{"id":9315,"date":"2026-03-19T13:44:30","date_gmt":"2026-03-19T04:44:30","guid":{"rendered":"https:\/\/www.dry-fog.com\/en\/?post_type=cases&#038;p=9315"},"modified":"2026-03-23T10:45:49","modified_gmt":"2026-03-23T01:45:49","slug":"nozzle-metal-003","status":"publish","type":"cases","link":"https:\/\/www.dry-fog.com\/en\/projects-technology\/cases\/nozzle-metal-003\/","title":{"rendered":"Aluminum Die Casting: Targeted Die Cooling With a Pneumatic Spray Nozzle to Shorten Cycle Time"},"content":{"rendered":"<section>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<h3 style=\"font-size: clamp(20px, 2vw, 30px);padding-left: 14px;margin-top: 0;margin-bottom: 0.8rem;border-left: 5px solid #0c9b6f\">Key Reasons for Implementation<\/h3>\n<ul style=\"list-style-type: disc;margin-left:2.8rem;font-size: 1rem;line-height:1.6rem\">\n<div style=\"margin-bottom:0.8rem\">\n<li>Use of a pneumatic (air-atomizing) nozzle that minimizes the risk of wetting the die and surrounding areas<\/li>\n<\/div>\n<div style=\"margin-bottom:0.8rem\">\n<li>Precise cooling of the die\u2019s thick sections<\/li>\n<\/div>\n<li>A compact, lightweight body that places minimal load on the end of a robotic arm<\/li>\n<\/ul>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<div style=\"margin-top:3rem;margin-bottom:3rem;width:100%;border-bottom:1px solid #E9E9E9\"><\/div>\n<\/div>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<div style=\"float: left;padding-top:1.5rem;padding-left: 2rem\">\n<img decoding=\"async\" loading=\"lazy\" src=\"https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/call-1.jpg\" alt=\"\" width=\"330\" height=\"296\" class=\"alignleft size-medium wp-image-5969\" \/>\n<\/div>\n<div style=\"float: right;margin-top: 4rem;margin-right: 3%\">\n<ul style=\"list-style-type: none;margin-left:0rem;font-size: 1.2rem;font-weight: bold;line-height:1.6rem\">\n<div style=\"margin-bottom:0.8rem;background:url(https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/check.svg) no-repeat 0 0;background-size:auto 20px;padding-left: 30px\">\n<li>Not sure which product is right for you?<\/li>\n<\/div>\n<div style=\"margin-bottom:0.8rem;background:url(https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/check.svg) no-repeat 0 0;background-size:auto 20px;padding-left: 30px\">\n<li>Curious about the total cost?<\/li>\n<\/div>\n<div style=\"margin-bottom:0.8rem;background:url(https:\/\/www.dry-fog.com\/jp\/wp-content\/uploads\/sites\/2\/2024\/10\/check.svg) no-repeat 0 0;background-size:auto 20px;padding-left: 30px\">\n<li>Wondering where to start?<\/li>\n<\/div>\n<div style=\"margin-bottom:0.8rem;font-size: 0.8rem;font-weight: bold;padding-left: 30px\">\n<li>We\u2019re here to help \u2013 reach out with any questions.<\/li>\n<\/div>\n<\/ul>\n<div style=\"text-align:center;margin-top:2rem;margin-bottom: 2rem\">\n<a style=\"margin-bottom:1rem;margin-left:2rem;justify-content: center;align-items: center;padding: 0.5rem 4rem;color: #fff;font-weight: 500;font-size:1.2rem;width:auto;background: #0C9B6F;border-radius: 30px\" href=\"https:\/\/www.dry-fog.com\/en\/contact\/\" target=\"_blank\" rel=\"noopener\">Contact Us<\/a>\n<\/div>\n<\/div>\n<div style=\"clear:both\"><\/div>\n<\/div>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<div style=\"margin-top:0rem;margin-bottom:3rem;width:100%;border-bottom:1px solid #E9E9E9\"><\/div>\n<\/div>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<h3 style=\"font-size: clamp(20px, 2vw, 30px);padding-left: 14px;margin-top: 0;margin-bottom: 0.8rem;border-left: 5px solid #0c9b6f\">Challenges Faced by the Customer<\/h3>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">At a plant manufacturing aluminum die-cast components for automobiles and motorcycles, a project was launched to <span style=\"font-weight:bold\">reduce cycle time<\/span>.<\/p>\n<p><img decoding=\"async\" src=\"https:\/\/www.dry-fog.com\/en\/wp-content\/uploads\/sites\/3\/2026\/03\/nozzle-metal-003-image_1.jpg\" alt=\"\" width=\"820\" class=\"aligncenter size-full wp-image-6304\" \/><\/p>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">As the team reviewed the process, <span style=\"font-weight:bold\">crankcase die cooling<\/span> emerged as a key bottleneck. <\/p>\n<p><img decoding=\"async\" src=\"https:\/\/www.dry-fog.com\/en\/wp-content\/uploads\/sites\/3\/2026\/03\/nozzle-metal-003-image_2.jpg\" alt=\"\" width=\"820\" class=\"aligncenter size-full wp-image-6304\" \/><\/p>\n<p><img decoding=\"async\" src=\"https:\/\/www.dry-fog.com\/en\/wp-content\/uploads\/sites\/3\/2026\/03\/nozzle-metal-003-image_3.jpg\" alt=\"\" width=\"820\" class=\"aligncenter size-full wp-image-6304\" \/><\/p>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">Under normal operating conditions, the die is opened after each shot, and a release agent is sprayed each time to suppress the rise in die temperature. However, because the crankcase has a complex shape and thick sections, the die temperature could reach as high as <span style=\"font-weight:bold\">400\u00b0C<\/span> under certain conditions.<\/p>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">When die temperature exceeded 400\u00b0C, defects such as soldering and surface imperfections occurred, and the die itself could also be damaged. As a result, the machine had to be stopped so the die could cool naturally.<\/p>\n<div style=\"text-align: center;margin-bottom: 10px\">\n<img decoding=\"async\" src=\"https:\/\/www.dry-fog.com\/en\/wp-content\/uploads\/sites\/3\/2026\/03\/nozzle-metal-003-image_4.jpg\" alt=\"\" width=\"820\" class=\"aligncenter size-full wp-image-6304\" \/><\/div>\n<p style=\"margin: 10px 0 30px 0;text-align: center;font-size: 0.85rem;color: #666\">When die temperature exceeds 400\u00b0C, the machine must be stopped and the die allowed to cool naturally.<\/p>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">It took <span style=\"font-weight:bold\">more than 10 minutes for the die temperature to drop naturally<\/span> to the specified 250\u00b0C. During that time, the machine remained stopped, bringing a critical process in the line to a halt.<br \/>\nTo <span style=\"font-weight:bold\">shorten this idle time<\/span>, the customer began exploring spray-based cooling and contacted IKEUCHI for support.<\/p>\n<\/div>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<div style=\"margin-top:5rem;margin-bottom:3rem;width:100%;border-bottom:1px solid #E9E9E9\"><\/div>\n<\/div>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<h3 style=\"font-size: clamp(20px, 2vw, 30px);padding-left: 14px;margin-top: 0;margin-bottom: 0.8rem;border-left: 5px solid #0c9b6f\">Solutions Proposed by IKEUCHI<\/h3>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">After reviewing the application, our sales representative selected the <a href=\"https:\/\/www.dry-fog.com\/en\/products\/noz-pne-seto-sp\/\" style=\"color: #00a273\" target=\"_blank\" rel=\"noopener\">SETO-SP<\/a> Series, a twin-fluid spray nozzle that mixes cooling water with compressed air to generate a fine mist.<br \/>\nCompared with a hydraulic (single-fluid) nozzle driven solely by liquid pressure, it produces much smaller droplets, <span style=\"font-weight:bold\">reducing the risk of wetting<\/span>  the die and surrounding areas.<\/p>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">The SETO-SP also features a soft spray while maintaining a tightly controlled spray pattern, allowing it to <span style=\"font-weight:bold\">cool specific areas with high precision<\/span>. This made it possible to concentrate cooling on <span style=\"font-weight:bold\">the die\u2019s thick sections<\/span>, where heat buildup was most severe.<\/p>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">The nozzle body is <span style=\"font-weight:bold\">compact and lightweight<\/span>, measuring approximately 20 mm square and less than 50 mm in overall length. Even when mounted at the end of a robotic arm, it places minimal load on the arm and is easy to handle\u2014another feature the customer valued highly.<\/p>\n<p><img decoding=\"async\" src=\"https:\/\/www.dry-fog.com\/en\/wp-content\/uploads\/sites\/3\/2026\/03\/nozzle-metal-003-image_5.jpg\" alt=\"\" width=\"820\" class=\"aligncenter size-full wp-image-6304\" \/><br \/>\nSETO-SP Series Pneumatic Spray Nozzles<\/p>\n<\/div>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<div style=\"margin-top:5rem;margin-bottom:3rem;width:100%;border-bottom:1px solid #E9E9E9\"><\/div>\n<\/div>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto\">\n<h3 style=\"font-size: clamp(20px, 2vw, 30px);padding-left: 14px;margin-top: 0;margin-bottom: 0.8rem;border-left: 5px solid #0c9b6f\">Benefits Achieved<\/h3>\n<p><img decoding=\"async\" src=\"https:\/\/www.dry-fog.com\/en\/wp-content\/uploads\/sites\/3\/2026\/03\/nozzle-metal-003-image_6.jpg\" alt=\"\" width=\"820\" class=\"aligncenter size-full wp-image-6304\" \/><\/p>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">Previously, natural cooling of the die required more than 10 minutes, during which the machine remained stopped and the line was idle.<br \/>\nWith the introduction of the SETO-SP, <span style=\"font-weight:bold\">cooling time was reduced to approximately 60 seconds<\/span>.<\/p>\n<p style=\"list-style-type: disc;margin-left:1.2rem;font-size: 1rem;line-height:1.6rem\">IKEUCHI\u2019s spray nozzles continue to support cycle-time reduction and productivity gains in aluminum die-casting operations.<\/p>\n<p><img decoding=\"async\" src=\"https:\/\/www.dry-fog.com\/en\/wp-content\/uploads\/sites\/3\/2026\/03\/nozzle-metal-003-image_7.jpg\" alt=\"\" width=\"820\" class=\"aligncenter size-full wp-image-6304\" \/><\/p>\n<\/div>\n<div style=\"max-width:824px;margin-left:auto;margin-right:auto;text-align:center;margin-top:3rem\"><iframe loading=\"lazy\" width=\"100%\" height=\"422\" src=\"https:\/\/www.youtube.com\/embed\/6uhAujC5iW4\" title=\"YouTube video player\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\"><\/iframe><\/div>\n<\/section>\n","protected":false},"featured_media":0,"template":"","cat_cases":[87],"tag_cases":[410,533,543,534],"acf":[],"_links":{"self":[{"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/cases\/9315"}],"collection":[{"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/cases"}],"about":[{"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/types\/cases"}],"wp:attachment":[{"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/media?parent=9315"}],"wp:term":[{"taxonomy":"cat_cases","embeddable":true,"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/cat_cases?post=9315"},{"taxonomy":"tag_cases","embeddable":true,"href":"https:\/\/www.dry-fog.com\/en\/wp-json\/wp\/v2\/tag_cases?post=9315"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}