50th Porcelain Enamel Institute Technical Forum. Ceramic Engineering and Science Proceedings, Volume 10, Issue 5/6

196 Pages·2002·8.834 MB·English

by  John B. Wachtman

Proceedings of the
50th Porcelain Enamel Institute
Technical Forum
William McClure
Conference Director
A Collection of Papers Presented at the
50th Porcelain Enamel Institute
Technical Forum
October 4-6, 1988
The Ohio State University
Columbus, OH
Published for the
Porcelain Enamel Institute, Inc.
by
The American Ceramic Society, Inc.
757 Brooksedge Plaza Drive
Westerville, OH 43081-6136
Copyright@ 1989, The American Ceramic Society, Inc
and The Porcelain Enamel Institute
I I
fkecutive Director & Publisher Edhr
W. Paul Holbrook John B. Wachtman
Director of Publications Pnductinn Manager
Linda S. Lakemacher Alan Hirtle
Committee on Publications: David W. Johnson, Jr., chair; Ronald E. Loehman;
Richard E. Tressler; Robert J. Eagan, ex oficio; W. Paul Holbrook, oficio;
Waltraud M. Kriven, a oficio; John B. Wachtman, a oficio.
EditohlAdvisory Board: Waltraud M. Kriven, chair; Carol Janteen, chair-elect;
M.
Uma Chowdry; David Cranmer; George Gehringer; Michael Gruteeck; David B.
Marshall; Thomas 0. Mason; Thomas F. Root; Karl E. Spear; Mark A. Stett;
Russell K. Wood.
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CESPDK Vol. 10, NO. 5-6, pp. 387-573, 1989
I
The American Ceramic Society assumes no responsibility for the statements
and opinions advanced by the contributors to its publications, by the speakers
or
at its Drorrams.
Copyright 0 1989, by the American Ceramic Society. Permission to photocopy
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Foreword
A Word From the Technical Forum Chairman
It was a real pleasure to serve as Chairman of the 1988 PEI Technical
Forum, and I am pleased that the record of the meeting can be
presented in these Proceedings. This is the 50th of these published
Proceedings, and the complete volumes beginning with the 1937 Forum
represent an outstanding record of the porcelain enameling industry's
progress over more than five decades. We believe this latest edition is
a worthy companion piece to all those which have preceded it.
The program for the 1988 Technical Forum proved to be a
particularly full and diverse one, covering virtually every facet of the
porcelain enamel industry. The program was launched by two reports
on innovations in porcelain enamel throughout the world. Then the use
of robotics was presented. Information followed on catalytic coating,
screening, and aluminum enamels. A session on steels was followed by
several papers dealing with regulatory actions impacting our industry.
Again this year, increased use of pickle-free systems received
attention-as did the growing number of electrostatic powder systems
in use; quality control practices played an important role, and safety
and environmental affairs were covered. Special interest was shown in
evaluation of new detergents being introduced. The problem of
outgassing was covered from several viewpoints. The Forum was
concluded with a special session examining distortion in firing.
We were pleased to have another outstanding "Back to Basics"
workshop held on the day before the start of the Technical Forum. We
commend Floyd Williams (Porcelain Metals Corporation) for making all
the necessary arrangements and for heading the excellent "faculty"
up
that led the workshop attended by more than 80 industry representa-
tives.
As we send these Proceedings to you, I want to express my
appreciation to all of the speakers and to the session chairmen and their
companies for their great contribution. Also, I want to thank the
members of the Forum Committee who put together the program and
helped in countless ways to make certain it was effectively carried out.
Finally, we are deeply appreciative to Dr. Dennis Readey and to all of
the others at The Ohio State University for their many kindnesses in
their role as host university for this year's Forum. The contribution of
all these individuals and many others has been a most essential
ingredient in the success of this year's PEI Technical Forum.
William McClure, Chairman
1988 Technical Forum Committee
I
Each issue of Ceramic Engineering and Science Proceedings includes a collection of
technical articles in a general area of interest, such glass, engineering ceramics, and
as
refractories. These articles are of practical value for the ceramic industries. The
issues are based on the proceedings of a conference. Both The American Ceramic
Society, Inc., and non-Society conferences provide these technical articles. Each issue
is organized by an editor who selects and edik material from the conference. Some
issues may not complete representations of the conference proceedings. There Is
be
no other review prior to publication.
I
Table of Contents
........
Overseas Advances in Porcelain Enamel Processing 387
William D. Faust and Albert L. Gugeler
..............
Observations on Innovations from Abroad 391
Cullen L. Hackler
.....................
Use of Robots in a Range Plant 392
Jerry Gelbaugh
..................
Robotics for Wet Spray Applications 393
Jon Wojtowicz
Robotic Application of Porcelain Enamel in a
...............................
Dishwasher Plant 394
David Yarber
..........
Historic Overview of Continuous Clean Coatings 400
William F. Dykstra
.................................
Silk Screening 403
A. Laurendeau
............................
Screening Over Bisque 409
Frank Corum
.......................
Latest in Aluminum Enamels 410
Paul R. Lee and Joseph P. Hingsbergen
........
Steels for Porcelain Enameling-Present and Future 413
D. L. Bowley
Improved Enameling Steel Through High Flow
..........................
Hydrogen Box Annealing 421
K. G. Brickner and H. B. Kincaid
........
Advances in Open Coil Annealing Process Controls 430
Michael Kanur
....................
Comments on Regulatory Actions 437
James J. Carleton
........
Observations on Waste Minimization: EPA Outlook 442
Jack E. Waggener
Achieving Pickle-Free Bond at Lower Firing
..................................
Temperatures 443
Susan D. Kutbay
Effect of Iron Phosphate on a Pickle-Free Ground
..................................
Coat System 454
David L. Mimms
......................
Dishwasher Plant Observations 457
Narayan B. Sedalia
Formulation Improvements in Base Coats for Two
..................
Coat-One Fire P/E Powder Systems 459
Eric Van Horn
Base Coat/Cover Coat Interactions in Porcelain
..........................
Enamel Powder Systems 470
Frank A. Kuchinski and Cynthia J. Labant
........................
Supplier Quality Assurance 480
Peter F. Jacoby
Innovations in Frit .M..an.u.f.a.c.tu.r.i.n.g. U.s.i.n.g .S.P.C.. a.n.d. ......
Computer Control 481
Shaun W. Baker
Individuals and Moving Range Charts: SPC
....................
Techniques in Frit Manufacturing 488
Timothy S. Brumbly
......................
Pigments and the Environment 492
Demetra Balmer
Decommissioning of Waste Water Treatment Facility
....................
of Metal Pretreatment Operations 498
Jon Hakim
.............................
Waste Minimization 510
David S. Cameron
Zero Discharge, Zero Pollution, and Source
....................................
Reduction 513
Robert H. Elliott, Jr.
............
Changes in Laundry Detergent Formulations 514
A. James Fuchs
............
The Changing Nature of Laundry Detergents 522
Vernon C. Jett
Powder Porcelain Enamel-Outgassing and/or
................
Blackspecks Related to Steel Substrate 528
L. Steele
Larry
Role of Metal Preparation in Outgassing Problems
.................
with Porcelain Enamel Powder Spray 531
Holger Evele and Leroy P. Weinmann
Outgassing in a Two Coat-One Fire Powder
....................................
Operation 539
Arnold Moss
M.
Development in Second Generation Porcelain
........................
Enamel Powder Cover Coats 541
William L. Rauch
Differences and Comparisons of Wet and Powder
.......................
Porcelain Enamel Covercoats 548
Cynthia J. Labant and Cullen L. Hackler
Coating Wire Grills and Racks with Porcelain
................................
Enamel Powder 554
Roy M. BinkIey
......................
Warpage as a Result of Firing 555
Floyd J. Williams
.......................
Role of Enamels in Warpage 560
Keith Corbett
Production Experiences with Steel Sag Testing vs
.................................
Parts Warpage 566
J. Michael Horton
.........
1988 PEI Technical Forum Final Attendance List 569

Ceram. Eng. Sci. Proc. pp.
10[5-61 387-390 (1989)
Overseas Advances in Porcelain Enamel Processing
WILL- D. FAUSTA ND ALBERT L. GUGELER
Ferro Corporation
4150 East 56th Street
Box 6550
P.O.
Cleveland, OH 44101
Significant processing advances occurring worldwide are described. Conventional
wet applications and dry powder processesses used with no pickling are noted. Single
firing of multiple coats repod.
is
The present state of enameling techniques worldwide is undergoing
continuing and significant changes. Research into methods, materials,
and applications is actively being supported in many countries. Table
I lists abstracts representing selected current ongoing R&D projects.
Some of these subjects will be topics for the International Enamel-
ers Congress in Czechoslovakia in 1989. This R&D work is supporting
active commercial development worldwide. Many manufacturers in
Europe, North and South America, Australia, and China are utilizing
recent and newer technical developments (see Table 11).
Powder application (including the two coat-one fire process), no
nickel-no pickle ground coats, and no degreasing have been some of
these developments that have kept the porcelain enamel process
competitive with other coatings. Simplicity and economy are key
considerations for new and current enamelers.
The adaptation of the enamel powder application technique and
traditional wet application is now producing a new method that has
been described as simpler and more economic than all powder or
traditional methods.
In Europe, considerable activity is going on in adapting the wet/wet
and wet/dry two coat-one fire processes. All grades of sheet steel are
Albert Gugeler has a ceramic engineering degree from Iowa State University. He has been
L
at Ferro since He has served manager, frit quality control; and manager, P/E
1955. as
development lab. Presently, he is international product coordinator for Ferro.
William D. (Darry) Faust is Ferro’s manager, porcelain enamel research. Previously, he was
group leader for inorganic coating research. Darry received his in ceramic engineering
B.S.
from Clemson. He also holds an M.S. degree in management from Case Western Reserve
University.
387
being used; however, low carbon steel is said to give the best results.
The no pickling process has been adapted to this methodology also.
With the wet/wet and wet/dry processes, two-sided application is
possible, which up until now has not been achieved with the dry/dry
process for two coat-one fire.
Recent use of these processes is said to produce improved quality
of the ware. The mechanical and chemical properties of these systems
is said to be comparable to conventional two coat-two fire systems.
These developments have been made to reduce the overall enamel-
ing costs. However, the commercial use of these systems has been too
recent to allow comprehensive cost comparisons. The combination of
wet application and dry application together is said to reduce the
necessary floor space requirements of such a system.
Limited production experience has shown technical feasibility of
these processes. One company of which we are aware has been using
the wet/dry two coat-one fire process for over 6 years, enameling over
15 000 stove pipes per month.
This installation has reported a 50% reduction in personnel needed,
a 30% reduction in the necessary groundcoat used, and a 50% reduction
in the amount of covercoat used vs a conventional two coat-two fire
wet system.
A range manufacturer in France has started with a wet/dry two
coat-one fire system for kitchen range parts.
Both industrial research and development and commercial applica-
tions are active in many geographic locations. Europe, the Americas,
and the Far East are adapting recent developments in the enamel
industry, which a few years ago were restricted to only a limited
number of countries. In the future, it is foreseen that more rapid
change will be evident as new techniques and process improvements are
reported and then adapted. The recent developments reported continue
to make enameling an important coating, one which paints will have
more difficulty displacing.)
388