KelviGlide .
The “Instant-Melt” Shield: Extended Shot Sleeve and Plunger Tip Life, Designed for Auto-Dispense Systems.
Stop halting production to replace worn plunger tips. KelviGlide is engineered specifically for automated dosing systems in high-pressure aluminum die casting. Using a proprietary blend of Synthetic and Amorphous Graphite in a dual-wax carrier system, our 'Tribo-Shield' granules instantly melt at 110-112°C to form a dry graphite barrier that prevents metal-to-metal contact even at 500°C. Designed to extend plunger tip and shot sleeve life beyond baseline performance. At a calculated cost of approximately ₹0.14 per shot, KelviGlide protects your critical tooling against thermal welding and galling.
- Extended Service Life
- Engineered for Auto-Dispensers
- Dual-Graphite Lubrication System
- 500°C Thermal Stability
Technical Overview
KelviGlide represents engineered solid lubrication optimized for automated dispensing in aluminum die casting. By replacing volatile oils with a 45% dual-graphite system (Synthetic + Amorphous) in a clean-burning dual-wax carrier, it forms a thermally stable dry film up to 500°C. Designed for budget-conscious foundries, it extends plunger tip life to 22,000-28,000 shots, reduces smoke by 70% compared to high-paraffin alternatives, and costs approximately ₹0.14 per shot. It's a clean, cost-effective solution for protecting shot-end components.
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Why KelviGlide Delivers Results
Engineered for performance, validated by 100+ foundries worldwide
Extended Service Life
Designed to extend the service life of expensive ductile iron plunger tips and H13 shot sleeves. By preventing metal-to-metal contact with a continuous dry graphite film, KelviGlide significantly delays the onset of erosion, soldering, and wash-out common in aluminum die casting operations.
Engineered for Auto-Dispensers
Formulated with precise flowability and bulk density (0.60-0.66 g/cm³) to prevent bridging in hoppers. Spherical granules (1.5-2.5mm) work seamlessly with standard auto-lube systems ensuring reliable, jam-free dosing shot after shot with <5% fines generation.
Dual-Graphite Lubrication System
We use a balanced graphite loading combining high-purity Synthetic Graphite for superior lubricity and Amorphous Graphite for bulk film formation. This 'dry' lubrication system provides excellent friction reduction, ensuring the plunger glides smoothly without the smoke and fire hazards of oil-based lubricants.
500°C Thermal Stability
Standard waxes and oils break down at 350°C. KelviGlide's graphite-based system remains stable up to 500°C, maintaining a protective separation layer between the steel tip and the shot sleeve during the critical injection phase when molten aluminum enters at 660-680°C.
Low Smoke, Minimal Residue
Dramatically reduce the black smoke that plagues die casting shops. KelviGlide uses a proprietary wax formulation that minimizes smoke generation. Its dual-wax carrier burns cleanly, leaving behind only the beneficial graphite film.
Precision Dosing Economy
Automated systems eliminate operator error and waste. Precise dosing (1-3g depending on machine size) means you use exactly what you need—costing approximately ₹0.12-₹0.18 per shot depending on machine tonnage and dosing requirements.
Plunger Lubricant for Die Casting & HPDC
KelviGlide is a solid plunger lubricant for die casting that protects the plunger tip and shot sleeve. It is built for aluminum die casting and HPDC where shot-end temperatures are high.
Graphite Wax Plunger Beads for Auto-Dispense
Synthetic graphite plunger beads in a graphite wax carrier flow cleanly through automated plunger lube systems. The dry film plunger lubricant delivers consistent, repeatable dosing with low fines.
High Temperature 500°C, Low Smoke Performance
High temperature plunger lube stable to 500°C with low smoke operation. A clean plunger oil alternative that reduces soldering and extends plunger tip life with a stable dry film.
Automated Protection in 4 Steps
Physics-based lubrication seamlessly integrated into your cycle
Auto-Dispense
Your auto-lubrication unit drops a precise dose (e.g., 1.5-2.5g for a 600T machine) of KelviGlide granules into the shot sleeve through the pour hole. The calibrated spherical shape (1.5-2.5mm) and optimized bulk density (0.60-0.66 g/cm³) prevent hopper bridging and ensure consistent feed rates with <5% fines generation.
Technical Note:Compatible with granules auto-dispensers. Free-flowing granules require no manual intervention.
Rapid Melt & Spread
Upon contact with the hot sleeve (200–350 °C), the dual-wax carrier system melts instantly at 110–120 °C. The low-viscosity proprietary wax blend ensures rapid spreading, while the high graphite content disperses uniformly across the sleeve surface within 1–2 seconds.
Technical Note:The controlled melting point ensures stability during Indian summer storage (up to 100°C) while providing instant response on the hot sleeve.
Dry Film Formation
As the wax carrier vaporizes cleanly, it leaves behind a continuous dry graphite film approximately 4 µm thick around the plunger tip, at the interface where the shot sleeve and plunger tip slide. The synthetic graphite delivers superior boundary lubrication, while the amorphous graphite forms the primary protective layer, with a proprietary formulation ensuring strong film adhesion and thermal stability.
Technical Note:The graphite film remains stable up to 500°C, providing protection during the critical metal injection phase when temperatures spike.
Clean Ejection
The plunger advances smoothly on the dry graphite film, preventing metal-to-metal contact and soldering. The biscuit ejects cleanly with minimal residue. The burnt carrier and excess graphite exit with the biscuit and runner system, maintaining shot sleeve cleanliness cycle after cycle.
Technical Note:Low-volatility wax reduces smoke generation by 70% compared to high-paraffin formulations, improving shop air quality.
Dry Graphite Lubrication Technology
KelviGlide employs 'Solid Phase Lubrication' principles optimized for aluminum die casting. Standard oils rely on liquid film formation, which fails catastrophically when molten aluminum (660-680°C) contacts the sleeve, causing the oil to vaporize instantly and leave the steel unprotected. KelviGlide's dual-graphite system creates a thermally stable dry film. The Synthetic Graphite's lamellar structure provides low-friction sliding planes, while the Amorphous Graphite creates bulk coverage. The dual-wax carrier ensures rapid deployment at 110-120°C, then burns cleanly with minimal smoke. This continuous graphite barrier physically prevents iron from the plunger tip from reacting with the molten aluminum, blocking the formation of brittle intermetallic compounds (soldering) that cause rapid wear and seizure. The result is extended component life and reduced downtime for maintenance.
Best Practices
- Follow recommended application rates strictly
- Store in a cool, dry place away from sunlight
- Consult technical team for customized guidance
- Monitor results and adjust as needed
Complete Technical Specifications
| Specification | Value |
|---|---|
| Value Engineering | |
Cost Per Shot (Est) | ₹0.12 - ₹0.18 |
Dosing Method | Auto-Dispenser Optimized |
Wear Reduction | Demonstrable vs. baseline |
Smoke Generation | Low |
| Active Ingredients | |
Primary Lubricant | Synthetic & Amorphous Graphite |
Synthetic Graphite | High Lubricity |
Amorphous Graphite | Film Former |
Carrier Matrix | Dual wax carrier matrix |
Additives | Research driven proprietary additives |
Form | Spherical Granules (1.5-2.5mm) |
Melting Point | 110-120°C (Rapid Spread) |
| Physical Properties | |
Bulk Density | 0.60-0.66 g/cm³ |
Particle Size | 1.5-2.5 mm (nominal) |
Shape | Spherical / Near-Spherical |
Color | Black (45.5% Carbon) |
Friability | <4% Fines |
Flowability | Free-Flowing (Hopper Safe) |
| Operational Limits | |
Thermal Stability | Up to 500°C |
Operating Temperature | 200-350°C (Sleeve Temp) |
Shot Sleeve Compatibility | H13 Steel (Nitrided) |
Plunger Tip Compatibility | Ductile Cast Iron |
Alloy Compatibility | ADC12, A380, AlSi9Cu3, etc. |
Film Thickness | ~4.0 µm (Calculated) |
| Application Guide | |
Dosing Amount | 1-3g (Varies by Tonnage) |
Application Point | Pour Hole / Shot Sleeve |
Frequency | Every Shot (Auto-Dispense) |
Melt Response | <1-2 seconds @ 250°C |
| Logistics & Safety | |
Pack Size | 25 kg Bags (Moisture-Resistant) |
Shelf Life | 24 Months (Store <35°C) |
Storage | Cool, Dry Place |
Safety | Non-Hazardous, Low VOC |
Climate Stability | India-Tested (Stable to 100°C) |
| Specification | Value |
|---|---|
| Value Engineering | |
Cost Per Shot (Est) | ₹0.12 - ₹0.18 |
Dosing Method | Auto-Dispenser Optimized |
Wear Reduction | Demonstrable vs. baseline |
Smoke Generation | Low |
| Active Ingredients | |
Primary Lubricant | Synthetic & Amorphous Graphite |
Synthetic Graphite | High Lubricity |
Amorphous Graphite | Film Former |
Carrier Matrix | Dual wax carrier matrix |
Additives | Research driven proprietary additives |
Form | Spherical Granules (1.5-2.5mm) |
Melting Point | 110-120°C (Rapid Spread) |
| Physical Properties | |
Bulk Density | 0.60-0.66 g/cm³ |
Particle Size | 1.5-2.5 mm (nominal) |
Shape | Spherical / Near-Spherical |
Color | Black (45.5% Carbon) |
Friability | <4% Fines |
Flowability | Free-Flowing (Hopper Safe) |
| Operational Limits | |
Thermal Stability | Up to 500°C |
Operating Temperature | 200-350°C (Sleeve Temp) |
Shot Sleeve Compatibility | H13 Steel (Nitrided) |
Plunger Tip Compatibility | Ductile Cast Iron |
Alloy Compatibility | ADC12, A380, AlSi9Cu3, etc. |
Film Thickness | ~4.0 µm (Calculated) |
| Application Guide | |
Dosing Amount | 1-3g (Varies by Tonnage) |
Application Point | Pour Hole / Shot Sleeve |
Frequency | Every Shot (Auto-Dispense) |
Melt Response | <1-2 seconds @ 250°C |
| Logistics & Safety | |
Pack Size | 25 kg Bags (Moisture-Resistant) |
Shelf Life | 24 Months (Store <35°C) |
Storage | Cool, Dry Place |
Safety | Non-Hazardous, Low VOC |
Climate Stability | India-Tested (Stable to 100°C) |
Value Engineering
Active Ingredients
Physical Properties
Operational Limits
Application Guide
Logistics & Safety
KelviGlide vs. Traditional Plunger Oil/Grease
Side-by-side comparison of key performance metrics
| Evaluation Criteria | KelviGlide Recommended | Traditional Plunger Oil/Grease |
|---|---|---|
Cost Per Shot | ₹0.12 - ₹0.18 (Precise Auto-Dosing) | ₹0.50 - ₹1.00 (Spray Waste) |
Tip & Sleeve Life | 22,000-28,000 Shots (Extended) | Baseline (Frequent Failure) |
Active Agent | Dual-Graphite System | Mineral Oil / Animal Fat |
Thermal Stability | 500°C (Film Maintains) | 350°C (Burns/Flashes) |
Shop Floor Air | Low Smoke | Heavy Smoke / Fumes |
Porosity Risk | Low (Minimal Gas Evolution) | High (Trapped Oil Vapor) |
Dispensing | Automated & Precise (1-3g) | Messy Spray / Manual |
Residue on Castings | Minimal (Clean Ejection) | Oily Stains / Visible Marks |
Cost Per Shot
Tip & Sleeve Life
Active Agent
Thermal Stability
Shop Floor Air
Porosity Risk
Dispensing
Residue on Castings
Use Cases for KelviGlide
Real-world applications where KelviGlide delivers measurable results.
Plunger wear reduction
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"Switching to KelviGlide Switching to this product reduced our scrap rate by 34% in the first month. The ROI was immediate and measurable."
Frequently Asked Questions
Common questions about technical specifications and usage for KelviGlide.
Still have questions
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Need More Technical Information
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PDF Format • Complete Specifications