F W Gartner, Thermal Spraying,Ltd

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F W Gartner, Thermal Spraying,Ltd 25 Southbelt
Industrial Drive, Houston, Texas 77047 USA
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BRENCOAT? BR-4? NON WETTING CERAMIC and BRENCOAT?
SYPHONING SYSTEM
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BR-4 Multi Layered Ceramic Coating
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BR-4. Resists Thermal Shock Resists Thermal
Cycling Temperature Range 600C to 1200 C
Non Wetting- Molten Aluminum, Bath and Dross
Good Impact resistance Zero Iron transfer
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Zero Iron Transfer/Loss
Test was carried out with 2 dia. bar on an
agitator in a bath of molten Aluminum Alloy (8
Si/0.3 Mg/bal. Al) at approx. 700C. Working day
was 8-9hr or 266hr total. BATH WITH IRON BAR WAS
RUNNING AT 25PPM IRON. BATH WITH BR-4 COATED
IRON BAR WAS 0.0PPM IRON. Iron bars were cleaned
and pre-heated between cycles. BR-4 did not
require either.
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COATING SYSTEMS USED
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Short list of some of the parts coated with
BR-4. 1. Ladles (Aluminum Casting Industry) 2.
Dross conveyor (Tomago Aluminum, New South Wales,
Australia) 3. Dross and Bath Skimmers (Tomago) 4.
Pouring Launders (Casting Industry) 5. Pouring
Chute (Portland Aluminum, Victoria, Australia) 6.
Mixing Rotor (Tomago) 7. Bath Crucible Lids
(Hydro, New South Wales, Australia) 8. Robotic
Dross skimmers (Portland Aluminum, Victoria,
Australia) 9. Furnace Dams (Portland) 10. Mixing
shafts (Portland) 11. Bath Crucible Lids (Comalco
Riotinto, Queensland, Australia) 12. Sprue
Bushings (Aluminum Wheel Casting) 13. Casting
Wheel (Comalco)
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Casting Ladles.Ladles used in the Aluminum
casting industry.Eliminates most OHS problems
that are caused by the product sticking to the
ladle. No need for the operator to clean the
Ladle ½ way through their shift.(MAHLE
Automotive, Victoria, Australia. Casting pistons.)
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Dross Conveyor.History Constant daily
re-coating of aluminum sealer and replacement of
conveyor every 6 months.BR-4 Conveyor was put
into service in April 2005 and is still in
service, still has no need for cleaning or any
damage from Bath, Product or Dross.(Tomago,
Dross Removal and Processing)
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Dross Skimmers.History Skimmers needed cleaning
on a daily basis and replacement every 4
weeks.BR-4 No cleaning required for 8 weeks,
cleaning then required on the tips only, with the
BR-4 making it easier to clean. Total life 20
weeks. (Tomago, Dross and Bath removal from
Crucible)
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Pouring Launder History Constant cleaning and
re-application of Boron Nitride.BR-4 Needs
very little cleaning. Material releases
easily.(Casting Industry)
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Mixing Rotor.History Life span 4 weeks, iron
transfer 45 of rotor tip.BR-4 Life span 12
weeks, iron transfer Nil. Rotor taken out of
service for re-coating prior to any rotor tip
wear. Note Transport rack manufactured to
protect rotor.(Tomago, TAC Rotor)
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Bath Crucible lid.History 4 to 6 month life.
BR-4 12 months minimum life.( Hydro and
Comalco, Bath processing)
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Furnace Dams.History Replace every 3
months.BR-4 Coated dams went into service
October 2005. New coated Dams were supplied in
July 2006 but have not been needed to date as the
old ones are still serviceable. (Portland
Aluminium, Ingot Room)
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Sprue Bushings. History Bushing normally gave
only 7 to 9 shifts.BR-4 (3 years Later) we
achieve 33 to 36 shifts from each bushing.(ION
Automotive, South Australia)
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Casting Wheel. History needing either cleaning
or repair 4 to 5 times a month. BR-4 constant
use for 2 months before re-coating.(Portland
Aluminum, Ingot room)
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Crucible Cleaning Chute.History Constantly
fouling with dross build-up. Repair needed every
3 months. BR-4 In service without the need for
cleaning for over 12 months. Still looks like
new! Dimension 7 x 12.(Tomago, Crucible
Cleaning and processing.)
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Goose necks.History Life span 2 to 4 weeks.
BR-4 Coated Necks 12 weeks.(Comalco, Product
Tapping)
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Brencoat Syphoning System
Syphoning Tip
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Siphon Assembly Animation
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BR-4 Ceramic Coating
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Impact resistant Solid Ceramic Anti spark panel
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Brencoat Syphoning System
Re-useable syphoning system Barrel Tip No
Pre-Heating Required No Reaming Required No
Cleaning of Molten Metal Build-up
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BR-4 Coating internals of Tip Barrel
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No Temperature change from Pot to Crucible
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BR-4
Provided by FW Gartner
Thank You.