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High Technology Lubrication for Sawing Aluminum


Precision lubricants, sometimes called micro-applied lubricants, have revolutionized the sawing of aluminum -- billets, extrusions, ingots, sheet and plate -- in recent years.  This new technology, which is believed to have its origins in the aerospace industry, is now the standard in plants around the world.

Users know these products by various trade names - CanMist and others.  All offer advanced chemical properties and require special applicators for precise application of minimal quantities of coolant/lubricant to the saw blade surfaces.

The function of saw coolants/lubricants is to cool the blade and prevent the accumulation of metal build-up of hot metal in the "gullet" of the blade.  Precision lubricants typically offer significant advantages over the water emulsions, solvent carried oils, and wax sticks which were previously used:


  • better quality cut ends
  • drier cut ends
  • less cleaning of parts and machinery
  • reduced lubricant costs
  • lower smoke generation
  • minimal staining of parts
  • drier saw chips - easier to sell or reclaim
  • increased tool life
  • improved safety (not OSHA regulated)
  • no coolant maintenance, reclamation, or disposal
  • reduced storage, freight, and handling costs

Chemical technology has continued to improve the performance of sawing fluids, resulting in improved quality, with no odor, elimination of smoke, non staining, non freezing, ease of removal in anodizing and painting, and improved pricing.  Most of these products are biodegradable, non-toxic, and environmentally sound.  Depending on the application, additives may be included for increased heat extraction, to be non-staining in heat treating, and to provide extreme pressure and wear properties.  The quality and performance of these products are expected to continue to be improved in the future.

Precision Applicators

Special applicator systems are needed to precisely meter and dispense the tiny amounts of these micro-applied sawing fluids in exactly the right location.  In the most common designs, fluid is metered by air-driven positive-displacement injector pumps, which dispense a variable fluid volume per stroke.  The driving air is likewise adjustable through a pneumatic timer, and the spray pattern may be fine tuned by adjusting the atomizing air, which is delivered separately to the applicator nozzle through a coaxial tube.

Many commercially available micro-applicators have not been compatible with high-tech sawing fluids, so it is important to insure compatibility of seals and other components.  Some designs have been difficult to repair.  Recent improvements to applicator systems include:


  • larger reservoirs (up to ½ gallon)
  • self-priming fluid injectors
  • manifolds and mounting brackets for yhe spray tips
  • improved component materials - seals, metals, fittings
  • more easily repaired

Amcol Corporation has recently introduced the unique "T-60 Posi-Pump," which incorporates multiple injector pumps in a single extruded aluminum body - normally 1 to 5 injectors per unit, but even 8 or 10 are possible.  Brass components and Viton seals insure fluid compatibility and long life; there is no stacking of pumps and no O-rings.  The injectors are inherently self-priming, and vapor lock and cavitation are eliminated.

Tooling Lubrication for Non-Ferrous Extrusion

Specialty lubricants and release agents for high temperature non-ferrous extrusion press tooling from Amcol may be used to prevent metal build-up on tooling and to prevent sticking.  Typical applications:


  • fixed dummy blocks
  • butt shear blades
  • hot log shear tooling and entry lubrication

Lubricants of this family increase productivity by reducing metal build-up on dummy blocks, butts stuck to the ram or butt shear blade, and logs hanging up at the entry to the hot shear.  Fluids may be applied by hand-held wand or sprayed automatically.

Automatic Lubrication of Press Tooling

Automatic spray applicators relieve the operator from the job of periodically hand spraying the dummy block and butt shear and save downtime by spraying automatically during the press dead cycle.  Automatic applicator systems available from Amcol are custom tailored to the individual press.  They may be purchased complete with control timers or may be actuated from the press PLC control system.  They are typically configures to apply fluids periodically, for example, after every 5 or 10 billets are extruded.
Similar applicators may be added to hot log shears to eliminate problems of hang-up at the point where the log enters the shear tools.


For more information contact:

Amcol Corporation

21435 Dequindre  -  Hazel Park MI 48030 USA

Tel:    248-414-5700    Fax:    248-414-7489

Or contact:

Al Kennedy  -  Agent for portions of the southeastern USA

Kennedy Eurotech, Inc.  -  4 Oak Point  -  Newnan GA 30263 USA

Tel:  770-304-1000 or 800-364-7995  -  e-mail: alkennedy@numail.org