IN-SITU COATING PREPARATION

– A LATEST TREND IN
REFRACTORY COATINGS
WITH COST SAVING OPPORTUNITY
FOR AUTOMOTIVE AND JOBBING FOUNDRIES.

- Vinayak Ghotge
Vice President
Forace Polymers Pvt. Ltd,
Haridwar.
 BACKGROUND

In the mid of 20th century, most of the foundries were using

refractory coatings in the powder form. Foundries used to soak
coating refractory powder overnight, use bentonite / dextrin as
binder, mix well the coating either manually or with the help of a
mixer. Largely, the coating was being applied by brushing or
swabbing and seldom by spraying.

23 March 2022 Vinayak Ghotge

 TECHNOLOGOCAL CHANGE

In the latter part of 20th century, foundries started

modernizing and automation came in to picture. Apart from
automation in moulding, core making, coating practices also
were mechanized. Foundries adopted modern high
productive coating practices such as dipping and flooding,
over conventional practices such as brushing and swabbing.

23 March 2022 Vinayak Ghotge

 TECHNOLOGOCAL CHANGE

Coating methods such as brushing, swabbing and spraying

requires skill and are also time consuming, whereas dipping and
flooding are high productive and the operator skill required is
relatively low. However these coatings specially designed with
adequate rheological properties in order to control the wet film
thickness, coating penetration, flow properties etc. Keeping in
mind this requirement, ‘ready for use’ (RFU) coatings were
developed and became quite popular since then.

23 March 2022 Vinayak Ghotge

 Refractory Coatings : Present Scenario

➢ Presently most of the coatings are supplied in

RFU or paste form

➢ Subsequently it is diluted to application

consistency

➢ Coating is supplied in 30 to 40 Kg plastic

buckets / carboys

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 Pain Areas in Present System

➢ Buckets / carboys warpage during transportation

➢ Leakage / spillage problem during transportation
➢ Settling / sedimentation issues
➢ Larger storing space
➢ Bacterial attack on longer storage
➢ Shelf life issues.
➢ Too much handling of buckets , disposal …… etc.
(For 30 MT per month : 1000 Buckets)

➢ High Packaging Cost

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 New Trend

➢ Coating will be supplied in Powder form.

➢ It will be supplied in 25 / 50 Kg HDPE bags.
➢ Coating will be manufactured in your premises.
➢ Day to day manufacture and distribution.

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 Supply of Coating
in Powder Form
Modus Operandi

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Scope of the Project

Coating Supplier
will provide one
suitable mixer
for in-situ coating
manufacturing.

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23 March 2022 Vinayak Ghotge
 Scope of the Project

➢ Supply coating in powder form will be in 25 or 50 Kg bags.

➢ Coating supplier will provide one suitable mixer for coating

manufacturing.

➢ Coating supplier will train concerned workman for

manufacturing / testing of the coating.

➢ Fresh coating will be supplied to the shop every day as per

foundry need.

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Support Required from Foundries

➢ Allocate suitable space for mixer installation

➢ Use of laboratory for testing

➢ Provide manpower for coating manufacturing.

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 Advantages / Benefits to Foundries

➢ Supply of coating as & when needed – JIT

➢ Fresh lot every time. No ageing.
➢ No shelf life issues.
➢ Much less storage space for powder coating bags.
Less than 50 %
➢ Substantial reduction in price due to elimination of
buckets / carboys

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 Financial Savings to Foundries

❖ Presently most of the foundries are procuring Al-Si RFU

coating with landed cost say Rs. 31.00 /- per Kg.

❖ Coating supplier will supply powder coating @ budgetary

price say Rs. 54/- per Kg.

❖ 1 Kg of powder coating will yield 2 Kg of RFU coating.

❖ As such the effective cost of RFU coating will be

Rs. 27.00/- Per Kg.

❖ Savings in RFU coating will be Rs. 4.00/- per Kg.

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 Financial Savings to Foundries

❖ Savings in RFU coating will be Rs. 4.00/- per Kg.

❖ Coating consumed per month : 30 MT

❖ Savings per month : Rs. 1,20,000/-

❖ Savings per annum to Foundries: Rs. 14.40 Lacs.

❖ Less : Cost of electricity used for manufacturing the coating

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 Financial Savings to Foundries
Assumption – Mixer will consume 3 units of electricity for making 1 MT coating.
– Cost of electricity Rs. 10/- per unit
– Total electricity consumed for 30 MT coating per month will be
90 (30X3) units

Total electricity cost : 90 X 10 = Rs. 900 per month, i.e. Rs. 10800/- per year

Net Savings to Foundries : 1440000 – 10800 = 1429200

i.e. Net Savings per year will be Rs. 14.29 lacs.

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 FIELD TRIALS

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 Trial - 1
Particulars Details
Product Name : F/C 142 PW
Quantity : 200 Kg
Mixing Time : 20 minutes
As made baume : 65
Water Dilution : 25 % approx.
Diluted Viscosity : 15.0 Seconds
Coating Method : Dipping
Wet Film Thickness : 225 – 250 µm
Casting Name : JD Free Float Volute Core

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Trial - 1

Cores Coated with F/C 142 PW

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Trial - 1

Casting Finish with F/C 142 PW

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 Trial - 2
Particulars Details
Product Name : F/C 142 PW
Quantity : 200 Kg
Mixing Time : 20 minutes
As made baume : 66
Water Dilution : 25 % approx.
Diluted Viscosity : 14.50 Seconds
Coating Method : Dipping
Wet Film Thickness : 250 – 300 µm
Casting Name : Two Cyl. Block

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Trial - 2
Cores Coated with F/C 142 PW

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Trial - 2
Casting Finish with F/C 142 PW

Results:-
23 March 2022 Excellent Casting surface finish with Forcoat 142 PW Vinayak Ghotge
 Trial - 3
Particulars Details
Product Name : F/C142 PW
Quantity : 200 Kg
Mixing Time : 20 minutes
As made baume : 65
Water Dilution : 25 % Approx.
Diluted Viscosity : 14.5 Seconds
Coating Method : Over Pour
Wet Film Thickness : 175 – 200 µm
Casting Name : Transmission Housing

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 Trial - 3
Cores Coated with F/C 142 PW

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Trial - 3

Casting Finish with F/C 142 PW

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 Trial - 4
Particulars Details
Product Name : F/C 142 PW
Quantity : 200 Kg
Mixing Time : 20 minutes
As made baume : 65
Water Dilution : 25 % Approx.
Diluted Viscosity : 14.5 Seconds
Coating Method : Swabbing
Wet Film Thickness : 175 – 200 µm
Casting Name : Transmission Housing

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Trial - 4

Swabbing with F/C142 PW

Cores Coated with F/C142 PW

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Trial – 4 : Casting Results

Casting Finish with F/C 142 PW

Casting Finish with F/C142 PW

23 March 2022 Casting finish at par with present coating being used Vinayak Ghotge
 Trial - 5
Particulars Details
Product Name : F/C ZPW
Quantity : 200 Kg
Mixing Time : 20 minutes
As made baume : 100
Specific Gravity : 1,95
Coating Method : Brushing
Number of coats : Two
Casting Weight : 3,50 MT

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Trial - 4

Mould Coated
with F/C ZPW

Casting Results : The casting finish was excellent.

No sand sticking/ sand fusion observed.
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 Benefits to Foundries

By using powder coating customers have realized following

benefits
➢ JIT Supply of coating.
➢ Fresh lot every time. No bacterial attack
➢ No shelf life issues.
➢ Much less storage space for powder coating bags.
Less than 50 % of buckets
➢ Substantial Cost Savings

23 March 2022 Vinayak Ghotge

 CONCLUSION

From the trials above, it is evident that is-situ coating

preparation using powder coating technology not only helps
foundrymen to use it on all types of castings of any size but also
yields substantial cost savings, which will help foundries to
increase their profitability

23 March 2022 Vinayak Ghotge

 Thank You

23 March 2022 Vinayak Ghotge