cooling Water : 2 pc
Cycle time --- (17%) reduction
Spray time --- (38%) reduction
Air blow time --- (50%) reduction
Die lube type Water soluble type (emulsion) WFR-5AP
Spray quantity --- 1.5 ml/shot

Successful mass production of fin shape thin fin shape casting product - Kyoei diecast Co., Ltd.

Product image

Succeeded in mass production of thin fin shape casting product with WFR improved metal flow.

Product Name Heat sink for LED head light
DCM size 250t
Material ADC12 / HT-1
Die lube type WFR-3R

Produce thick wall casting with WFR - PT. Astra Daihatsu Motor (Indonesia)

Product image
Product Name Housing Clutch for Daihatsu XENIA
DCM size 1.250t
Material ADC12
  Before Now
Spray Application Manual spray Manual spray
Cycle time --- (11%) reduction
Spray time --- (14%) reduction
Air blow time --- (44%) reduction
Die lube type Water soluble type (emulsion) WFR-3R

Success mass production for aluminum appearance part in Indonesia with WFR - PT. Astra Daihatsu Motor (Indonesia)

Product image
Product Name Cover Head Cylinder for Daihatsu
DCM size 800t
Material ADC12
  Before Now
Spray Application Manual spray Manual spray
Cycle time --- (10%) reduction
Spray time --- (19%) reduction
Air blow time --- (12.5%) reduction
Die lube type Water soluble type (emulsion) WFR-3R

Suitable for small and precision die casting part - Progress Co., Ltd.

HDD Digital video OP frame

Succeeded mass production for appearance part of electrical product which required high quality paint finish with WFR.

Product Name HDD Digital video OP frame
DCM size 150t
Material ADC12
Die lube type WFR-0
Nos. of Spray nozzle 1 pc
Spray quantity 0.2 ml/shot

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