EP2244852A2 - Enduits pulvérulents - Google Patents

Enduits pulvérulents

Info

Publication number
EP2244852A2
EP2244852A2 EP09711876A EP09711876A EP2244852A2 EP 2244852 A2 EP2244852 A2 EP 2244852A2 EP 09711876 A EP09711876 A EP 09711876A EP 09711876 A EP09711876 A EP 09711876A EP 2244852 A2 EP2244852 A2 EP 2244852A2
Authority
EP
European Patent Office
Prior art keywords
powder
coated
sizing
cores
mineral
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP09711876A
Other languages
German (de)
English (en)
Inventor
Angelos Psimenos
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
FURTENBACH GmbH
Original Assignee
FURTENBACH GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by FURTENBACH GmbH filed Critical FURTENBACH GmbH
Publication of EP2244852A2 publication Critical patent/EP2244852A2/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C3/00—Selection of compositions for coating the surfaces of moulds, cores, or patterns

Definitions

  • the present invention relates to powdered sizing and its composition, production and application methods to lost molds as well as to other mineral and metallic articles (hereinafter referred to as "articles to be coated") in the foundry industry.
  • the manufacturing processes of casting are generally distinguished according to the patterning equipment, the molding materials, the mold making and the casting method. Casting is mainly divided into two groups, namely
  • Special processes include low pressure casting, composite casting, bell casting, art casting and casting.
  • Lost molds (which are also understood below as cast cores) are usually made of sand with suitable binders, so-called moldings.
  • a model is required, a sample of the casting to be produced.
  • permanent models are made of plastic, wood or metal depending on requirements. They contain not only the image of the casting to be cast, but also the gate, which are the channels through which the casting material is filled and distributed in the mold and removed by the air contained in the mold and the gases produced during casting. Continuous models are surrounded by the molding sand, which is then compacted by shaking and pressing so that it is stable. As a rule, castings are formed on both sides, so the mold is divided into lower and upper boxes so that the model can be removed again before casting. Then the top and bottom boxes are reassembled and the liquid cast material is poured into the resulting mold.
  • the binders of the foundry sand are selected to where possible be destroyed by the casting heat and the mold thereby disintegrating by itself, otherwise the mold must be mechanically destroyed in order to remove the casting.
  • Lost models are not removed from the mold before casting, so the mold can be one-piece.
  • the models are destroyed after pouring the casting material, either by evaporation, by melting or otherwise decomposing (eg polystyrene), or by being melted out before casting (wax, synthetic resins).
  • the molding material used to make lost molds (and cores) consists of a molding base, a binder and often other additives.
  • the molding material must be tailored in its composition to the molding and core-making process (e.g., densification, bedding), casting metal (e.g., casting temperature) and purpose (e.g., greater gas permeability in cores).
  • the usual wet coatings are sizing and varnishing, which can be applied by brushing, dipping, flooding or spraying. As sizing or blackening suspensions or dispersions of refractory materials are referred to, which are applied in the form of a thin coating on cores, molds or Lost Foam models, casting tools in the foundry industry and other mineral and metallic objects.
  • the present invention now relates to an application method of sizing to lost molds and cores, casting tools in the foundry industry as well as other mineral and metallic articles.
  • Alcohol sizing in which alcohol is used as the carrier liquid.
  • the most commonly used alcohol is isopropanol, whereby additions of other alcohols (for example ethanol and in some countries also methanol) are used to influence certain properties.
  • Water is used as the carrier liquid water.
  • the selection of the carrier liquid depends primarily on the binder system used, the production process at the user and the possibility of drying in the processing of the sizes.
  • the finished sizes are to be treated due to sedimentation due to storage time and transport. Since the main processing work has already been done by the manufacturer with special mixing units, the processing in the foundry is limited to mere homogenization, which can be done mainly directly in the delivery container. In this case, high shear forces are to be avoided in order to exclude any changes in the flow behavior of the sizing. Before the preparation of the size should never be skimmed off the liquid supernatant, since in this supernatant, the binders and additives are dissolved, which significantly influence the application properties of the size.
  • the powder component is a mixture of fillers and powdered additives
  • the paste component however, a mixture of suspending agent, fillers, binders and liquid additives.
  • the swelling process of the suspending agent or thickener in the size has already been completed, and only a homogeneous mixture of paste, fillers and carrier liquid has to be added.
  • a stationary mixing plant with a corresponding stirring unit (dissolver) is required.
  • Diving is today the fastest and most economical type of coating and can also be easily automated by dipping robots with a constant range of moldings.
  • the advantage of the automated dipping process is the regularity.
  • over-coating the core marks can be detrimental if the parts need to be assembled into larger systems.
  • Another disadvantage is the loss of material during the process (drops, dipping pool residues, etc.).
  • Spraying is one of the application processes with the highest losses in terms of material usage.
  • the spray mist furthermore requires additional measures to prevent work.
  • the layer thickness of the coating varies to varying degrees depending on the employed employee and can lead to casting defects.
  • Brushing is certainly the simplest but at the same time most time consuming form of coating.
  • a significant advantage of painting is that core marks and cooling iron do not have to be coated.
  • This form of sizing application is mainly found in large cores and molds which are allowed to take up little carrier liquid. The layer thickness depends both on the experience of the respective employee and on the processing setting of the sizing.
  • a mixture of refractory particles is completely coated with a polymer as a binder, after which these coated refractory particles are applied to molds by an electrostatic powder spray method.
  • DE 31 01 565 discloses an electrostatic coating of a plastic film, wherein the coating on the backfill facing side of the film is applied before the backfill is introduced, so that the sizing between plastic film and backfill (ie lost form or core) is.
  • EP 1 669 475 relates to a simple powder coating of a body part, wherein the surface of the body part has been pretreated, for example with a solution comprising zirconium and a silane.
  • the object of the present invention is therefore to avoid the disadvantages associated with conventional application processes for liquid sizes and to simultaneously exploit the advantages of using dry powder sizes in a process for applying a refractory coating to lost molds, cores and other mineral and metallic objects.
  • the lost forms, cores and other mineral and metallic objects coated with a solution, dispersion or suspension of a polymer are made conductive by applying an electrolyte solution and the refractory coating is applied in the form of a dry size by means of an electrostatic or tribostatic powder spraying process.
  • the powder sizings are not dispersed or suspended in water or alcohol before use but are applied dry to the article to be coated. Applying the Powder finishing is carried out in a stationary, closed, emission- and dust-free process with the appropriate equipment.
  • Powder coating or powder spraying is a coating process in which a generally electrically conductive material or article is coated with a suitable powder.
  • the powder is sprayed electrostatically or tribostatically on the substrate to be coated and then baked.
  • the object must be degreased well in advance.
  • the powder particles are electrically charged by friction, to then be applied by compressed air to the object to be coated. The particles then adhere to it due to their electrical charge. Whenever an electrostatic process is mentioned below, this also means a tribostatic process.
  • polymer means all organic and inorganic polymer substances, irrespective of their chemical composition, which can be dissolved, dispersed or suspended in water or organic solvents.
  • Thermoplasts and / or aminoplasts are preferably used.
  • Thermoplastics have no crosslinking points and are meltable on exposure to temperature, but are solidified on cooling, while aminoplasts, mainly urea and melamine resin, are thermosets, but have the property once more under the action of temperature
  • aminoplasts mainly urea and melamine resin
  • thermosets but have the property once more under the action of temperature
  • the surfaces of the objects to be coated are rendered conductive by application of an electrolyte solution prior to application of the size Trag can be done for example by dipping, flooding, spraying and / or brushing
  • the articles are dried after the application of the electrolyte solution and before the application of the size.
  • the articles may also be electrostatically coated with the size without prior drying.
  • Metallic objects do not require any pretreatment, since their surface is inherently conductive.
  • the refractory coating applied in the form of a dry sizing by electrostatic powder spraying is heated in a continuous or batchwise charging furnace, preferably by a heating process selected from the group consisting of hot air heating, infrared heating and light pulse Heating method and electron beam heating, as well as combinations thereof.
  • a heating process selected from the group consisting of hot air heating, infrared heating and light pulse Heating method and electron beam heating, as well as combinations thereof.
  • thermoplastic or aminoplastic polymer refers to all polymers, regardless of the chemical composition, which change their state of aggregation from “solid” to “pasty” or “liquid” as a result of the action of temperature in general, the condensation products of aldehydes (eg formaldehyde) with amines (eg urea / thiourea, melamine, cyanamide) understood, for example urea, melamine, thiourea resins, inter alia
  • the dry sizing for use in this process comprises mineral fillers, avoiding rheological additives such as suspending agents, thickeners, fluxes or crosslinking agents.
  • the powder sizes consist - except for conventional auxiliaries, especially for an electrostatic powder spray process - practically only from the mineral fillers, without suspending agents, thickeners, flux or crosslinking agents, which are not necessary in the process according to the invention.
  • the preparation of the powder sizes according to the invention is carried out by a homogeneous mixing of the raw materials used. A digestion for several hours, as in conventional potholes necessary, is not required. This results in a cost savings in terms of personnel and energy costs.
  • the process according to the invention is a solvent-free or solvent-reduced process in which no or extremely reduced amount of organic emissions is produced.
  • the methods of applying the powder sizes of the present invention to cores, molds, lost foam models in the foundry industry, and other mineral and metallic articles include, for example, the following steps:
  • the objects to be coated are cleaned and their surface rendered conductive by means of an electrolyte solution.
  • Metallic objects do not require any pretreatment, since their surface is inherently conductive.
  • an aqueous solution of an alkali, alkaline earth or metal salt or a dilute, aqueous solution of an organic or inorganic acid or base is used as the electrolyte solution.
  • the order can be done, for example, by dipping, flooding, spraying and / or brushing, if desired, the articles are dried after the application of the electrolyte solution. Care must be taken to ensure that the objects to be coated do not form a Faraday cage if possible, otherwise a tribo-static method should be used rather than an electrostatic procedure.
  • polymer means all organic and inorganic polymer materials, irrespective of their chemical composition, which can be dissolved, dispersed or suspended in water or organic solvents, for example polyacrylates, polyvinyl alcohols and polyvinyl derivatives, phenol novolaks, urea and melamine resins , Polyamines, polyamides, thermosetting oils and natural polymers such as lignin derivatives, tannin derivatives, cellulose derivatives, starch derivatives, polysaccharides, water glasses and inorganic polymers such as polysilicates and polyphosphates.
  • polymer means all organic and inorganic polymer materials, irrespective of their chemical composition, which can be dissolved, dispersed or suspended in water or organic solvents, for example polyacrylates, polyvinyl alcohols and polyvinyl derivatives, phenol novolaks, urea and melamine resins , Polyamines, polyamides, thermosetting oils and natural polymers such as lignin derivatives, tannin derivatives, cellulose derivatives, starch
  • the size is in solid powder or granular form, in any case includes a mixture of mineral fillers, such as. Alkaline earth oxides, metal oxides, graphite, etc.
  • the size can be used directly without further preparation.
  • the powder spray process (EPS process) for the finish application is as follows:
  • the powder sizing is fluidized with air in a powder container, ie loosened with air surges.
  • the air used may have a maximum water vapor content of 1.3 g / m 3 .
  • the air pressure is 5 - 12 bar.
  • the fluidized powder from the container to the spray gun for example, an EPS hand spray gun from the trade with ceramic nozzle, promoted and there by means of integrated high voltage generation (nominal input voltage 10 V eff., Frequency 15-20 kHz, nominal output voltage 100 kV, polarity negative) electrostatically charged and ejected in the direction of the core to be coated, shape, lost foam models, mineral or metallic object.
  • the electrostatic forces direct the powder particles to the objects to be coated.
  • the objects to be coated must be well grounded before spraying.
  • Especially suitable for small parts is also a variant that works in a fluidized bath.
  • the electrostatic charging of the powder particles can be carried out according to the present invention with the following types of spray guns:
  • the powder particles are negatively charged.
  • the corona electrodes have a high voltage of about 100 kV.
  • air ions are generated, which charge the powder particles electrostatically. Disturbances in the coating layer may possibly occur due to the "rejuvenating effect". This is caused by air ions, which charge the deposited powder layer.
  • Suitable nozzle systems are available for customization. In the method of the present invention are particularly suitable nozzle systems made of ceramic or stainless steel.
  • the polymers which are present in the polymer layer applied before application of the size melt.
  • the molten polymer anchors to the surface of the article to be coated and forms a closed, very well-adherent polymer film, which acts as a binder and binds the powdery fillers of the size.
  • the baking takes place, depending on the chemical composition of the polymer contained at temperatures between 100 - 400 ° C.
  • the aim is a rapid and effective warming and thus a burn-in of the applied sizing powder.
  • This can e.g. be achieved by hot air drying or jet drying.
  • the following heating methods are available for "stoving" the powder sizings:
  • Hot air drying An effective but slow heating and drying can also be achieved with conventional hot air drying
  • Infrared Usually carried out with infrared radiators emitting heat from 200 ° C to 400 ° C. According to the nature and surface of the coated articles, the infrared rays are absorbed or reflected by them. The non-reflected radiation fraction leads to a rapid increase in temperature of the powder size and the objects to be coated. The rapid heating of the powder size and the melting or flow of the thermoplastic or aminoplastic polymer requires a precise adherence to the heating time. The infrared heating is only to be used in continuous processes in which the transport speed can be precisely matched to the dry material, so that there is no overheating of the coating at individual points of the object to be coated.
  • Light pulse warm-up process In principle, a kind of UV radiation heating method.
  • UV rays are collimated by reflectors and directed as parallel bundles on the surface of the coated articles. This makes it possible to change the distance between the surface of the coated article and reflectors within a range of about 1000 mm.
  • This type of heating is particularly suitable for polyester polyurethane or urea or melamine resins as a binder. The heating time is between 15 and 35 seconds.
  • Electron beam heating This process is used to cure powder layers that are more than 400 ⁇ m thick. They harden completely in fractions of a second, which is why the process enables correspondingly high belt speeds.
  • electrons are emitted from a tungsten wire and bundled in an electric field.
  • the bundled electrons (electron beam) spread over the entire width of the conveyor belt.
  • the curing of the polymer contained takes place without heat development in an about 100 mm long irradiation zone.
  • This process is economical only at high throughput rates. In addition, special safety precautions are necessary because the radiation is very dangerous for humans.
  • the following wavebands may be selected as needed:
  • Infrared Wavelength range 1 mm to 800 nm; Frequency range 3.1011 to 3.75.1014 Hz.
  • the experiments were performed with cold box, hot box and furan (no-bake) cores and lost foam models.
  • the objects to be coated were made conductive by dipping or spraying with different electrolyte solutions. Eight pieces of cold box, hot box, furan (no-bake) sand cores and lost foam models were pretreated with each solution. Of these, four were dipped and four sprayed.
  • the electrolyte solutions used were: a) 5.0% MgSO4 solution (pH 6.5). b) 5.0% Na 2 HPO 4 solution (pH 9.1). c) 5.0% Na 2 SO 4 solution (pH 5.5). d) 5.0% Ni (CH 3 COO) 2 solution (pH 5.5). e) 5.0% FeSO4 solution. f) 10.0% citric acid (pH 1, 8). g) 2.0% H2SO4 (pH 1.5). h) 1, 5% H3PO4 (pH 1, 8). i) 2% KOH (pH 12).
  • the cores and Lost Foam models were dried for 5 minutes at 120 0 C by hot air drying.
  • Powder sizing 1 consisting of:
  • the comparative product is an alcohol sizing (ie same composition but suspended in alcohol).
  • Powder sizing 2 consisting of:
  • the comparative product is a water-based (i.e., same composition but suspended in water).
  • the specific composition of the sizes was chosen because such sizes are often used in the foundry industry and the sizes are very high or low density, eg zircon 3.9-4.8 g / cm 3 , mica 2.7-2 , 8 g / cm 3 and graphite 2.1 - containing 2,3.g / cm 3.
  • the powder sizing was fluidized with air in the powder container of the coating test plant, ie loosened with air surges.
  • the air used had a water vapor content of 0.9 g / m 3 , the air pressure was 8 bar.
  • the fluidized powder sizes were transferred from the container to the spray gun, e.g. a corona hand spray gun with ceramic nozzle, where it is electrostatically charged by means of integrated high voltage generation (nominal input voltage 10 V rms, frequency 15 - 20 kHz, nominal output voltage 100 kV, polarity negative) and in the direction of the pretreated and grounded sand cores or Lost Foam models pushed out.
  • the spray gun e.g. a corona hand spray gun with ceramic nozzle
  • integrated high voltage generation nominal input voltage 10 V rms, frequency 15 - 20 kHz, nominal output voltage 100 kV, polarity negative
  • the coated cores and Lost Foam models were treated by hot air drying for 15 minutes at 250 0 C and IR-drying for 5 minutes at 300 0 C.
  • the applied powder layer had a thickness of 200-250 ⁇ m.
  • Example 1 The sand cores and Lost Foam models coated in Example 1 were cast in iron foundry in the foundry.
  • Sand cores and Lost Foam models which are coated with the respective reference product alcohol or water-based size, served as comparison.
  • the castings produced using powder-coated sand cores and lost foam models are of the same quality as those below Use of the respective wet sizes produced castings.
  • FIG. 1 shows a cross-section of a powder-coated article
  • FIG. 2 shows a large-scale and automatically operating plant for the processing of powder sizes according to the EPS process designed according to the present invention.
  • a powdered article according to the invention is constructed in cross-section from the powder layer (1), a conductive layer and polymer layer (2) and the article itself (3).
  • a plant for processing powder sizes according to the EPS process consists of the following components:

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Mold Materials And Core Materials (AREA)

Abstract

L'invention concerne un procédé pour l'application d'un revêtement réfractaire sur des moules perdus, des noyaux et autres objets minéraux et métalliques. Selon l'invention, avant l'application du revêtement réfractaire, les moules perdus, les noyaux et autres objets minéraux et métalliques sont rendus conducteurs par application d'une solution électrolytique et sont enduits d'une solution, dispersion ou suspension d'un polymère. Le revêtement réfractaire est ensuite appliqué sous forme d'enduit sec par un procédé de pulvérisation électrostatique ou tribostatique de poudre. L'invention concerne également un enduit sec à utiliser dans ce procédé.
EP09711876A 2008-02-22 2009-02-05 Enduits pulvérulents Withdrawn EP2244852A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AT0029608A AT506484B1 (de) 2008-02-22 2008-02-22 Pulverschlichten
PCT/AT2009/000043 WO2009103098A2 (fr) 2008-02-22 2009-02-05 Enduits pulvérulents

Publications (1)

Publication Number Publication Date
EP2244852A2 true EP2244852A2 (fr) 2010-11-03

Family

ID=40935788

Family Applications (1)

Application Number Title Priority Date Filing Date
EP09711876A Withdrawn EP2244852A2 (fr) 2008-02-22 2009-02-05 Enduits pulvérulents

Country Status (7)

Country Link
US (1) US20110045198A1 (fr)
EP (1) EP2244852A2 (fr)
AT (1) AT506484B1 (fr)
BR (1) BRPI0906012A2 (fr)
CA (1) CA2715139A1 (fr)
MX (1) MX2010009083A (fr)
WO (1) WO2009103098A2 (fr)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP5784484B2 (ja) * 2011-12-28 2015-09-24 花王株式会社 水性塗型剤組成物

Family Cites Families (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1475069A (en) * 1974-09-03 1977-06-01 West Of England Securities Ltd Manufacturing a foundry mould or core
US3996410A (en) * 1974-09-19 1976-12-07 Andersen Corporation Method and composition for treating substrates and coated articles obtained thereby
DE2753104B1 (de) * 1977-11-29 1978-11-09 Wagner Maschf Heinrich Verfahren zum Aufbringen von Schlichten
JPS5834218B2 (ja) * 1979-02-15 1983-07-25 フオセコ・インタ−ナシヨナル・リミテツド 溶融金属と接触する消耗性基質の被覆
DE3101565A1 (de) * 1981-01-20 1982-10-28 Passavant-Werke AG & Co KG, 6209 Aarbergen Verfahren zum herstellen einer giessform
JPH0688119B2 (ja) * 1988-05-25 1994-11-09 株式会社アーレスティ ダイカスト鋳造法
GB9107249D0 (en) * 1991-04-06 1991-05-22 Foseco Int Tribo-electrical coating of bodies of low electrical conductivity
US5749409A (en) * 1995-12-18 1998-05-12 General Motors Corporation Method of forming refractory coated foundry core
US7273634B2 (en) * 1999-10-15 2007-09-25 Fitzgibbons Jr Robert T Coatings and additives containing ceramic material
JP2006161110A (ja) * 2004-12-08 2006-06-22 Nippon Paint Co Ltd 車両のシャシ用金属表面の塗装前処理方法及び粉体塗料の塗装方法

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See references of WO2009103098A3 *

Also Published As

Publication number Publication date
AT506484B1 (de) 2011-02-15
US20110045198A1 (en) 2011-02-24
MX2010009083A (es) 2010-09-07
WO2009103098A3 (fr) 2009-12-17
AT506484A1 (de) 2009-09-15
BRPI0906012A2 (pt) 2015-06-30
WO2009103098A8 (fr) 2009-10-15
CA2715139A1 (fr) 2009-08-27
WO2009103098A2 (fr) 2009-08-27

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