Control, adjustment and preparation of coatings for foundries are the most important prerequisites for perfect casting without coating layer related defects. With its newly developed intelligent coating unit, Foseco has set itself the task of eliminating such errors from the outset.
Poor application control can undermine coating performance and can in some instances lead to excessive scrap or rectification work. Hence Foseco has developed a range of equipment that is designed to optimise coating control at application.
Automated coating control and adjustment
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 the 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.
The Foseco Intelligent Coating Unit (ICU) was introduced in 2019 to improve the handling and application of mould/core coatings in ferrous foundries. It offers a way for foundries to improve process reliability, as well as casting quality. Further developments of the ICU concept since then have led to the launch of new modular and integrated solutions that extend its use to a wider range of foundries, and show payback on investment within a year of installation. The very latest innovation is the first handheld density measurement tool, which has been released as a replacement for traditional Baumé and flow cup testing when manual coating control is required.
The Intelligent Coating Unit (ICU) automates the process of measuring and controlling the dilution of refractory coatings to ensure the correct consistency is maintained and the properties required for optimum application are achieved. The ICU is fully ATEX certified and ensures the safest operation with solvent coating.
Improved control: The coating density is controlled in real-time and measured more accurately than with any other device – up to the fourth decimal place. In addition, the continuous measurement system provides excellent data for improved process control, calibration and auditing and is operator independent.
Improved consistency: The ICU delivers even greater consistency in wet layer thickness applied.
Improved handling: The system is fully automatic, virtually maintenance-free and easy to operate. It works with very few moving parts, making it the most robust automated coating system in the industry. The ICU is suitable for all application methods, including spraying, dipping and flow coating and can be connected to all major packaging systems, from drums to bulk silos.
For more information contact Foseco South Africa on TEL: 011 903 9500 or visit www.foseco.com
