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infohouse.p2ric.org/ref/09/08993.pdf visited on 22.4.

2012
In an effort to increase yield and improve the quality of castings, foundries-apply refractory slurriesto sand molds and cores to minimize surface defects that may occur during casting. The coatings are typically suspensions of high meltingp oint refractories in a liquid carrier. After application, it is necessary to dry the coating to prevent gas formation when the hot metal is poured into the mold. The formation of gases may cause casting defects. After thlieq uid carrier is evaporated, a protective refractory layer remains on the mold surface. In the past, foundries typically used solvent-based carriers because they dry quickly without external heating. However, chemical solvents are toxic, flammable, and costly. The trend today is toward water-based coatings ... but they require long drying times using conventional ovens. Consequently, there is a neetdo find a more rapid method for drying the water-based coatings to increase production.

The Old Way


Decatur Foundry in Decatur, Illinois, one of Illinois Power Companys customers, used a 67kW electric resistance heater systemto dry the water-based wash coatingso n their molds and cores. Their system consisted of electric heaters suspended above the mold conveyor. A total of 30 feet of molding line heaters was used to dry the molds. Although these units were relatively efficient they still required I 20 minutes to dry the coating on each surface and used 4.5kWhlmold. The heaters operated continuously and were

independent of the production rate. Occasionally an open gasflame torch was also required to insure complete Figure 1. Isometric of the infrared mold wash coating system at drying. Decatur Decatur Foundry. started looking for a better method to dry their water-based mold wash coatings.

The New Way


At the request of Lowell Griffith of Illinois Power, The EPRl Center for Materials Production (CMP) and BGK Finishing Systems, Inc. reviewed the process to determine what mightb e done to reduce the drying time and thus increase productivity. BGK, a manufacturer of short-wavelength. infrared systems with experience in drying all types of coatings, recommended that the electric resistance dryer be replaced with an infrared/ forced air unit. With funding from CMP, BGK built a prototype unit consisting of 15 2500 watt lamps, (a total of 37.5kW) and installed it at Decatur Foundry in 3 working days without interrupting production. See Figure 1. The system is energized by a fully automated control panel and can be turned on or off to match the mold production rate. The operating voltage is adjustable andth e oven lamps and forced air fan are controlled by timers. These features allow the oven to have a (customized) variable heating rate by varying the wattage (24kW for Decaturs operation) to accommodate different sized and shaped molds. The infrared unit totally dried coatings at the rateo f one every 3 minutes compared to 20 minutes for the previous method, an 85% imrovement. In addition, electrical usage averaged about 1.2 kwh per mold compared to 4.5 kwh per mold for the old system, a 73% reduction in energy usage

The Results: A MoreEfficient Drying Line


Improved product quality and reduced scrap rateB. y combining

electric infrared heat with regulated air flow the unit can dry the coating in deep cavities and mold pockets. This has essentially eliminated surface defects and thus improved mold and casting quality. Energy savings. After installing their new drying station, Decatur's yearly energy cost decreased from $12,000 to $3,000. Much of this energy savings stems from the controllability of the infrared unit, which cycles off at a predetermined time after heating the mold surface to the desired drying temperature. Production flexibility.T he system's electronic-power controllers make it possible to make quick and easy switchovers to various sized and shaped molds with minimal adjustments. Because of the instant on/off feature of IR emitters, operators can change production runs, with ease, thus reducing the time between runs and increasing production capacity. Process control. The system at Decatur is a fixed cycle-on/cycle-off operation. With the mold in position in the heating zone, the drying cycle is initiated. When the drying cycle is completed, the power shuts off and the system is poised for the next mold and another cycle. (BGK also offers features to make systems totally automated, i.e., continuous feed and product sensors.) Improved working conditions. The replacement of isopropyl alcohol and trichloroethane-based coatings with aqueous carriers has provetno be environmentally sound and has met all existing EPA regulations. In addition, the IR elements concentrate the heat on the mold, releasing less hetaot the surroundings thereby providing a more comfortable working environment during the summer months. Space savings. The old mold drying conveyor was reduced in length from

30 feet to 3 feet freeing up valuable floor space.

What Was the Payback?


The installation cost was approximately $1 2,000 and, based on the energy savings alone ($9,000 per year), the payback period was a little more than ay ear.

Role of the Electric Utility


Lowell Griffith of Illinois Power and CMP personnel discussed Decatur's need for ab etter process for drying their water-based mold wash coatings. The problem was reviewed with BGK Finishing Systems, Inc. engineers. Their recommendation was t

Sand Mold and Core Coatings

Fosecos sand mold and core coating products help foundry operators achieve the best available casting surface finishes at the highest possible level of operational efficiency. Because we focus our efforts on advanced rheology and suspension technologies, and use only the highest quality refractory components, Fosecos sand coating products provide as-cast excellent surface performance, particularly in critical applications. They are also noted in the industry for their ease of use and process productivity. http://www.fosecomet.com/index.php?option=com_content&task=view&id=107&Itemid=157 visited on 22 4 2012

Fosecos Sand Coating products provide: Reduced defects, particularly surface defects like veining, sand burn-in, and metal penetration. Increased productivity, because Fosecos pioneering work in coating rheology and suspension technologies allows full-rate production of castings, minimizing coated core scrap and rectification, coating process variation and handling slow-downs. Improved quality, in addition to reducing defects, by acting as a robust element in a consistent foundry process and by improving the metallurgical properties and surface appearance of castings.

Water-based coatings

RHEOTEC coatings are water-based, slurry refractory formulations containing a carefully engineered blend of specialty refractory solids. They are used to coat cores for the high-production casting of gray/ductile iron and non-ferrous alloys. Typical casting components produced using RHEOTEC coatings include engine heads and blocks, brake rotors, gear boxes and axle housings. Rapid Dry and Color Change on Drying products are available. For foundries with demanding applications, RHEOTEC XL coatings provide exceptional resistance to veining and penetration defects. Superb dipping rheology (flow characteristics). No runs or drips. Highly uniform and consistent coating coverage. Low foaming tendency. Important in automated coating application systems. Outstanding suspension stability. Low level of settling in use. Sediment remains soft and easily re-mixed. Compatible with most core processes -- hot-box, shell, oil sand, the ECOLOTEC Process, Epoxy/Acrylic/Furan - SO2, Phenolic-Urethane and Phenolic - Methyl Formate. Excellent as-cast surface quality. Reduces or eliminates veining, burn-in and metal penetration defects. Highly cost-effective in use. Greatly reduced blast cleaning requirement. Can eliminate additional manual cleaning operations. Convenient form of delivery. Easily handled, mixed and diluted. Will not degrade core substrate. Durable coated surface resists abrasion during core handling.

HOLCOTE coatings are water-based slurry refractory coatings for cores and molds. The principal refractory contained in these coatings is typically a high-purity zircon. HOLCOTE coatings are recommended for use in the casting of iron and steel alloys. These coatings should be used where metal casting sections are in the medium to heavy size range. Excellent rheology (flow characteristics) provides a highly uniform coating layer to molds or cores when applied via brush, spray or flowcoat methods. Outstanding suspension characteristics. Sediment is soft and easily re-dispersed. The resultant coated surface is hard and smooth, free from runs and drips. As-cast surface quality is excellent (no burn-in, burn-on or penetration defects), even with the heaviest casting sections.

Strip/peel of sand from the casting surface at shakeout is significantly improved. Casting cleaning costs are greatly reduced. Compatible with all types of chemically-bonded sand and green sand.

Solvent-based coatings

ISOMOL coatings are flammable, solvent-based mold and core coatings. The principle refractory contained in these coatings is a high-purity zircon. ISOMOL coatings are recommended for use in the casting of iron, steel and non-ferrous alloys. These coatings can be used through a wide range of metal casting sections.

ISOMOL coatings provide excellent casting surface quality. Resultant casting finish is smooth and free from burn-in, burn-on and metal penetration defects. This coating is both easy to apply and economical to use. Casting cleaning costs are significantly reduced.

http://www.indiamart.com/foilforms-sj-industries/foundry-chemicals.html visited on 22 4 2012 at 9 ;00 pm Graphite paints :Water & alcohol based

Zircon paints : Water & alcohol based magnesite paints

Zircon Mould Wash Water Based & Alcohol Based


Zircon Based Mould Wash is a ZrO2 based paint/mould wash for use in the Steel Foundries for superior surface finish of your castings and reduced casting problems such as sand fusion, burn ons, surface finish etc. We manufacture both water based & alcohol based Zircon mould wash.

http://www.ha-international.com/content/products/refractory_coatings.aspx visited on 22 4 2012 10.00pm

Refractory Coatings
HA International provides a complete range of refractory coatings to meet all of your foundry needs.

Refractory coatings are used on molds and cores to enhance the surface finish of the casting and reduce casting defects which occur at the sand-metal interface.

Mold Lite PLUS is an alcohol based Refractory Coating designed specifically for Jobbing applications.
Mold Lite Plus is extremely effective when used in the production of heavy sectioned iron and steel castings. It is specifically designed for gray, ductile iron and steel castings with metal wall thicknesses of over three inches.

Performance Factors Cast large section steel with a variety of refractories Used with all No Bake resin systems. Excellent light-off characteristics, light-off does not cause blistering or cracking. Proven effective in the production of valves, compressor parts and various process machinery. Proven effective for flow coating heavy metal sectioned molds.

Product Line
Three variations of Mold Lite Plus are currently offered to allow for optimal operation at the foundry.

Dura Kote is a water based Refractory Coating designed specifically for Jobbing applications. Dura Kote
is specifically designed for use with all No Bake sands and is extremely effective when used in the production of large section iron and steel castings. Formulated with water, Dura Kote is an environmentally sound refractory coating that provides low VOC, low HAP, and low odor.

Performance Factors Cast large section steel with a variety of refractories Used with all No Bake resin systems.

Proven effective in the production of valves, compressor parts and various process machinery. Proven effective for flow coating heavy metal sectioned molds. Product Line Three variations of Dura Kote are currently offered to allow for optimal operation at the foundry. the Techni Kote 6000 Series. This technological advancement coatings offers The Best Total Solution foundry by optimizing production and in

casting performance.

Techni Kote 6000 Series provides better coating efficiency and improves the quality of castings. A reduction in overall

operational expenses is achieved with lower scrap rates, increased coating mileage, elimination of

sand additives, and reduced cleaning room costs.

Techni

Kote 6000

Series

technology will hit a home run for

your foundry. Call your sales rep

The Refractory System


The refractory system is the most important part of the coating, as it will determine the effectiveness of the coating. The type, shape, size distribution, thermal expansion, chemical reactivity, thermal conductivity and specific gravity are the basic criteria for selection of the proper refractory.

The most commonly used liquid carriers are water and alcohol. The suspension system must keep all of the refractory material and other additives homogeneously dispersed. The binder system is designed to bond the refractory particles to each other and the sand matrix and are used in very small amounts. Finally, chemical modifiers are used to enhance the coating with wetting agents, defoamers, preservatives and stabilizers.

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