The main factors affecting coating thickness:

·Stirring

·Density/viscosity

·Sand core immersion speed

·Sand core immersion coating time

·Soaking speed of sand core

Coating thickness

The thickness of the coating applied to the surface of the sand core/mold is related to the efficiency of immersion coating, coating consumption, drying furnace rate, and casting quality. Therefore, the coating thickness needs to achieve repeatability and consistency.

Through ProService homogenization stirring, you can achieve good coating performance

The main purpose of a good mixing system is to evenly mix various materials and keep them in a suspended state. The ProService coating preparation system CPP and dip coating, designed specifically for coating preparation workshops, is aimed at greatly reducing mixing energy, not only saving energy, but also not damaging the main performance of the coating, avoiding the generation of bubbles and preventing bacterial growth in the coating.

Robot solution for sand core handling and immersion coating

Common stirring defects: sedimentation and excessive stirring

Casting coatings are composed of different materials: refractory minerals, carriers (solvents), adhesives, suspensions, and other additives (such as lubricants, insecticides, etc.). Coatings often experience precipitation after being excessively or unevenly mixed. Precipitation can lead to inconsistent coating thickness even on the same sand core.

Traditional dip coating detection

The common methods (DIN cup/ISO cup and Pome meter) have obvious limitations:

·Relying on manual intervention

·Can only be measured in batches

·Manual recording by operators (usually on paper)

·Only measure on the surface of the coating

·The measurement results depend on the type of viscosity cup/Baume meter and its degree of wear and tear

Paint variables can cause product differences

For certain coatings, the difference in 1-2 ° Be (or 1-second viscosity cup) can affect the wet layer thickness of 80 microns. The frequency of paint testing is usually once per shift or once a day, but under certain specific conditions and seasons, solvent evaporation and mixing may alter the characteristics of the paint between two measurements. Coating inspection is usually carried out during the preparation stage, but the key position is overlooked: inspection inside the coating tank

ProService Dynamic Coating Control and Preparation System: Real time, Stable, Flexible, and Affordable

·Control the frequency high (density measurement once per second) to detect changes in paint performance and respond promptly.

·Automatically measure paint and solvents (water or alcohol) to compensate for paint consumption and solvent evaporation.

·Automatic measurement ensures that the process flow is independent of the operator's skills.

A high-precision automatic detection system can ensure the performance required by the quality department.

·Coating control can be carried out not only on the coating preparation equipment CPP, but also directly in the immersion tank or flow coating operation simultaneously.

Density stability in CPP systems

Sand core drying system on multi-layer pallets

Two Choices for Dip Coating Process

Dip coating and flow coating operations are usually carried out by robots and operators. Robot immersion coating can fully ensure the repeatability of the coating, while manual immersion coating process makes the thickness of the coating variable. Because the immersion operation is influenced by the working status of different operators, and even under the same person's operation, there will be a uniform effect.

The immersion coating process may cause a change in coating thickness of up to 100 microns.

ProService integrated system to ensure coating repeatability

If you are unable to use robot immersion coating due to layout, budget, complexity, and flexibility reasons and still use manual immersion coating, Proservice has designed a customized immersion coating system for the core making workshop (through a robotic arm), and the coating thickness will not be affected by manual operation (immersion depth, time, and speed are controlled by Proservice equipment).

In addition, ProService can provide the following units to improve the immersion coating system:

·Low temperature drying system (<140 ° C), which gives the sand core good mechanical properties and reduces energy consumption and emissions in the foundry

·Robot support for processes such as sand core transportation, uncoating, and paint dripping

·Assembly and dispensing system of sand cores