A Reduction of Interior Peel off Defect in a Robot Spray Coating Process

Abstract:

Article Preview

The Teflon coating on the hardened aluminum surface is the process of creating a film on the smooth surface which requires three layers of coating and each layer must be cured at a certain temperature. Due to a complexity of the process, peel off defect is one of the intimidate defects in the coating process. The objective of this research is, therefore to determine optimal coating parameters in order to reduce the peel off. A robot attached with a spray gun at the end effector is used to spray Teflon onto the hardened aluminum work-piece. Typically, there are three steps coating process i.e. primer, middle, and top. In this research, only the prime coating layer is studied due to the fact that the peel off defect normally occurs from this layer. A curing temperature immediately after coating is one of the root causes besides air pressure, an angle of the spray gun and fan pattern. Therefore, the experimental design technique is used to determine the relationship among these mentioned variables and identify the optimal condition. The 2k factorial is used in the experimental design and analysis of variance is used to analyze the result. It is found that the optimal condition of curing temperature at 95 degree Celsius, air pressure at 2.5 bars, a gun angle at 60 degrees, and the fan size at 5 Volt setting at the robot controller provides a better result. The peel off defect is reduced from 2.88 to 1.60 percent.

Info:

Periodical:

Edited by:

Sujan Debnath

Pages:

8-12

DOI:

10.4028/www.scientific.net/MSF.911.8

Citation:

T. Kasorn and S. Prombanpong, "A Reduction of Interior Peel off Defect in a Robot Spray Coating Process", Materials Science Forum, Vol. 911, pp. 8-12, 2018

Online since:

January 2018

Export:

Price:

$38.00

* - Corresponding Author

[1] Naval Ordnance Station: A Plasma Flame Spray Handbook, Kentucky, NOS (1977), pp.59-71.

[2] D. Matejka and B. Benko, Plasma Spraying of Metallic and Ceramic Materials, Czechoslovakia, John Wiley & Sons (1989), pp.91-93.

[3] R.B. Heimann, Fundamental and Applications of Thermal Plasma Technology, A lecture series at the School of Energy and Materials, King Mongkut's Institute of Technology Thonburi (1995), pp.26-27.

[4] D. Matejka and B. Benko, Plasma Spraying of Metallic and Ceramic Materials, Czechoslovakia, John Wiley and Sons (1989), pp.119-125.

[5] M. Winnicki, A. Malachowska and A. Ambroziak: Taguchi Optimization of the Thickness of a Coating Deposited by LPCS. Archives of Civil and Mechanical Engineering. Vol. 14 (2014), pp.561-568.

DOI: 10.1016/j.acme.2014.04.006

[6] T. Van Steenkiste and D.W. Gorkiewica, Analysis of Tantalum Coating Produced by the Kinetic Spray Process. Journal of Thermal Spray Technology. Vol. 13 (2) (2004), pp.265-273.

DOI: 10.1361/10599630419418

[7] K. Hajmrle and M. Dofman, Flame Sprayed Co(Ni)WC Coating, Modern Dev. In Powder Metallurgy, Vol. 15/17 (1985), pp.609-626.

[8] C. Pierlot, L. Pawlowski, M. Bigan and P. Chagnon, Design of Experiments in Thermal Spraying: A Review. Surface and Coatings Technology. 202 (2008) pp.4483-4490.

DOI: 10.1016/j.surfcoat.2008.04.031

[9] P.O. Buzby and J. Nikitich, HVOF Thermal Spraying of Nitride Parts, Advanced Materials & Processes, Vol. 140 (1991), No. 6, pp.53-57.

[10] S. Kato, A. Kanaki, K. Urayama and F. Ikasaki, Plasma Spraying of Ti-B Composite Powder, Proceedings of the Fourth National Thermal Spray Conference, Pittsburgh, Pennsylvania, pp.411-415.

[11] N.H.N. Yusoff, M.J. Ghazali, M.C. Isa, A.R. Daud, A. Muchtar and S.M. Forghani, Optimization of Plasma Spray Parameters on the Mechanical Properties. Materials and Design. 39 (2012) 504-508.

DOI: 10.1016/j.matdes.2012.03.019

[12] S.M. Forghani, M.J. Ghazali, A. Muchtar, A.R. Daud, N.H.N. Yusoff and C.H. Azhari, Effects of Plasma Spray Parameters on TiO2-Coated Mild Steel using Design of Experiment (DOE) Approach, Ceramics International. 39 (2013) pp.3121-3127.

DOI: 10.1016/j.ceramint.2012.09.092

[13] K. Murugan, A. Ragupathy, V. Balasubramanian and K. Sridhar, Optimizing HVOF Spray Process Parameter to Attain Minimum Porosity and Maximum Hardness in WC-10Co-4Cr Coating. Surface and Coating Technology. 247 (2014) pp.90-102.

DOI: 10.1016/j.surfcoat.2014.03.022

[14] S. Hong, Y. Wu, B. Wang, Y. Zheng, W. Gao and G. Li, High-Velocity Oxygen-Fuel Spray Parameter Optimization of Nanostructured WC-10Co-4Cr Coating and Sliding wear Behavior of the Optimized Coating. Matrials and Design. 55 (2014) pp.286-291.

DOI: 10.1016/j.matdes.2013.10.002

[15] S. Luangkularb and S. Prombanpong, Material Consumption and Dry Film Thickness in Spray Coating Process. Proceedings of the 47th CIRP Conference on Manufacturing Systems. Vol. 17 (2014), pp.789-794.

DOI: 10.1016/j.procir.2014.02.046

[16] O. Poonkwan, V. Tangwarodomnukun and S. Prombanpong, Optimization of Teflon Spraying Process for Non-Stick Coating Application. Industrial Engineering. (2015), pp.833-839.

DOI: 10.1007/978-3-662-47200-2_87

[17] Y. Wongyai and S. Prombanpong, Finding the Optimal Condition of Exterior Spray Coating for Cookware Products, MATEC Web of Conferences (2015).

DOI: 10.1051/matecconf/20152603012

[18] M. Choikhrue, S. Prombanpong and P. Sriyotha, An Effect of Coating Parameters to Dry Film Thickness in Spray Coating Process (2016).

DOI: 10.4028/www.scientific.net/kem.709.95

In order to see related information, you need to Login.