CPT International 03/2016

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K QUALITY ASSURANCE critical components which are highly specified, it was important to demonstrate the capability of the system and gain approval for the process change from +GF+’s customers. To demonstrate the consistency of the process control a set of tests were conducted over a four week period: »» The weight pick-up of coating was measured both before and after drying The wet and dry weight pick-up of the coating is respectively proportional to the wet and dry applied layer thickness of coating, and knowing the area Figure 3: Automated dipping of test pieces Figure 4: Quality assurance checks of wet layer coating thickness »» Transverse test bars were produced using a PUCB binder following a standardized procedure »» The uncoated weight of each test piece was recorded »» Sample coating was removed from the Coating Preparation Plant at regu lar intervals »» The density of the sampled coating was measured accurately using a calibrated pyknometer and recorded, as was the solids content of the sample. »» Coating was applied to the test pieces using an automated dipping device (Figure 3) which controlled both speed and dwell-time of the dipping operation of coverage and density of the coating allows the average layer thickness to be calculated. The result of this intense study over the four week period showed that: »» At a target density of 1.15 g/cm 3 the average CPP density was 1147g/cm 3 »» The standard deviation for the dataset was only +/- 0.001g/cm 3 »» The measured dry coating weight per core was on average 11.2 g with a standard deviation of only +/- 0.25 g Overall this was assessed as extremely accurate and reproducible, with the variance in weight pick-up onto the cores indicating that the layer thickness was very consistent over the four week trial period as the CPP maintained the coating density within very tight control limits. The test method was designed to replicate the foundry process where the coating supplied at specific density is applied to the cores using automated robots that control both speed of dipping and dwell time within the coating. Subsequent quality checks within the foundry continue to validate the process, with the CPP maintaining a very consistent density of supplied coating and regular wet layer thickness checks (Figure 4) confirming consistent coating layer application. Process assurance For the control of water-based coating products it is essential to implement good housekeeping procedures 22 Casting Plant & Technology 3 /<strong>2016</strong>
to prevent contamination of the product resulting in bacterial attack and a degradation of the product rheology leading to a change in application properties. In order to avoid this risk, +GF+ has chosen the optional water disinfection system to be installed on the CPP. This system ensures that all incoming water used for dilution is disinfected and hence avoids any coating product deterioration due to bacterial infection over time. The advantage of the system installed is that it achieves this disinfection without the use of harsh chemical additives that may cause dermatological reactions if in contact with operators or adversely affect the rheological performance of the coating. continuous improvement and can be tailored to every customer requirement. Acknowledgement Thanks to +GF+ Mettmann Automotive, in particular Mr M.Busch for his invaluable and trustworthy cooperation. Our value adding solutions for your process www.foseco.com References www.cpt-international.com Customized CPP at Georg Fischer, Mettmann, Germany http://bit.ly/1LqhBw8 Summary The benefits of the implementation of the CPP into the full casting process at +GF+ Mettmann can be concluded as: 1. Continuously controlled coating application 2. Repeatability of applied layer thickness 3. Quality assurance and historical data availability 4. Operator independent 5. Cost savings through reduced scrap and re-work 6. Maintaining core shop and foundry-processes at an optimized balance 7. Improved working environment Considering the continuously growing demand for foundry process consistency, an acknowledgement of the need for a consistent coating due to its influence on casting quality is required. The CPP concept is now accepted as the way forward to achieving this goal. As with all technical equipment, the CPP design is subjected to Our services provide you with real added value. ASK Chemicals experts look forward to hearing from you: Phone: +49 211 711<strong>03</strong>-0 E-Mail: addedvalue@ask-chemicals.com www.ask-chemicals.com
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Page 12 and 13: K COREMAKING Author: Thorsten Schau
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Page 20 and 21: K QUALITY ASSURANCE Authors: Christ
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Page 28 and 29: K QUALITY ASSURANCE Author: Ralf Si
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Page 38 and 39: K SOFTWARE Author: Matthias Holzapf
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Page 56 and 57: K BROCHURES Insulation technology 4
Page 58 and 59: K INTERNATIONAL FAIRS AND CONGRESSE
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CPT International 03/2016

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