Coatings for Iron Foundries

Foseco’s sand mould and core coating products help foundry operators achieve the best available casting surface finishes at the highest possible level of operational efficiency. The range of products have been specifically engineered so that they can be applied by dipping, flow coating, brushing, swabbing and spraying. 

Coatings for Jobbing Iron

Water and solvent based refractory coatings for semi-automated and hand moulding short run production in iron foundries.

This sector is typified by the variety of size and shape of cast components, ranging from many tonnes to less than a kilo. The processing of such components in, typically, short runs requires flexible manufacturing techniques. This variety and flexibility is reflected within the coating product ranges on offer from Foseco. 

Coatings for Production Iron

Water and solvent based refractory coatings for automated high production iron foundries.

Production iron foundries are highly automated, often with a large proportion of cored castings. The application of coating is normally via a dipping operation.
The range of coatings is focussed on providing exceptional dipping characteristics, whilst ensuring internal surfaces are free from casting defects.
Specific coatings are available to offer superb protection against a number of common defects including RHEOTEC XL which offers unparalleled protection against the formation of veining defects. 

Equipment

Intelligent Coating Unit

The ICU (Intelligent Coating Unit) automates the coating preparation from its as supplied state to the density that delivers the most consistent layer thickness – continuous monitoring, control and adjustment ensures optimized coating performance utilization. The ICU is ready for Industry 4.0 standards.

Flow coating equipment

The equipment consists of three main parts: the pressure tank, the control box and the catchment tray. It operates on the principle of displacement of the coating from the tank via a flexible hose by use of low pressure compressed air.
No other power source is required and the low degree of wear due to the absence of mechanically moving parts in contact with the coating is of special advantage. 

Full Mould and Lost Foam Processes

The SEMCO perm and STYROMOL ranges of water based coatings are designed to promote excellent surface finish and dimensional stability of the polystyrene pattern. Permeability and composition have been specifically designed to meet the requirements of lost foam. 

Spun Pipe and Rolls

SPUNCOTE coatings are products formulated to provide a permeable coating with very low gas evolution for the centrifugal casting process. The coating will help to deliver a smooth surface finish of the casting and promote easier stripping of the finished casting. 

SPUNCOTE SP coatings are specially formulated to provide a range of textured surface to the centrifugally cast component especially suited to the production of cylinder liners, through the use of the appropriate coating and process parameters the texture can be defined as rough, spiny or wormy. For more information refer to our “Coatings for high performance cylinder liners” brochure. 

Metallurgical Coatings

ACTICOTE is a range of coating products that prevent the disruption of the graphite formation in the surface skin of castings. For example reducing the reversion of compacted graphite to flake graphite within the surface of compacted graphite iron (CGI) castings. 

TELLURIT chill-promoting coatings are suitable for grey cast iron and are ideal for producing a wear resistant surface.

In addition, there are several coatings in our SEMCO and TENO product ranges designed to help prevent flake reversion defects, especially those associated with acid set chemically bonded binder systems. 

Electrostatic Coatings

TRIBONOL powder coatings are a range of mould and core coatings for electrostatic deposition. The electrostatic method of application circumvents problems of solvent vapour, flash hazard and lengthy oven drying. It is a totally dry process.