COATING FOR IMPROVED

INNER CLEANLINESS
Author: Christoph Genzler

The following article is the result of a long-lasting cooperation between two companies which have committed
during times when the internet, social media and smart phones were in their infancy, to commonly develop
future visions.

One company located in Skovde, Sweden has developed a new metal pouring process (FPC – Future Process for
Casting) and they run their new foundry based on this technology.

The subject presented in this article was commonly developed over the last 20 years. The coating technology
discussed delivers multiple improvements to inner cleanliness or in other words reduces the quantity of
remaining particles in inner critical channels. Obviously, this improves engine lifetime and additionally reduces
downtime due to, for example the exchange of oil or coolant liquids – a still hot current subject.

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Foundry Practice No. 269
Particle adherence using Very clean internal surfaces
conventional coating even in narrow channels

INTRODUCTION To be able to measure emissions in a The influence of a coating manufacturer

comparable way, they are measured in to the final engine life and performance
Nov. 16, 2017 (WASHINGTON) relation to the work performed by an by coating selection applied seems to
The following is a statement from Allen engine and the units used are grams be very limited in this context and even
Schaeffer, Executive Director of the per kilowatt-hour. For certification, a more if we think about an impact on
Diesel Technology Forum. [1] well defined fuel is used, very similar performance of the engine itself. In the
to standard fuel but with closer past all a coating could do was to ensure
“Diesel is the most energy efficient tolerances.”[2] (Table 1). a defect free component.
internal combustion engine. It has
achieved dominance as the technology Euro 7 Emission Norms – 2020 CO2 Today the influence of a coating applied
of choice in the trucking industry over Goals: at a thickness of about 3 human hairs
many decades and challenges from “Euro 7 emission norms are expected goes way beyond the actual cast
many other fuel types. Still, today, to be implemented in 2020, with a component. It can modify the metal
diesel offers a unique combination CO2 emission target of 95 grams per matrix and the performance of the final
of unmatched features: proven fuel kilometer. The Euro 6 CO2 target of 130 engine.
efficiency, economical operation, gm/km will then have to be reduced
power, reliability, durability, availability, by 27% with a slew of technology Let’s ask the question: What determines
easy access to fueling and service adoptions and enhancements.”[4] This a powerful and environmentally friendly
facilities, and now near-zero emissions applies for cars and vans, but has not engine?
performance.” been defined for trucks, yet.
“We all benefit from a more efficient
freight system. Fuel and powertrain
choices are one part of that. The
Legal requirements and limit values
greatest opportunity for efficiency Law NOx PM HC CO
gains, fuel savings, lower greenhouse from g/kWh g/kWh g/kWh g/kWh
gas emissions and cleaner air – now –
is to get more truckers into the newest
R49.00 1982 18 - 3.50 14
generation of more fuel efficient and Euro 0 1990 14.4 - 2.40 11.2
near-zero emissions clean diesel
Euro 1 1993 8.0 0.36 1.10 4.5
technology, as rapidly as possible.”
Euro 2 1996 7.0 0.15 1.10 4.0
Legal requirements
Euro 3 2001 5.0 0.10 0.66 2.1
“The legal requirements for diesel
engines have been tightened several Euro 4 2006 3.5 0.02 0.46 1.5
times. Diesel engines are used in various
Euro 5 2009 2.0 0.02 0.46 1.5
types of vehicles, for various types of
traffic, and with varying loads. Euro 6 2013 0.4 0.01 0.13 1.5
Table 1. EU emission standards for heavy-duty diesel engines: Steady-state testing [3]

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Coating for Improved Inner Cleanliness
  OATING FOR
C
IMPROVED INNER
CLEANLINESS
The frequency of modern engines
regarding service intervals is becoming
longer and longer. In effect the mileage
until an oil change is required has
increased by 3 times on average
Figure 1. Contaminated coolant Figure 2. Residues in oil
from 5,000km to now ca 15,000km
sometimes even 30,000km. In addition
the technical demands on the oil itself
have become more severe.

But what if this modern engine runs not

on ordinary streets, motorways and on
shore, but off shore on the sea where
the next fuel and service station might
be some considerable sea miles away.
In this case the engine needs to be the
most reliable part of the total machinery.
Volvo has a marine department called
Penta, which designs and manufactures
complete engines for not just high
performance power boats (http://www.
frauscherboats.com/), but also for sea
rescue boats, towboats and others. In
order to extend the competitiveness of
this department and to raise the engine
performance ahead of all competition
new ways had to be developed which
Figure 3. Euro 6 Diesel Engine
involve all different steps in cast
component manufacturing.
The investigation of this “inner But before we go further, let us consider
What was considered in the past to be
cleanliness” concept is not simple the coating in more detail:
engine oil performance has now grown
because a common industrial standard is
into a new dimension: Inner Cleanliness.
not yet defined. All engine manufacturers After casting, the very complex cylinder
use internal standards, hence there is a head part has to undergo a number
Coatings are usually applied on sand
wide spread of OEM demands. Also, a of treatments. This consists of sand
cores that build the inner geometries
method for testing did not exist, hence shake-out, heat treatment and final shot
and complexities of an engine. In
the Volvo/Foseco cooperation had to blasting. The resulting casting surface
particular, thin sections in the engine
establish a reproducible and repeatable for a conventional coating is shown in
block or cylinder head are prone to
way of evaluating remaining particles figures 4-6 at each of the process stages.
defects and also sand adherence due to
inside a casting.
shot blast kinetic energy loss.

If a coating could contribute to the inner
cleanliness of a cylinder-block or head all
the following manufacturing steps from
heat treatment up to final machining
would become easier and more efficient
and the economic value would increase.

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Foundry Practice No. 269
As coating is the first material the metal contacts when entering the mould cavity, the coating usually adheres to the cast surface in
the as-cast state.

Casting is defect free, but sand still

adheres to the inner surface: SEM of coating layer on casting surface: SEM of coating layer sand side:

Fully sintered surface Still loose coating particles

Figure 4. Immediately after shake-out

Coating layer adhering but starting

to flake off: SEM of coating layer on casting surface: SEM of coating layer sand side:

Fully fused surface Sintered particles

Figure 5. After heat treament

Coating still adhering in areas unreachable

by shot blasting: SEM of coating layer on casting surface: SEM of coating layer sand side:

Cracked but still adhering Sand and coating particles seem to create
a network

Figure 6. After shot blasting

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Coating for Improved Inner Cleanliness
 WHAT CAN BE
ALTERED IN A COATING
TO MAKE IT LESS
ADHERING TO THE
CASTING AFTER FINAL
SHOT BLASTING?
One aspect is the coating flake
formation. After pouring, the coating
layer forms a ceramic shell that breaks
down into flakes during shake out and
further cleaning steps. These flakes
could be used as a carrier for the debris
adhering to them. By engineering the
coating to form strong and well defined
flakes that readily detach from the
casting surface and do not themselves
contribute (e.g. by disintegration) to
further particle formation, it is possible
to improve the cleaning of the casting
even at inaccessible positions.

During trials the newly developed

coating demonstrates how the correct
ceramic shell formation helps to remove
almost all remaining particulates,
leaving a very clean casting surface
(Figure 7 and 8). The result is an engine
that performs better, longer and more
efficiently.

Figure 7. Casting section only after shake out

Figure 8. Cast Surface right after shot blasting

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Foundry Practice No. 269
 FURTHER COATING Scabbing Inner Cleanliness Coating at 1100 ° C
PROPERTIES Layer thickness 280 µm
0.2
Besides the coating flake effect, two 0.18
more characteristics are important to 0.16
produce a defect-free casting, which 0.14
0.12

Δp(P-P0)
are Gas Permeability and Anti-Veining
0.1
Properties.
0.08
0.06
Gas Permeability: 0.04
During the pouring process gas is 0.02
developed by the binder combustion in 0
a sand core. This means that the gas 0 5 10 15 20 25 30
A B
pressure behind a coating layer increases Normalised time (s)
rapidly during the pouring process. In
cases where the gas permeability is Figure 9. SEMCO* IC coating; showing extended resistance to scab formation
too low, coating can flake off and cause
scabbing defects in areas that cannot be
cleaned (in particular on cylinder head Scabbing Semco Sil std at 1100 ° C
castings) and hence will lead to scrap. Layer thickness 280 µm
Reading above about coating flake
0.3
formation could lead to the idea that
this new coating is very impermeable 0.25
or in other words has a very low gas
0.2
permeability. The opposite applies
Δp(P-P0)

(Figures 9 and 10) 0.15

0.1
Foseco has developed a special test
that enables the determination of a gas 0.05
permeability in ambient and elevated 0
temperatures. 0 5 10 15 20 25 30
Point A: Time at which the sample is put
Normalised time (s)
in the heated atmosphere A B
Point B: Time at which the sample scabs
Figure 10. Conventional coating; showing poor scabbing resistance
– immediate pressure drop

„
Distance A – B: Scabbing Resistance
 
In the above example, two values can be
observed:
1. The lower the value on p  the
lower the pressure resistance 
the higher the gas permeability in ALTHOUGH THE NEW INNER
ambient conditions CLEANLINESS COATING IS
2. The longer the curve expands the
greater the scabbing resistance 
STRONGER IN TERMS OF
the higher the gas permeability in CERAMIC FLAKE FORMATION,
elevated temperature conditions THE GAS PERMEABILITY
(here 1100°C) IS STILL BETTER THAN A
CONVENTIONAL COATING.

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Coating for Improved Inner Cleanliness
 Silica Sand Silica Sand Silica Sand Silica Sand Silica Sand Silica Sand
Core PU Cold Box Binder PU Cold Box Binder PU Cold Box Binder PU Cold Box Binder PU Cold Box Binder PU Cold Box Binder
Composition Zircon / Solvent Cold / Solvent Alu.silicate / Solvent Alu.silicate / Water Coke / Solvent Zircon / Solvent
Coating Coating Coating Coating Coating Coating

Result Crack Formation Veining Good Good Veining Crack Formation

Figure 11. Coating

Silica Sand Silica Sand Silica Sand Silica Sand Silica Sand Silica Sand
Core Sodiumsilicate Binder PU Cold Box Binder Furan (Phosphoric Acid) Furan (PTS Acid) Alkali Phenol Resin Bentonite
Composition Coke / solvent Cold / Solvent Coke / Solvent Coke / Solvent Coke / Solvent Coke / Solvent
Coating Coating Coating Coating Coating Coating

Good - some
Result Good Strong Veining
spots on surface
Some Veining Good Good

Figure 12. Binder

Special Sand Chromite Sand Zircon Sand Silica Sand Silica Sand
Silica Sand
Core PU Cold Box Binder PU Cold Box Binder PU Cold Box Binder PU Cold Box Binder PU Cold Box Binder
PU Cold Box Binder
Composition Zircon / Solvent Zircon / Solvent Zircon / Solvent Zircon / Solvent
Uncoated
Coke / Solvent
coating Coating Coating Coating Coating

Veining and Metal

Result Good Good Good Veining
Penetration
Veining

Figure 13. Sand

ANTI VEINING
Foundrymen consider the silica Comparing the conventional product (figure 14) with the new inner cleanliness coating
expansion at 573°C as the temperature (figure 15). It can be seen that the SEMCO* IC has higher resistance to vein formation.
at which the moulding material is most
prone to veining defects. The best test
to compare individual anti-veining
properties of coatings is to conduct a
veining block test. In this test, up to 6
different coatings can be compared side
by side, keeping sand, binder and other
parameters constant so that the pure
coating performance can be determined.
Figues 11-13 show an overview of
options of anti-veining performance [5].

Figure 14. Conventional Coating Figure 15. Inner Cleanliness Coating

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Foundry Practice No. 269
 SUMMARY REFERENCES
CONTACT
A specially developed coating that 1. https://www.dieselforum.org/ -
can improve inner cleanliness in very Press release, Nov. 16 2017 - Allen
complex engine components will help Schaeffer, executive director of the
the automotive industry to achieve even Diesel Technology Forum.
more stringent emission demands than 2. https://www.volvotrucks.com/
the current applied Euro 6 standard, but content/dam/volvo/volvo-trucks/
moreover also extend service intervals markets/global/pdf/our-trucks/
that will help to limit further resource Emis_eng_10110_14001.pdf -
depletion and improve our heritage for Lars Mårtensson, CHRISTOPH GENZLER
the next generations. 3. www.dieselnet.com EUROPEAN
4. https://ww2.frost.com/ - Frost
PRODUCT MANAGER
& Sullivan – European Emission
ACKNOWLEDGMENT Regulations – Will Stringent COATINGS
Emission Regulations Choke
I would like to specifically acknowledge
Automotive Industry Or Will OEMs [email protected]
the extraordinary cooperation with
Find Their Way Out? April 26, 2016
two outstanding foundry experts; Tore +31 7424 92 195
5. Foseco internal test – Veinblock
Nilsson and Sten Bergman, Volvo GT0.
test
Without their expertise and support this
project could not have been taken so far.

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Coating for Improved Inner Cleanliness