ICU - INTELLIGENT COATING UNITAutomated coating control and adjustment

C O A T I N G S F I L T R A T I O N F E E D I N G S Y S T E M S M E L T S H O P R E F R A C T O R I E S M E TA L L U R G I C A L A N D P O U R I N G C O N T R O L B I N D E R S C R U C I B L E S

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049 53 57 64 79

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29 Be27 Be

16“ (4) 15“ (4)

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Wet layer thickness (µm) Baumé (°Bé) Viscosity din 4mm (s)

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Increasing requirements from foundry applications such as thinner wall sections, complex internal geometries and new alloys, are driving the demand for high-performance coatings. However, high performance coatings need to be applied consistently to achieve best possible results on a repeatable basis.

Poor application control can undermine coating performance and can in some instances lead to excessive scrap or rectification work. Hence Foseco has developed a new range of equipment that is designed to optimise coating application.

Traditional coating application controlBaumé and viscosity testing are widely used in the industry. The primary objective of these and other measures of control is the consistent application of optimum coating layer thickness. However, the robustness of such control methods is affected by a number of variables1:

High performance mould and core coatingshould be applied consistently

Variables+ Operator�infl�uence+ Coating temperature+ Core temperature+ Ambient foundry temperature+ Energy put into a coating by pumping and mixing

The applied wet layer thickness can change significantly ifeither the Baumé or the viscosity control specificationapplied during the application is too broad (Fig. 1).

To leave these critical parameters to a manual control and adjustment risks a number of problems that can eventually lead to increased cleaning and scrap costs.

Fig. 1 Coating baumé and viscosity vs. wet layer thickness

1refer to Foundry Practice 246 for more information

Volume of coating (g) added to 80 g of water

Bé /

Sec

Layer (µm)

Wet layer thickness (µm)

Baumé (°Be)

Viscosity DIN 4 mm (s)

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Viscosity is highly influenced by temperature, however, foundries do not typically adjust the set viscosity specifications in the cooler or warmer period of the year. Temperature induced viscosity change will have an influence on the final layer thickness applied, and therefore casting quality.

Density controlDensity is directly related to the applied solids content in the coating (Fig. 2). Consequently, if coating density can be controlled, wet layer thickness consistency is greatly improved.

Automated coating controlThe Intelligent Coating Unit (ICU) uses robust sensors to measure very accurate density to the 4th decimal. It automates the adjustment of the coating preparation from its as supplied state to the required density to achieve the desired wet layer thickness.

Water disinfecting system on ICU

Dip tank with integrated ICU control system

Main ICU assembly - filters

achieve the desired wet layer thickness. Consequently, application consistency is lifted to previously unachievable levels.

Process consistencyThe consistency of the process is carefully monitored and controlled through a series of reports, information screens, text messages and alarms. The system also generates a comprehensive database of coating application information.

VersatilityThe ICU is available in 300 or 600 litre versions. Its built-in intelligence enables the unit to be highly configurable.It can receive coating from all typical coating supply methods and can supply all application processes, such as dip tanks, flow coating stations and spray equipment.

Optional water disinfection modules can be incorporated.

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Fig. 2 Coating density vs. dry and wet layer thickness

Volume of water (g) added to 100 g of coating

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Controlling coating density, and ultimately wet layer thickness, enables the foundry to optimise coating application. Wet layer thickness can be adjusted to suit the demands of specific applications.Consequently, a number of benefits are achieved:

Benefits + Consistent coating layer thickness + �Improved�coating�application�efficiency + Reduction of coating layer related defects + Reduced casting scrap + Fewer scrap moulds / cores + Optimised drying + Improved productivity + Reduced coating disposal costs + Improved working environment + Lower casting manufacturing costs + Improved�foundry�profitability

*FOSECO and the Logo are trade marks of the Vesuvius Group, registered in certain countries, used under licence. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system of any nature or transmitted in any form or by any means, including photocopying and recording, without the written permission of the copyright holder or as expressly permitted by law. Applications for permission shall be made to the publisher at the address mentioned. Warning: The doing of an unauthorised act in relation to a copyright work may result in both a civil claim for damages and criminal prosecution. All statement, information and data contained herein are published as a guide and although believed to be accurate and reliable (having regard to the manufacturer’s practical experience) neither the manufacturer, licensor, seller nor publisher represents nor warrants, expressly or impliedly: (1) their accuracy/reliability, (2) that the use of the product(s) will not infringe third party rights, (3) that no further safety measures are required to meet local legislation. The seller is not authorised to make representations nor contract on behalf of the manufacturer/licensor. All sales by the manufacturer/seller are based on their respective conditions of sale available on request.© Foseco International Limited 03/18.

Foseco International LimitedDrayton Manor Business Park,Tamworth, Staffordshire,England B78 3TLPhone: +44 (0)1827 262021 Fax: +44 (0)1827 283725 www.foseco.comPlease contact your local Foseco team01

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FOSECO. A PARTNER TO BUILD ON.

Automated coating control Optimising coating application to achieve the highest performance

ICU Features + Advanced, fast and almost maintenance free

inline density measurement system + Double filter setup for uninterrupted operation + Oversized 3” diaphragm pump to minimise shear

stress on coating + Smart, web connected control cabinet with

touch screen remote viewing/data logging + Remote access for service + Optional 24/7 service contract + Frequency inverter operated stirring device + Reliable overfill protection + 300 or 600 ltr working volume for continuous

homogenisation & correct coating density supply + Optional Viscosity Measuring system + Coating Temperature Measurement + UV water treatment for disinfection of the water

used for dilution

Dip tank with integrated ICU

ICU control accuracy and level control

ICU intelligence integrated