To meet the latest quality demands Metso:Outotec was challenged to improve coating application consistency, reduce casting defects, at the same time automate coating control and adjustment and to improve quality control.

Metso:Outotec is a Finnish company specialising in mining equipment. Metso:Outotec has a global footprint with 15 000 employees in over 50 countries and provides sustainable technologies, end-to-end solutions, and services to the aggregates, minerals processing, and metals refining industries. The Metso:Outotec foundry in Prerov, Czech Republic produces metallic ware parts for Metso:Outotec’s mining customers.

The parameters
Alloy: Predominantly CrMo Steel (minority Mn Steel)
Coremaking: CO2-resol, PUR cold box Moulding process: Alkaline phenolic binder technology
Casting temperature: 1 480 to 1 520°C Pouring weight: max. 8 tons

Foseco’s products used included the ICU Pro unit, TENO* coating 5000 A-80, FENOTEC* 280 ES binder, FENOTEC HC 10, 20, 30, 35, 45 binders, STELEX* PrO filters and KALMINEX* XTA sleeves.

The solution
The Foseco 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.

The outcome
The use of the ICU unit resulted in a uniform coating layer thickness, reduced coating waste, removed sand particles in the coating and increased core shop productivity by 25%. Casting scrap and rework levels were also reduced.

For more information contact Foseco South Africa on TEL: 011 903 9500 or visit https://www.vesuvius.com/en/our-solutions/en-za/foundry.html