KelviRelease UltraCast .
HydraSpread™ Technology: Instant Wetting. Flawless Release.
KelviRelease UltraCast represents the next evolution in aluminum HPDC lubrication technology. Engineered with proprietary 'CrystaLube' siloxane chemistry and 'HydraSpread' super-wetting technology, it conquers the notorious Leidenfrost effect on superheated dies (350°C+), ensuring instant film formation where conventional lubricants fail. Designed for high-volume foundries demanding consistent performance across varying conditions, it delivers exceptional anti-soldering protection, clean thermal decomposition, and unprecedented hard-water stability—all at extreme dilution ratios (1:100 to 1:150) that slash operating costs by up to 40%. PFAS-Free. NPE-Free. Made in India for Indian foundries.
- HydraSpread Instant Wetting Matrix
- CrystaLube Anti-Soldering Shield
- ThermaClean Decomposition System
- HyperConcentrate Economy Platform
Technical Overview
KelviRelease UltraCast redefines economical high-performance in aluminum HPDC lubrication. Combining breakthrough HydraSpread Leidenfrost suppression with CrystaLube anti-soldering chemistry and ThermaClean thermal stability, it delivers premium-level performance at 30-40% lower cost than imported brands. Works at extreme dilutions (1:150) even in hard water (500 ppm+). PFAS-free, NPE-free, and engineered specifically for the demanding, variable conditions of Indian foundries. Made in India. No compromise on performance. No compromise on cost.
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Why KelviRelease UltraCast Delivers Results
Engineered for performance, validated by 100+ foundries worldwide
HydraSpread Instant Wetting Matrix
Powered by next-generation polyether-modified reactive surfactants that shatter the Leidenfrost barrier. Achieves instant, complete wetting on die surfaces at 300-350°C where standard water-based lubricants bead, bounce, and evaporate. Ensures uniform film coverage across complex geometries, cores, and slides.
CrystaLube Anti-Soldering Shield
Proprietary alkyl-aryl siloxane technology creates a molecular-level barrier between molten aluminum (°C) and die steel. Prevents intermetallic welding and aluminum pickup up to 350°C die temperature. Maintains boundary lubrication during ejection for clean, drag-free part release every shot.
ThermaClean Decomposition System
Advanced thermal-stable polymers resist carbonization and tar formation during molten metal exposure. Burns clean with light, non-tacky residue (no black staining). Minimizes die buildup and varnish formation, extending time between intensive cleaning cycles by 3-5x.
HyperConcentrate Economy Platform
Ultra-high active solid formulation (15-25%) enables extreme working dilutions of 1:100 to 1:150—up to 60% higher than conventional emulsions. Dramatically reduces concentrate consumption, storage requirements, and cost-per-spray. Typical savings: 30-40% vs. premium imported brands.
HardGuard Water Tolerance System
Reinforced with advanced chelation technology (EDTA complex + molybdate synergist) that locks onto calcium and magnesium ions. Maintains stable emulsion in industrial water up to 500-600 ppm hardness without soap scum, precipitation, or performance loss. Eliminates costly water softening infrastructure.
MicroStable Emulsion Technology
Manufactured using precision Phase-Inversion methodology to achieve micro-scale particle dispersion. Guarantees zero hard settling, no phase separation for 12+ months storage, and instant redispersion after standing. Passes through 100-mesh filters without clogging—perfect for automated dosing systems.
Water Based Die Release Agent for Aluminum
KelviRelease is a water based die lubricant for aluminum and HPDC. It delivers consistent wetting and clean release at 350°C die temperatures.
Prevent Aluminum Soldering & Pickup
The anti-sticking die coating blocks aluminum pickup on the die, reduces soldering, and helps reduce die casting defects.
High Dilution, PFAS Free, Hard Water Compatible
Runs at high dilution (1:100 to 1:150), PFAS free, and stable in hard water. An economical die release agent built for Indian foundries.
The 4-Stage Protection Sequence
Precision-engineered for the extreme thermal environment of aluminum HPDC
HydraSpread Activation (The Leidenfrost Solution)
As the diluted spray contacts the superheated die surface (300-350°C), conventional water-based lubricants would instantly vaporize into steam, creating the 'Leidenfrost effect'—a vapor cushion that prevents wetting. KelviRelease's proprietary polyether-modified siloxane chemistry drastically reduces surface tension to <25 dynes/cm, allowing droplets to penetrate the vapor barrier and wet the steel surface instantly. This ensures complete, uniform coverage.
Technical Note:Defeats film boiling. Enables effective heat transfer and film deposition.
Multi-Layer Film Formation (Controlled Decomposition)
As the water carrier evaporates, the emulsion undergoes controlled phase separation. The high-density polymeric wax dispersion forms the outermost sacrificial thermal barrier, absorbing initial heat shock. Beneath this, the alkyl-aryl siloxane complex migrates to the die-metal interface, creating a molecular-level release layer. Ethoxylated surfactants enhance spreading and compatibility across the entire die geometry.
Technical Note:Stratified film architecture. Each layer serves a specific thermal or tribological function.
CrystaLube Anti-Soldering Barrier (°C Challenge)
When molten aluminum (650-°C) impacts the coated die, the outer wax layer instantly sacrifices itself, creating a temporary insulating cushion. The underlying siloxane chemistry, engineered for extreme thermal stability, forms a chemically inert boundary layer that prevents direct aluminum-steel contact. This molecular barrier physically blocks intermetallic compound formation (soldering) while maintaining excellent heat transfer for controlled solidification.
Technical Note:Prevents Fe-Al intermetallic welding. Superior to graphite without carbon contamination.
ThermaClean Release & Ejection (Zero Carbon Philosophy)
Unlike conventional oils that carbonize into sticky tar under extreme heat, KelviRelease's thermal-stable polymers decompose cleanly. Any residue remaining post-casting is light-colored, non-tacky, and microscopically thin—often invisible. Parts eject smoothly with minimal ejector force. The casting surface is bright, clean, and immediately ready for downstream processes (painting, plating, machining) without aggressive washing.
Technical Note:Clean thermal decomposition. Extends die cleaning intervals by 3-5x.
Why Leidenfrost Suppression Is Everything
Traditional die lubricants fail at the first hurdle: wetting. When liquid contacts a surface above its boiling point (the Leidenfrost temperature), it levitates on a cushion of its own vapor, preventing contact and heat transfer. This causes 'beading,' 'skittering,' and uneven film formation—leading to hot spots, soldering, and inconsistent release. KelviRelease's HydraSpread technology solves this using polyether-modified reactive surfactants that reduce surface tension to extreme levels, allowing droplets to 'punch through' the vapor layer and establish intimate contact with the die steel. Once wetting is achieved, cooling efficiency, release performance, and anti-soldering protection all follow automatically. This is why Leidenfrost suppression is ranked as Priority #1 in the product design hierarchy—without it, nothing else matters.
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 |
|---|---|
| Performance Metrics | |
Working Dilution Range | 1:100 to 1:150 (Stable to 1:200) |
Die Surface Temperature | 250°C - 350°C (Optimal) |
Molten Metal Resistance | 650°C - °C Aluminum |
Cost Efficiency | 30-40% Savings vs. Premium Imports |
Water Hardness Tolerance | Up to 500 ppm CaCO₃ (600 ppm max) |
Thermal Residue | Clean / Light Tan / Non-Staining |
| Physical Properties | |
Appearance | Milky White Micro-Emulsion |
Specific Gravity @ 25°C | 0.98 - 1.00 g/cm³ |
pH (Concentrate) | 9.0 - 9.5 (Buffered Alkaline) |
Odor Profile | Mild / Neutral / Non-Rancid |
Emulsion Type | Non-Ionic O/W Micro-Dispersion |
Particle Size | Sub-Micron Distribution |
| Application Parameters | |
Spray System Compatibility | All Standard Auto/Manual Systems |
Recommended Spray Pressure | 30-50 PSI (2-3.5 bar) |
Application Frequency | Every Shot Cycle (Standard HPDC) |
Spray Coverage | Uniform - Dies, Cores, Slides |
Nozzle Filterability | Passes 100-Mesh (150 micron) |
| Environmental & Safety | |
PFAS Status | 100% PFAS-Free (Zero Fluorinated Compounds) |
NPE Status | NPE-Free (No Nonylphenol Ethoxylates) |
Heavy Metals | None (Compliant with RoHS/REACH) |
VOC Content | Minimal (Water-Based Chemistry) |
Operator Safety | Low Odor / Non-Irritating / Non-Flammable |
| Logistics & Packaging | |
Available Pack Sizes | 20 kg Pails / 200 kg Drums / 1000 kg IBC |
Shelf Life (Sealed) | 12 Months (6 Months Guaranteed) |
Storage Temperature | 5°C - 40°C (Optimal: 15-25°C) |
Storage Stability | No Separation / No Hard Settling |
Freeze-Thaw Resistance | Minimum 3 Cycles |
| Specification | Value |
|---|---|
| Performance Metrics | |
Working Dilution Range | 1:100 to 1:150 (Stable to 1:200) |
Die Surface Temperature | 250°C - 350°C (Optimal) |
Molten Metal Resistance | 650°C - °C Aluminum |
Cost Efficiency | 30-40% Savings vs. Premium Imports |
Water Hardness Tolerance | Up to 500 ppm CaCO₃ (600 ppm max) |
Thermal Residue | Clean / Light Tan / Non-Staining |
| Physical Properties | |
Appearance | Milky White Micro-Emulsion |
Specific Gravity @ 25°C | 0.98 - 1.00 g/cm³ |
pH (Concentrate) | 9.0 - 9.5 (Buffered Alkaline) |
Odor Profile | Mild / Neutral / Non-Rancid |
Emulsion Type | Non-Ionic O/W Micro-Dispersion |
Particle Size | Sub-Micron Distribution |
| Application Parameters | |
Spray System Compatibility | All Standard Auto/Manual Systems |
Recommended Spray Pressure | 30-50 PSI (2-3.5 bar) |
Application Frequency | Every Shot Cycle (Standard HPDC) |
Spray Coverage | Uniform - Dies, Cores, Slides |
Nozzle Filterability | Passes 100-Mesh (150 micron) |
| Environmental & Safety | |
PFAS Status | 100% PFAS-Free (Zero Fluorinated Compounds) |
NPE Status | NPE-Free (No Nonylphenol Ethoxylates) |
Heavy Metals | None (Compliant with RoHS/REACH) |
VOC Content | Minimal (Water-Based Chemistry) |
Operator Safety | Low Odor / Non-Irritating / Non-Flammable |
| Logistics & Packaging | |
Available Pack Sizes | 20 kg Pails / 200 kg Drums / 1000 kg IBC |
Shelf Life (Sealed) | 12 Months (6 Months Guaranteed) |
Storage Temperature | 5°C - 40°C (Optimal: 15-25°C) |
Storage Stability | No Separation / No Hard Settling |
Freeze-Thaw Resistance | Minimum 3 Cycles |
Performance Metrics
Physical Properties
Application Parameters
Environmental & Safety
Logistics & Packaging
KelviRelease UltraCast vs. Imported Premium Brands (Chem-Trend / Kluber / Acme)
Side-by-side comparison of key performance metrics
| Evaluation Criteria | KelviRelease UltraCast Recommended | Imported Premium Brands (Chem-Trend / Kluber / Acme) |
|---|---|---|
Core Technology | HydraSpread + CrystaLube Dual System | Standard Polymer Emulsions |
Working Dilution | 1:100 to 1:150 (Extreme Economy) | 1:50 to 1:80 (Standard) |
Leidenfrost Performance | Instant Wetting at 350°C+ | Variable (Beading Common) |
Hard Water Tolerance | Up to 500 ppm (No Softening Needed) | Requires RO/Softened Water |
Thermal Decomposition | Clean / Light Residue (ThermaClean) | Variable / Carbon Buildup Risk |
Anti-Soldering (350°C) | Excellent (CrystaLube Barrier) | Good to Excellent |
Cost Efficiency | 30-40% Lower Cost-per-Shot | Baseline (Import Premiums) |
Environmental Compliance | PFAS-Free / NPE-Free / RoHS | Varies by Product Line |
Local Support | Made in India / Immediate Supply | Import Lead Times / Currency Risk |
Core Technology
Working Dilution
Leidenfrost Performance
Hard Water Tolerance
Thermal Decomposition
Anti-Soldering (350°C)
Cost Efficiency
Environmental Compliance
Local Support
Use Cases for KelviRelease UltraCast
Real-world applications where KelviRelease UltraCast delivers measurable results.
Die release performance
Improve Surface Finish in Die Casting
Achieve cleaner release, higher shot counts, and better surface finish with water-based release agents designed for aluminum, zinc, and magnesium die casting.
Aluminum die casting lubricant
Die Release Agent for Aluminum
Water based die release agent for aluminum die casting with consistent wetting, stable film formation, and clean release performance across production shifts.
HPDC die release performance
HPDC Die Release Agent
High-performance HPDC die release agent engineered for fast cycles, hot dies, and consistent spray coverage at elevated die temperatures.
Anti-sticking / anti-soldering
Prevent Aluminum Soldering on the Die
Anti-sticking die coating that prevents aluminum soldering, pickup, and buildup on die surfaces to extend polishing intervals and reduce scrap.
High dilution economy
High Dilution Die Release Agent (1:150)
High dilution die release agent engineered for 1:100 to 1:150 working ratios with stable film formation and consistent release at reduced concentrate usage.
Hard water compatibility
Hard Water Compatible Die Release
Die release agent that stays stable in hard water conditions, avoiding soap scum, nozzle buildup, and spray inconsistencies without water softeners.
PFAS-free compliance
PFAS Free Die Lubricant
PFAS free die lubricant designed for automotive and export compliance, delivering cleaner shop environments without sacrificing release performance.
India supply & alternatives
Die Release Agent in India
Made-in-India die release agent positioned as an economical alternative to imported brands with local supply, faster trials, and dedicated technical support.
"Switching to KelviRelease UltraCast 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 KelviRelease UltraCast.
Still have questions
Our technical engineering team is ready to assist with specific data sheets or application requirements.
Contact Technical SupportComplete Your Foundry Optimization
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PDF Format • Complete Specifications