coatings for jobbing iron and steel - foundry-planet …...prone areas pre-treated with penetration...
TRANSCRIPT
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The latest development in coatings for heavy iron and steel castings
Tim BirchInternational Marketing Manager – Foseco International Ltd
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Introduction
Product development for heavy iron and steel castings Fast dry water-based coatings Duplex Coating Single-layer flow coat application
The need for control Automatic control of density Effective mixing and coating homogenisation
Content
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Introduction to Total Coatings Management
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Identifying the needs of the market
Investment in R&D to fulfil the needs of the foundry customer: Increase capability to produce complex, defect-free castings Improve productivity and reduced re-work Reduce overall costs
Specialised testing equipmente.g Rheometry,
Molten metal facilities,SEM
£4.5 million investment in new Foundry R&D Facility (2014)
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Total Coating Management
End-to-end process control
Delivering Quality & Consistency at all process stages…..
…To ensure optimum performance at our Customers.
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R&D - Delivering new products for heavy iron and steel castings
• Fast dry water-based coatings• Duplex Coating• Single-layer flow coat application
New Products
New Process TechnologyNew Raw Materials
• Automated control• Improved mixing
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Fast Dry Water-Based Coating – Northern Europe Case Study
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Drying of Larger Components
For larger sized components the coating is applied by flow application
• Historically alcohol based systems are used and flamed-off for quick drying
• Health and Safety Issues arise
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Release of VOC’s into the environment Respiratory issues relating to solvents Restrictions on storage and use of flammable products ATEX or equivalent certification for associated equipment
Solvents – Health, Safety and Environmental Issues
Ref: European Chemical Agency Website
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Improved environmental benefits through elimination of solvents Reduced surface cracking of mould due to heat generated in flame-off Reduced burn-out of coating binder
BUT : air drying is significantly longer
Benefits of water-based products
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SEMCO FDC - a new range of water-based coatings for flow coating High solids content, with significantly less water to be evaporated off New rheological system allows excellent flow coating at higher solids
Layer build equivalent to a traditional coating (zircon, al-silicate or olivine fillers) Elimination of runs and drips Excellent casting performance
Faster drying water-based products
3 hour (75% solids)
5 hour (65% solids)
Drying time at 25oC (RH=60%)
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When used in combination with drying oven fast drying water-based coatings deliver: Improved productivity Reduction in drying energy requirements
SEMCO FDC – improved productivity and energy saving
Oven temperature set to 61oCSEMCO FDCWLT 275 – 300μ
StandardWLT 325 – 350μ
Equivalent dry layer thickness
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SEMCO FDC – improved productivity and energy saving
Surface Temperature / Moisture ContentTime in Oven Standard Coating SEMCO FDC0 minutes 25°C / 3.9% 25°C / 3.1%3 minutes 29°C / 3.7% 36°C / 0.7%6 minutes 40°C / 0.8% 48°C / 0.0%9 minutes 46°C / 0.4%12 minutes 48°C / 0.1% DRY
DRYResults50% reduction in drying time50% reduction in energy
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SEMCO FDC – improved productivity and energy saving
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Duplex Coating – North American Case Study
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Duplex Coating System
For the prevention of metal penetration and burn-on Specifically hot spot areas Undercuts where sand compaction is not optimum
Examples of burn-on and severe metal penetration
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Duplex Coating System
Prone areas pre-treated with penetration coating Fine zircon flour based coating (water or solvent based) Penetrates into surface of mould (3-5mm) Minimal surface layer build-up Completely fills all voids between sand grains
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Mould then coated with traditional coating (water or solvent-based) Flow coated Brushed etc…
If there is a failure of the surface coating layer in critical areas: Mould beneath completely sealed No voids between sand grains for metal to penetrate High refractory material prevents interaction with silica sand
Duplex Coating System
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Case Study 1: NORAM – Iron Jobbing Foundry
Significant problem with burn-on and metal penetration on large floor moulds.
Severe metal penetration and burn-on
WithHOLCOTE Z-Primer
(SEMCO 9223)
Clean casting
Note: Top coat is HOLCOTE 950(al-silicate coating)
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Case Study 1: NORAM – Iron Jobbing Foundry
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Case Study 2: NORAM – Steel Foundry
Problem – significant metal penetration in flange area
Solution – ISOMOL Z-primer (TENO ZKPX)• Brushed in critical areas• Penetration 3-5mm
Top coat - ISOMOL 578-85 (brushed) 2 layers (zircon based coating) Flame Dried between layers
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Casting Results Dramatic improvement in casting finish Metal penetration and burn-on eliminated
Converted floor molding coatings to the duplex coating technology
Case Study 2: NORAM – Steel Foundry
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Single Layer Flow Coating for Jobbing Foundries
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For larger moulds and cores Need to apply multiple coating layers to build-up required layer
thickness (>300um)
Productivity issues arise: Time for multiple applications Availability of crane Time to use crane (multiple times)
Casting quality issues: If done incorrectly the coating layers may de-laminate Brushing leads to inconsistency in layer and brush-marks
Single Layer Flow Coating for Jobbing Foundries
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New rheological system allows for: Thick layer (>700um) to be applied in one application Consistent layer build from top-to-bottom of mould surface No slumping No runs and drips No cracking on drying
Casting performance equivalent to that achieved with multiple-layer application
Single Layer Flow Coating for Jobbing Foundries
2/03/2017 Footnote
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Flow tests
A wide variety of flow characteristics can be obtained by modifying the formulation
Applied wet layer: 1000 μm
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Example – dry layer achieved on furan cores
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Dry layer≈ 1050 μm
Dry layer≈ 830 μm
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Hexagon Block – Steel Casting
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• Casting weight: ≈ 125 kg• Six different coatings
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Casting Comparison
bottom (ingate) top
R962Single layer thick coating
top layer: ≈ 850 μm
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SemcoCoat 9223 +SemcoZir 7300B (1x)
top layer: ≈ 450 μmpenetration ≈ 5mm
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In-house casting trials with steel
Casting design (severe conditions)• Cast weight approx. 210 kg• Increased core length
Magma simulation• Longer solidification times (≈ 53 min – 65 min)
#1
#4
#3
#20,0
20,0
40,0
60,0
80,0
100,0
1400,0
1440,0
1480,0
1520,0
1560,0
1600,0
0,0 10,0 20,0 30,0 40,0 50,0 60,0 70,0 80,0
Degree of solidificatio
n [%]
Temp
erat
ure
[⁰C]
Time [min]
Simulation of hexagon test casting: solidification and core temperature
Core #1 Core #2
Core #3 Core #4
maximum T steel around core#1 maximum T steel around core#3
Degree of solidification [%]
Tliquidus≈ 1520 ⁰C
Tsolidus ≈ 1470 ⁰C
Awaiting casting results
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Effective Mixing and Coating Control
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The effectiveness of a specific coating is controlled by the applied dry layer thickness
Too thin and the coating is not effective Too thick and material is wasted, plus risk of: Dimensional issues Scabbing Excessive runs and drips etc…
Wet layer thickness is a good proxy for dry layer
Measurement of dilution and adjustment
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Traditionally the application parameters for foundry coatings are defined by Baume or Flow Cup viscosity – related to applied layer
Both methods open to operator interpretation Measurement technique Supplier of measurement device (specifically Baume) Local standards (DIN, Ford, ISO etc..)
Baume vs. Flow Cup
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Lowest actual Baume = 24 275um Highest actual Baume = 30 440um
Layer Thickness variation
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Lowest actual Viscosity = 13.5 sec 260um Highest actual Viscosity = 16.5 sec 410um
Baume Flow Viscosity
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These measurements attempt to measure the combined influence of Solids Content (or dilution) Rheological effect of the gel For Baume – termed “Body” For Flow Cup – the viscosity
If we eliminate the need to measure rheology…. Batch-to-batch consistency from supplier Correct homogenisation of product
….An improved measurement technique can be adopted.
The Limitations of Baume and Flow Viscosity
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Flow cup and Baume incorporate the coating rheology into the measurement
If we have consistency of rheology from the supplier Density becomes the most effective measurement
Density measurement variations
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Density measurement of a coating
Density measured in range of +/- 0.004 g/ml
With variation of +/- 0.004 g/ml Variation in applied layer of +/- 10um
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Automatic Density Measurement Proven method of continuous density measurement Provides coating density measurement to 3 decimal places Complete homogenisation of the prepared coating
Continuous Density Measurement
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Coating density versus time Courtesy: Atlantis Foundry (Halberg), S.Africa
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Minimise scrap and re-work in the most cost effective manner
Ensure the coating you use is rheologically stable with time Apply most protection where it is needed – Z-Primer Improve your productivity
Fast drying water-based products Single layer flow coating to high layer thickness
Reduce your energy consumption Fast drying water-based products
Ensure you apply a sufficient protective layer every time Automated density control and coating homogenisation
Conclusions
2/03/2017 Footnote
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Questions
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Thank-you for your attention
Acknowledgements: Christoph Genzler Europe - Product Manager (Coatings)Bruce Lundeen North American - Product Manager (Mould & Core)Martien Haanepen R&D Scientist