Reducing Die Wear in Copper Extrusion

Tribology & Metallurgy

Tribological Root Causes of Extrusion Tool Failure

The extrusion of copper alloys exerts intense thermo-mechanical stresses on die bearings and internal mandrels. High friction coefficients at the metal interface result in severe adhesive and abrasive wear. Under the extreme pressures of the press, localized breakdown of the lubricant film causes direct metal-to-metal contact.

This microscopic galling gradually alters die geometry, leading to out-of-tolerance wall thicknesses and compromised surface finishes. Continuous operation with sub-optimal lubrication forces frequent die changes, reducing overall plant efficiency and OEE (Overall Equipment Effectiveness).

Engineering an Impenetrable Shear Layer

Mitigating this wear requires an engineered friction reduction system. PROMET's synthetic high-performance waxes provide exceptional load-carrying capacity (EP properties) without relying on abrasive solid fillers like graphite, which can ironically contribute to die scouring over time.

Upon application, the lubricant establishes a high-viscosity hydrodynamic wedge during the initial upset phase, transitioning smoothly into a resilient boundary layer during the steady-state extrusion. This constant separation of surfaces drastically limits thermal transfer to the tooling, preserving structural hardness and multiplying the tonnage produced per die.

Key Performance Metrics

Thermal Boundary Limit:	> 950 °C
Decomposition Profile:	Clean Phase Transition
Kinematic Viscosity (100°C):	Tailored formulations
Application Method:	Spraying, Dripping, or Swabbing
Graphite Content:	0% (No solid buildup)