COATINGS F I LT R AT I O N FEEDING SYSTEMS M E LT S H O P R E F R AC TO R I E S M E TA L LU R G I CA L A N D P O U R I N G C O N T R O L BINDERS CRUCIBLES

ICU - INTELLIGENT COATING UNIT

Automated coating control and adjustment
 High performance mould and core coating
should be applied consistently

Increasing requirements from foundry applications such Variables

as thinner wall sections, complex internal geometries and + Operatorinfluence
new alloys, are driving the demand for high-performance + Coating temperature
coatings. However, high performance coatings need to be + Core temperature
applied consistently to achieve best possible results on a + Ambient foundry temperature
repeatable basis. + Energy put into a coating by pumping and mixing

Poor application control can undermine coating The applied wet layer thickness can change significantly if
performance and can in some instances lead to excessive either the Baumé or the viscosity control specification
scrap or rectification work. Hence Foseco has developed applied during the application is too broad (Fig. 1).
a new range of equipment that is designed to optimise
coating application. To leave these critical parameters to a manual control
and adjustment risks a number of problems that can
Traditional coating application control eventually lead to increased cleaning and scrap costs.
Baumé 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:

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

90
450 Wet layer thickness (µm)
80 x
400 Baumé (°Be)
380 µ
70
x 350
Viscosity DIN 4 mm (s)
60 310 µ
x 300

Layer (µm)
50
Bé / Sec

x
Be / Sec

µm Layer
250
40
x
200

30 29 Be 150
27 Be
20 100
16“ (4)
15“ (4) 1
refer to Foundry Practice 246 for more information
10 50

0 0
49 53 57 64 79

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

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

2
 Viscosity is highly influenced by temperature, however, achieve the desired wet layer thickness. Consequently,
foundries do not typically adjust the set viscosity application consistency is lifted to previously unachievable
specifications in the cooler or warmer period of the levels.
year. Temperature induced viscosity change will have
an influence on the final layer thickness applied, and Process consistency
therefore casting quality. The consistency of the process is carefully monitored and
controlled through a series of reports, information screens,
Density control text messages and alarms. The system also generates
Density is directly related to the applied solids content in a comprehensive database of coating application
the coating (Fig. 2). Consequently, if coating density can information.
Dip tank with integrated
be controlled, wet layer thickness consistency is greatly ICU control system
improved. Versatility
The ICU is available in 300 or 600 litre versions. Its built-
Automated coating control in intelligence enables the unit to be highly configurable.
The Intelligent Coating Unit (ICU) uses robust sensors It can receive coating from all typical coating supply Water disinfecting system on ICU
to measure very accurate density to the 4th decimal. It methods and can supply all application processes, such as
automates the adjustment of the coating preparation dip tanks, flow coating stations and spray equipment.
from its as supplied state to the required density to
achieve the desired wet layer thickness. Optional water disinfection modules can be incorporated.
Fig. 2 Coating density vs. dry and wet layer thickness
1,300 400
Density
1,283 360
Dry
1,265 320
x
Wet layer thickness (µm)

Wet
x
1,248 280
Density [g/cm3]

1,230
x 240
x
1,213 200
x
1,195 160

1,178 120

1,160 80
25 30 35 40 45
Main ICU assembly - filters
50 55

Density Dry Wet Volume of water (g) added to 100 g of coating

3
 Automated coating control
Optimising coating application to achieve the highest performance

Controlling coating density, and ultimately wet layer ICU Features

thickness, enables the foundry to optimise coating ++ Advanced, fast and almost maintenance free
application. Wet layer thickness can be adjusted to inline density measurement system
suit the demands of specific applications. ++ Double filter setup for uninterrupted operation Dip tank with integrated ICU

Consequently, a number of benefits are achieved: ++ Oversized 3” diaphragm pump to minimise shear
stress on coating
Benefits ++ Smart, web connected control cabinet with
++ Consistent coating layer thickness touch screen remote viewing/data logging
++ Improved coating application efficiency ++ Remote access for service
++ Reduction of coating layer related defects ++ Optional 24/7 service contract
++ Reduced casting scrap ++ Frequency inverter operated stirring device
++ Fewer scrap moulds / cores ++ Reliable overfill protection
++ Optimised drying ++ 300 or 600 ltr working volume for continuous
++ Improved productivity homogenisation & correct coating density supply ICU intelligence integrated

++ Reduced coating disposal costs ++ Optional Viscosity Measuring system

++ Improved working environment ++ Coating Temperature Measurement
++ Lower casting manufacturing costs ++ UV water treatment for disinfection of the water
++ Improved foundry profitability used for dilution

ICU control accuracy and level control

FOSECO. A PARTNER TO BUILD ON. Foseco International Limited

Drayton Manor Business Park,
Tamworth, Staffordshire,
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