WO2011070840A1

WO2011070840A1 - Mold release agent composition, and casting method using same

Info

Publication number: WO2011070840A1
Application number: PCT/JP2010/067159
Authority: WO
Inventors: 正則高尾; 有松木; 真石川
Original assignee: ユシロ化学工業株式会社
Priority date: 2009-12-11
Filing date: 2010-09-30
Publication date: 2011-06-16
Also published as: JPWO2011070840A1; JP5635999B2

Abstract

Disclosed are: a mold release agent composition which can be used for the casting of a metal or the like and has excellent mold release properties; and a casting method using the mold release agent composition. Specifically disclosed is a mold release agent composition comprising a liquid medium and a nano carbon material (e.g., fullerene) (wherein the composition may be aqueous or oily), wherein the content of the nano carbon material is 0.00005 to 0.01 mass% (preferably 0.0001 to 0.01 mass%) wherein the total amount of the liquid medium and the nano carbon material is 100 mass%; and a mold release agent produced by diluting the mold release agent composition with a diluent, wherein the content of the nano carbon material is 0.0000005 to 0.005 mass% (0.005 to 50 ppm) [preferably 0.00005 to 0.005 mass% (0.5 to 50 ppm )] wherein the total amount of the liquid medium, the nano carbon material and the diluent is 100 mass%.

Description

Release agent composition and casting method using the same

The present invention relates to a release agent composition used for metal casting and the like, and a casting method using the release agent composition. More specifically, the present invention relates to a release agent composition having excellent releasability when used for metal casting, etc., despite the extremely small amount of compounded nanocarbon material, and the release agent composition. The present invention relates to a casting method using a mold composition, which can sufficiently suppress roughness of a release surface of a cast product.

In die casting such as aluminum die-casting, the die is prevented from welding with the cast product in which the molten metal is solidified, and the cast product is easily removed from the die without damaging it. A release agent is applied to the molding surface. These release agents are roughly classified into water-based and oil-based types, and in any release agent, waxes, esters, and silicone oils having high melting points and low thermal decomposition (high heat resistance) are used as lubricating components. , Graphite, silicate, and the like. Various inorganic powders are used as solid lubricants from the viewpoint of heat resistance. In the case of an aqueous release agent, the lubricating component is emulsified with a surfactant and used as an emulsion. On the other hand, in the case of an oil-based release agent, the lubricating component is used by dissolving or dispersing in a solvent such as petroleum.

In casting, a lubricant having a high thermal decomposition temperature is required to form a strong release film on the contact surface between a metal mold and a molten metal such as an aluminum melt that has a high temperature of 600 ° C. or higher. A mold release agent containing a lubricant is used. Thus, heat resistance is one of the important characteristics required for a mold release agent. From this viewpoint, for example, graphite is frequently used as an optimum lubricant. A mold release agent in which fine particles of aluminum oxide are blended is also known as a solid lubricant (see, for example, Patent Document 1). Furthermore, a mold release agent containing a silicone resin is also known as a solid lubricant (see, for example, Patent Document 2).

One of the biggest factors for stabilizing the solid lubricant blended in the mold release agent and functioning sufficiently as a lubricant is the formation of fine particles of the solid lubricant. When used, and mechanical dispersion such as stirring, the solid lubricant that has been used in the past usually has a limit of several μm to several tens of μm. Therefore, in recent years, fullerene has come to be used in the metalworking field, paying attention to actions such as lubricity. For example, a lubricant composition in which fullerene is added to a specific oil-based medium for the purpose of oxidation prevention is known. (For example, refer to Patent Document 3). Also known is a casting method in which a fullerene is attached to the cavity surface of a mold before filling with molten metal to form a carbon film, and a release agent is applied onto the carbon film (see, for example, Patent Document 4). .) Furthermore, film forming methods such as forming a lubricating film using fullerenes on the sliding surface or forming a fullerene film for releasing on the mold surface are also known (see, for example, Patent Document 5). .)

JP 2001-71092 A JP 2007-185678 A JP 2005-336309 A JP 2007-144499 A JP 2006-306010 A

However, although graphite has excellent lubrication performance, there are problems such as deterioration of the working environment and adhesion of black powder to the release surface, and it is currently desired to remove graphite. In addition to the solid lubricants described in Patent Documents 1 and 2, many of the conventional solid lubricants have a large particle size and can be uniformly dispersed in the release film formed on the molding surface of the mold. It's not easy. Therefore, the action of the solid lubricant is not sufficiently exhibited, the release resistance may become unstable due to local film rupture, and the release surface of a cast product or the like may be roughened.

On the other hand, Patent Document 3 merely discloses the addition of fullerene as an antioxidant, and does not disclose technical knowledge about the correlation between other properties of the release agent and fullerene. In addition, in the methods described in Patent Documents 4 and 5, the fullerene film is merely formed on the molding surface of the mold, and the fullerene is contained in the mold release agent and the action and effect are completely mentioned. Not.

The present invention relates to a release agent composition having excellent releasability when used for metal casting, etc., even though the amount of the nanocarbon material blended is extremely small, and this release agent composition An object of the present invention is to provide a casting method that can sufficiently suppress the roughness of the release surface of the cast product.

The present invention is as follows.
1. A release agent composition containing a nanocarbon material in a liquid medium, and when the total of the liquid medium and the nanocarbon material is 100% by mass, the content of the nanocarbon material is 0.00005. A mold release agent composition characterized by being -0.01% by mass.
2. 1. The nanocarbon material is a water-insoluble nanocarbon material. A release agent composition as described in 1.
3. 1. The nanocarbon material is fullerene. Or 2. The mold release agent composition as described in 2.
4). The above 1. containing a dispersant. To 3. The mold release agent composition of any one of these.
5. Above 1. To 4. It is a mold release agent composition formed by diluting the mold release agent composition of any one of these with a diluent, Comprising: The sum total of the said liquid medium, the said nanocarbon material, and the said diluent is 100 mass%. A release agent composition, wherein the content of the nanocarbon material is 0.0000005 to 0.005% by mass.
6). Above 1. To 5. A casting method comprising casting a material to be cast using the release agent composition according to any one of the above.
7). Above 1. To 5. An adhesion step for adhering the release agent composition according to any one of the above to the molding surface of the mold, filling the mold with the liquid casting material, and then molding the casting material into the mold 6. A solidification step for solidifying the inside of the mold and an extraction step for taking out the solidified material of the casting material from the mold. The casting method described in 1.
8). Above 1. To 5. 5. The mold release agent composition according to any one of the above, wherein the release agent composition is attached to a molding surface of a mold, and the release film containing the nanocarbon material is formed on the molding surface of the mold. Or 7. The casting method described in 1.

According to the mold release agent composition of the present invention containing a very small amount of nanocarbon material as a solid lubricant, it is possible to improve the mold release property of a cast product (solidified product) and the like and to release the cast product etc. Surface roughness can be suppressed sufficiently.
In addition, when the nanocarbon material is a water-insoluble nanocarbon material, the release agent composition is further improved and the release agent composition such as a cast product can be sufficiently prevented from being roughened. be able to.
Furthermore, when the nanocarbon material is fullerene, a release agent composition having particularly excellent releasability and capable of particularly sufficiently suppressing the roughness of the release surface of a cast product or the like can be obtained.
In addition, when the dispersant is contained, the nanocarbon material can be more uniformly dispersed, has better releasability, and can sufficiently suppress the roughness of the release surface of a cast product or the like. It can be set as a mold release agent composition.
According to another release agent composition of the present invention diluted with a diluent such as water, the release property is sufficiently improved in spite of a minute amount of the nanocarbon material, and a cast product or the like is used. Roughness of the release surface can be suppressed sufficiently.
According to the casting method of the present invention, it is possible to efficiently produce a high-quality cast product having no roughness on the release surface.
In addition, an adhesion step of attaching the release agent composition of the present invention or other present invention to the molding surface of the mold, filling the mold with a liquid material to be cast, and solidifying the material to be cast in the mold When the solidification step to be performed and the take-out step of taking out the solidified material of the cast material from the mold are provided in this order, a high-quality cast product can be manufactured more efficiently.
Further, when the release agent composition is attached to the mold surface of the mold and a release film containing the nanocarbon material is formed on the mold surface of the mold, the release film is easily formed, and excellent release properties are obtained. As a result, mold quality is manifested, and a high-quality casting with no roughness on the release surface can be produced more efficiently.

The present invention will be described in detail below.
(1) Release Agent Composition The release agent composition of the present invention is a release agent composition containing a nanocarbon material in a liquid medium, and the total of the liquid medium and the nanocarbon material is 100% by mass. In this case, the content of the nanocarbon material is 0.00005 to 0.01% by mass.
Another release agent composition of the present invention is obtained by diluting the release agent composition of the present invention with a diluent, and the total of the liquid medium, nanocarbon material and diluent is 100% by mass. The content of the nanocarbon material is 0.0000005 to 0.005 mass%.

The type, structure and shape of the “nanocarbon material” are not particularly limited. Examples of the nanocarbon material include fullerene, carbon nanotube [a material in which a six-membered ring network (graphene sheet) formed of carbon is formed into a single-layer or multilayer coaxial tube, and includes single-wall single-wall nanotubes and multilayers. And multi-wall nanotubes. ], Carbon nanofiber, helical carbon nanofiber, carbon nanoparticle (including nanohorn), carbon nitride film nanotube, carbon nitride film (nano) fiber, carbon nitride film nanoparticle, boron nitride carbon thin film formed on the surface Examples include carbon nanotubes, carbon (nano) fibers having a boron nitride carbon thin film formed on the surface, and carbon nanoparticles having a boron nitride carbon thin film formed on the surface. These nanocarbon materials may be used alone or in combination of two or more.

The nanocarbon material may be a derivative having a functional group in the carbon skeleton. For example, the nanocarbon material may be a fullerene derivative having a functional group in the carbon skeleton. Examples of this functional group include hydrophobic groups such as alkyl groups and aralkyl groups, and hydrophilic groups such as hydroxyl groups, amino groups, and carboxyl groups. These functional groups may be only one kind or two or more different functional groups.

In addition, the nanocarbon material may be water-insoluble or water-soluble. Here, “water-insoluble” means that, for example, the solubility in water in the temperature range of 0 to 100 ° C. is 1% or less, preferably 0.5% or less, more preferably 0.1% or less. means. Examples of the water-insoluble nanocarbon material include nanocarbon materials such as fullerenes and carbon nanotubes having no functional group. Moreover, as a water-soluble nanocarbon material, the nanocarbon material water-solubilized using the water-soluble polymer etc. is mentioned, for example. As the nanocarbon material, a water-insoluble nanocarbon material is preferable. When a water-insoluble nanocarbon material is used, a release agent composition having more excellent releasability can be obtained. Only one type of nanocarbon material may be used, or two or more types may be used in combination.

Fullerene can be used as the nanocarbon material. The kind and structure of the fullerene skeleton constituting the fullerene are not particularly limited. The carbon number of the fullerene skeleton is usually an even number, for example, an even number of 60 to 130, preferably an even number of 60 to 120, and more preferably an even number of 60 to 100. As the fullerene, for example, fullerene having a skeleton carbon number of 60, 70, 76, 78, 82, 84, 90, 94 and 96 and having a skeleton carbon number of 60 to 96, and a higher order fullerene having more skeleton carbon atoms are included. And fullerene having a skeleton carbon number of 60 is preferable.

Only one fullerene may be used, or two or more fullerenes of different types may be used in combination. For example, the fullerene may be a fullerene having a skeleton carbon number of 60, or may be a mixture containing a fullerene having a skeleton carbon number of 60 as a main component and containing at least one fullerene of a different type. The different types of fullerenes are not particularly limited, and examples include fullerenes having 60 to 96 carbon atoms (excluding those having 60 carbon atoms) and higher-order fullerenes having more skeleton carbons. As a mixture of two or more fullerenes having a skeleton carbon number of 60 as a main component, when the total of the skeleton carbon number of 60 fullerenes and other fullerenes is 100% by mass, for example, the skeleton carbon number of 60 A fullerene mixture containing 50 to 99% by mass of fullerene, preferably 60 to 98% by mass, more preferably 70 to 95% by mass, and still more preferably 75 to 90% by mass. As a specific example, for example, the fullerene having a skeleton carbon number of 60 in the above ratio and the skeleton carbon number of 70 fullerene is 0.5 to 30% by mass, preferably 1.5 to 25% by mass, more preferably 3%. A fullerene mixture containing ˜20% by mass, more preferably 8 to 15% by mass is mentioned.

The content of the nanocarbon material can be 0.0000005 to 0.01% by mass, preferably 0.000005 to 0.01% when the total of the liquid medium and the nanocarbon material is 100% by mass. The mass is preferably from 0.0001 to 0.01 mass%, more preferably from 0.00005 to 0.01 mass%, particularly preferably from 0.0001 to 0.005 mass%. A release agent composition having excellent releasability even when the content of the nanocarbon material is 0.0000005 to 0.01% by mass, and even when the content is less than 0.0001 to 0.005% by mass. It can be a thing. Note that the release agent composition of the present invention is generally used after being diluted 100 to 200 times with water or the like. Therefore, the lower limit of the content of the release agent composition before dilution can be set to 0.00005 to 0.000025% by mass, which is usually diluted to contain the nanocarbon material in the above range. Used as a diluted release agent composition.

Furthermore, the release agent composition of the present invention can be a release agent composition having excellent release properties even if the amount of the nanocarbon material is very small. That is, the content of the nanocarbon material is 0.00005 to 0.005 mass%, particularly 0.00005 to 0.001 mass%, when the total of the liquid medium and the nanocarbon material is 100 mass%. be able to. Thus, if the content of the nanocarbon material is extremely small, it is possible to obtain a release agent composition having excellent release properties and a more transparent and excellent appearance, and the nanocarbon material is gold. Dirt on the mold due to deposition on the mold surface is also prevented. In addition, since the nanocarbon material is extremely expensive, the release agent composition of the present invention that exhibits excellent releasability with a small amount of blending is extremely useful in practice.

The type of the “liquid medium” in which the nanocarbon material is mixed is not particularly limited. Examples of the liquid medium include water, an aqueous medium containing water (in addition to water, for example, lower alcohols having 1 to 3 carbon atoms such as methanol, ethanol, isopropyl alcohol, etc.), The release agent composition of the present invention may be an aqueous release agent composition in which the liquid medium is an aqueous medium, and the oil release agent composition in which the liquid medium is an oil medium. It may be.

The type of oil-based medium is not particularly limited. Examples of the oil-based medium include fats and oils and synthetic lubricating oils. Examples of the fats and oils include beef tallow, lard, rapeseed oil, coconut oil, palm oil, and nutka oil, and hydrogenated oils obtained by hydrogenating these fats and oils. Synthetic lubricating oils include fatty acids obtained from the above fats and oils, esters of fatty acids and alcohols, poly-α-olefins such as polybutene, polyols such as polyethylene glycol and polyol esters, other polyethers or polyesters, and Examples include higher alcohols. Furthermore, mineral oils such as kerosene, light oil, spindle oil, machine oil, neutral oil, turbine oil, cylinder oil, and liquid paraffin can also be used as the oil-based medium. These oil-based media may be used alone or in combination of two or more.

The liquid medium may be water, an aqueous medium, or a mixed medium of the aforementioned lower alcohol and an oil medium, and in this case, the content of the oil medium is not particularly limited. When the release agent composition is aqueous, when the release agent composition is 100% by mass, the content of the oil-based medium is usually 0.1 to 30% by mass, preferably 0.5%. -25% by mass, more preferably 1-20% by mass, and still more preferably 1-10% by mass. Further, when the release agent composition is oily, when the release agent composition is 100% by mass, the content of the oil-based medium is usually 50% by mass or more and less than 100% by mass, preferably Is 60 to 95% by mass, more preferably 65 to 90% by mass, still more preferably 70 to 90% by mass.

In the release agent composition of the present invention, in order to more uniformly disperse and contain the nanocarbon material in the liquid medium, one or more kinds of dispersants are usually contained. If the nanocarbon material is uniformly dispersed and contained in the liquid medium, destabilization of the release property due to the film rupture can be suppressed, and roughness of the release surface of a molded product such as a cast product can also be suppressed. preferable. The type of the dispersant is not particularly limited, and examples of the dispersant include hydroxystearic acid polymer, maleated polybutene, alkenyl succinimide, alkenyl succinate, and various surfactants. As the surfactant, any of a nonionic surfactant, an anionic surfactant, an amphoteric surfactant and a cationic surfactant can be used. These surfactants may be used alone or in combination of two or more.

Examples of the nonionic surfactant include polyoxyethylene alkyl ether, polyoxyalkylene (ethylene and / or propylene) alkylphenyl ether, polyethylene glycol (or polyethylene oxide) and higher fatty acids (for example, having 12 to 18 carbon atoms). Polyoxyethylene sorbitan alkyl ester formed using sorbitan, polyethylene glycol, and higher fatty acid (for example, linear or branched fatty acid having 12 to 18 carbon atoms). And other ester polymer compounds. These nonionic surfactants can also be used for emulsification or solubilization of oil-based media.

Examples of the anionic surfactant include fatty acid salts, sulfate ester salts, sulfonate salts, phosphate ester salts, and dithiophosphate ester salts. Furthermore, examples of amphoteric surfactants include amino acid type and betaine type carboxylates, sulfate esters, sulfonates, and phosphate ester salts. Examples of the cationic surfactant include aliphatic amine salts and quaternary ammonium salts.
When the dispersant is contained, the content thereof can be preferably 10 to 200 parts by mass, more preferably 50 to 150 parts by mass when the nanocarbon material is 100 parts by mass.

In addition to the above-described dispersant, the release agent composition may appropriately contain one or more of various additives generally used in the release agent composition as necessary. it can. Examples of such additives include (1) oily agents (such as carboxylic acid esters, hindered esters and alkylamines), (2) organic metal salts (such as zinc dithiophosphate and molybdenum dithiocarbamate), (3) Other solid lubricants (fluorine-based solid lubricants such as graphite, molybdenum disulfide, graphite fluoride and polytetrafluoroethylene), (4) silicone oil, (5) antioxidant, (6) rust inhibitor, And (7) anticorrosives and the like.

When other solid lubricants are used, graphite fluoride and fluorine-based solid lubricants have little effect on the work environment, and there is no particular problem. For example, graphite deteriorates the work environment due to the occurrence of black dirt. May bring. Therefore, when using other solid lubricants, it is preferable to pay attention to the type and blending amount. For example, in graphite and molybdenum disulfide, the content of these other solid lubricants is 1% by mass or less, preferably 0.5% by mass or less, when the release agent composition is 100% by mass. Preferably it is 0.1 mass% or less.

In addition, an extreme pressure additive is not usually used in the release agent composition, but it may be contained. When an extreme pressure additive (for example, a sulfur-based and phosphorus-based extreme pressure additive) is contained, the content thereof is 1% by mass or less, particularly 0.8% when the release agent composition is 100% by mass. A small amount of 5% by mass or less, and further 0.1% by mass or less is preferable.

The release agent composition of the present invention can be used as it is without being diluted. If necessary, it can be diluted with a diluent and used as another release agent composition of the present invention (hereinafter referred to as “diluted release agent”). When preparing this diluting release agent, water, an oil-based medium and / or the above-mentioned lower alcohol, particularly water, are used as the diluting agent. Further, the dilution rate is not particularly limited, but it can be generally 1.5 to 300 times, particularly 2 to 300 times, and further 5 to 300 times, preferably 10 to 300 times, more preferably 50 to 250 times. More preferably, it is 100 to 250 times. The content of the nanocarbon material in the diluted mold release agent is 0.0000005 to 0.005 mass% (0.005 to 50 ppm) when the total of the liquid medium, nanocarbon material and diluent is 100 mass%. ), Preferably 0.00005 to 0.005 mass% (0.5 to 50 ppm), more preferably 0.0001 to 0.001 mass% (1 to 10 ppm).

Furthermore, with this diluted mold release agent, even if the nanocarbon material is in a trace amount, it can be a diluted mold release agent having excellent mold release properties. That is, the content of the nanocarbon material is 0.0000005 to 0.0005 mass% (0.005 to 5 ppm), especially 0.005 mass% when the total of the liquid medium, nanocarbon material and diluent is 100 mass%. It can be 0.0005 to 0.0003 mass% (0.05 to 3 ppm), and further 0.00005 to 0.0001 mass% (0.5 to 1 ppm). In this way, if the content of the nanocarbon material is extremely small, it can be a dilute mold release agent that has excellent releasability, has a particularly excellent appearance, and prevents mold contamination. This is also advantageous in terms of cost. Accordingly, the release agent composition of the present invention is usually diluted with a diluent to the above magnification, preferably 10 to 300 times, more preferably 50 to 250 times, still more preferably 100 to 250 times. Used as a mold.
In this diluted mold release agent, the description relating to the mold release agent composition of the present invention is applied as it is for other matters except that the mold release agent composition of the present invention is diluted with water or the like. can do.

The preparation method of the release agent composition and the diluted release agent is not particularly limited as long as the nanocarbon material can be dispersed and contained in the liquid medium. Examples of equipment used for dispersion include ordinary dispersion equipment such as a three-one motor. In addition, the nanocarbon material can be refined and dispersed in a liquid medium using a dispersing device capable of powerful stirring and dispersion such as a bead mill, a high-speed stirrer, a homomixer, and an ultrasonic homogenizer. Thus, by using a high-performance dispersing device, a release agent composition and a diluted release agent can be efficiently prepared. Regardless of which equipment is used, the dispersion equipment should be selected and the dispersion conditions should be set so that the nanocarbon material is more evenly dispersed, resulting in a more homogeneous release agent composition and diluted release agent. Is preferred. Further, in such a preparation method, if the nanocarbon material is dispersed in a liquid medium such as water and an emulsion is formed, and then a shearing force is applied, there is a risk of causing emulsion breakage. Therefore, for example, an oily component and a dispersant such as a surfactant are mixed to prepare a mixture, and then a nanocarbon material is blended and dispersed in the mixture to prepare a preliminary dispersion, A method of blending the preliminary dispersion in water or the like and emulsifying the nanocarbon material is preferable.

The mold release agent composition and the diluted mold release agent can be used in the molding of a metal material using a mold and a non-metal material such as plastic, particularly in the molding of a metal material. Molding of the metal material includes casting and die forging, and the release agent composition and the diluted release agent are particularly useful as a release agent in casting. Moreover, the metal material used for shaping | molding is also not specifically limited, Copper alloys, such as aluminum alloys, such as duralumin, iron, copper, brass, etc. are mentioned. Furthermore, examples of the molding of the nonmetallic material include injection molding and the like, and the nonmetallic material used for molding is not particularly limited, and various thermoplastic resins such as polyamide and polyester are exemplified.

(2) Casting method The casting method of the present invention is characterized by casting a material to be cast using the release agent composition or the diluted release agent of the present invention.

The material and shape of the above “cast material” are not particularly limited. The cast material may be a metal material or a non-metal material such as plastic. Specifically, the material of the material to be cast includes (1) iron, cast iron, steel (carbon steel, stainless steel, etc.) and iron alloy, (2) nickel, titanium, aluminum, magnesium, zinc, copper, etc. Non-ferrous metals, alloys of non-ferrous metals such as Inconel (nickel-based alloy) and titanium alloys, (3) various thermoplastic resins such as polyamide and polyester, and the like.

The method for supplying the release agent composition and the diluted release agent is not particularly limited. For example, the release agent composition and the diluted release agent are sprayed (supplied in a liquid form from a nozzle) or applied to a molding surface of a mold such as a mold used for casting. And using an oil jug etc.)] and the like.

In the casting method of the present invention, the specific method and conditions for casting the material to be cast are not particularly limited. For example, an adhesion process in which a mold release agent composition or a dilute mold release agent is adhered to a molding surface of a mold by a method such as spraying or coating, and a liquid casting material (such as a molten metal) is filled in the mold. The casting method includes a solidification step for solidifying the material to be cast in the mold and a take-out step for taking out the solidified material (cast product) from the mold in this order. Further, in this casting method, the release agent composition or the diluted release agent can be adhered to the molding surface of the mold, and a release film containing the nanocarbon material can be formed on the molding surface of the mold. As a result, it is possible to produce a cast product that exhibits sufficient releasability and has no roughness on the release surface.

Hereinafter, the present invention will be specifically described by way of examples. In addition, this invention is not restrict | limited at all by these Examples.
(1) Preparation of aqueous release agent composition A commercially available fullerene mixture (manufactured by Frontier Carbon Co., Ltd., trade name “Nanomu Mix STF”) was used as a nanocarbon material. First, an aqueous release agent composition was prepared by combining an oily component and a surfactant (100 parts by mass when the nanocarbon material was 100 parts by mass) with a three-one motor (manufactured by HEIDON, The mixture is prepared by stirring with model “BL1200”, general-purpose type four blades, rotation speed 700 rpm, and then a predetermined amount of nanocarbon material is blended in this mixture, and in the same manner as described above, three minutes by a three-one motor Stir and mix to prepare a pre-dispersion, then blend the pre-dispersion in water so that the nanocarbon material has the content shown in Table 1, and stir with a three-one motor as above. Emulsified and prepared. Subsequently, these aqueous release agent compositions were diluted 200 times by mass with tap water to prepare sample solutions (diluted release agents). Further, a sample solution was prepared in the same manner using graphite (particle diameter: 8 μm) instead of the nanocarbon material.

(2) Releasability test The sample solution prepared in the above (1) was spray-coated on a steel plate to form a release film, and then a cylindrical body having an inner diameter of 76 mm was placed on the release film surface. Next, a molten aluminum alloy was poured into the cylindrical body. And after the molten metal solidified, the cylindrical body was pulled in the horizontal direction, and the mold release resistance was measured with a load cell. The results are also shown in Table 1. The test conditions are as shown in Table 2.

According to Table 1, even if the content of fullerene in the diluted release agent is a very small amount from 0.0000005 mass% (0.005 ppm) to 0.00005 mass% (0.5 ppm), it contains a solid lubricant. When it is not, and when it contains 0.00005 mass% (0.5 ppm) of graphite, it can be seen that the release resistance is lower than that of the graphite and it has excellent release properties.

(3) Appearance of release agent composition The above-mentioned fullerene mixture was blended with an almost colorless and transparent oil-based release agent, and the appearance was observed. As a result, when the blending amount was 0.1% by mass, a black opaque release agent composition was obtained in the same manner as when the same amount of graphite was blended. Further, when the blending amount was 0.01% by mass, the color was brown, and when the blending amount was less than this, a light-colored release agent composition having a transparent feeling was obtained. As described above, the release agent composition and diluted release agent of the present invention having a very small content of nanocarbon material were sufficiently transparent and had an excellent appearance.

(4) Contamination of mold surface of mold The deposition (generation of dirt) of the components of the release agent composition on the mold surface of the mold was evaluated by a non-deposition test. As a result, when 1% by mass of the fullerene mixture was blended and diluted 65 times with water (the content was 0.015% by mass), the deposition amount was large. On the other hand, when 0.1% by mass is blended and diluted 65 times with water (content is 0.0015% by mass), the deposition amount is the same as when no fullerene mixture is blended, There was very little and almost no dirt was generated. As described above, in the release agent composition of the present invention in which the content of the nanocarbon material is extremely small, the occurrence of dirt is sufficiently suppressed, and the diluted release agent in which the content of the nanocarbon material is very small. Then, it turns out that there is almost no generation | occurrence | production of dirt.

It should be noted that the present invention is not limited to the description of the above-described embodiments, and various modifications can be made within the scope of the present invention depending on the purpose, application, and the like. For example, when the prepared release agent composition is used as it is without diluting with water, it can be a release agent composition having excellent release properties, although the appearance and the like are slightly reduced.

The present invention can be used for die casting of various metals such as aluminum die casting.

Claims

A release agent composition containing a nanocarbon material in a liquid medium,
A release agent composition, wherein the total content of the liquid medium and the nanocarbon material is 100% by mass, and the content of the nanocarbon material is 0.00005 to 0.01% by mass.
The mold release agent composition according to claim 1, wherein the nanocarbon material is a water-insoluble nanocarbon material.
The mold release agent composition according to claim 1 or 2, wherein the nanocarbon material is fullerene.
The mold release agent composition according to any one of claims 1 to 3, comprising a dispersant.
A release agent composition obtained by diluting the release agent composition according to any one of claims 1 to 4 with a diluent,
Release agent characterized in that the content of the nanocarbon material is 0.0000005 to 0.005 mass% when the total of the liquid medium, the nanocarbon material and the diluent is 100 mass% Composition.
A casting method comprising casting a material to be cast using the release agent composition according to any one of claims 1 to 5.
An attaching step of attaching the release agent composition according to any one of claims 1 to 5 to a molding surface of a mold;
A solidification step of filling the mold with the liquid casting material and solidifying the casting material in the mold;
The casting method according to claim 6, further comprising an extraction step of taking out the solidified material of the casting material from the mold.
The mold release agent composition according to any one of claims 1 to 5 is attached to a molding surface of a mold, and a release film containing the nanocarbon material is formed on the molding surface of the mold. The casting method according to claim 6 or 7.