Canadian Finishing & Coatings Manufacturing Magazine Jan/Feb 2023 - 32

INDUSTRIAL FINISHING: ESD COATING AUTOMATION
punches, " says Scotchmer. " Some machines are used to repair
aerospace and military components. Some coatings and repairs
are for bearings, seals, and wear components. We are the largest
ESD coater in the world, with some 20 full-time coaters, so we
have some experience. "
ESD, with its low heat input, negligible HAZ, and fast
quenching, not only reduces the use of some traditional welding
processes but specifically permits and facilitates repair of
expensive components that would otherwise be discarded when
worn. In addition, the company says, the superior metallurgical
bond of welds with ESD compared to the joints of typical cold
spray applications means that coatings with ESD are generally
superior to those of cold spray applications for wear and corrosion
resistance.
Automating Consistency
When Huys needed to automate its manual ESD coating process,
a micro-arc welding process that fuses material to a substrate,
it turned to Pierce Design & Tool based in Dover, Del. due to the
complexity of the project. Founded by owner Frank Rementer,
this company uses its 35 years of manufacturing engineering
experience and technical knowledge to design and build
machinery for clients requiring custom solutions.
" ESD is a very low-heat-input process, " explains Scotchmer.
" With manual applications, repeatability and consistency are
always a concern. ESD operates slower than other welding
processes, and as a relatively new process, some of the parameters
are not well understood. It requires exceptionally light force,
for example, and temperature and voltage are lower than other
welding processes. Consequently, automating the ESD coating
process was fraught with difficulties and challenges. "
What had previously been accomplished manually would now
need a low-profile and sturdy gantry system to automatically
move the coating heads into position, providing a level of
consistency, repeatability, and overall control of the parameters
that is difficult to achieve in a manual process. Additional
parameters for the new machine included specific load, speed,
and space constraints, as well as consistent application of the
surface material. With those goals established, Pierce Design
reached out to PBC Linear for the linear motion components.
" Due to the cantilevered loading of the ESD applicator heads,
it was very important for the gantry system to be low profile
and sturdy, " explains Rementer. " PBC Linear designed a linear
motion solution that not only eliminated the time-consuming
alignment of separate parallel round rails during assembly but
also increased throughput and overall consistency of machine
operation. "
The Integral-V Technology (IVT) product line would provide
the best option for the project. Specifically, the AAQ linear
guide offers a low-profile, wide-based rail option for the gantry,
giving ample support to the cross-axis that holds the ESD heads.
The combination of precision-machined aluminum rails and
hardened stainless-steel races delivers a reliable carriage and rail
system to any application requiring lightweight components that
do not sacrifice strength.
This high precision is achieved through PBC Linear's patented
Simultaneous Integral Milling Operation (SIMO), which uses
synchronized cutters to ensure dimensional and rail form
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accuracy. With standard rail lengths greater than three and a half
meters and tight tolerances at .002 inches (.05 mm), the microarc
welder design assures consistent and reliable positioning.
Additional products include round rail and ball bearing pillow
blocks, which serve as the linear motion on the cross-axis design.
Here is where PBC Linear provided not only its products but
also its engineering expertise to help customers successfully
complete their goals.
" In this case, our client needed oscillating motion to propel the
ESD system back and forth along the cross-axis, " says Rementer.
" PBC Linear's application engineers were able to advise them by
suggesting an old-school reciprocating linkage. "
The IVTAAQ low-profile rail and carriage system met all the
requirements for load and speed while providing a space-saving
option. The two-piece assembly eliminated the time-consuming
and arduous task of having to align separate parallel round rails.
In addition, IVTAAQ led to an increase in throughput and overall
consistency of operation. The combination of high-quality
products and engineering expertise has provided Pierce Design &
Tool with a high-value partner in linear motion solutions.
" I rely on PBC Linear because of its excellent quality products
and sales support, " concludes Rementer. " Plus, PBC Linear's
engineering support is unmatched. I suggest leveraging the
expertise of PBC Linear to not only select the right PBC products
but also to offer input into the machine design as a whole. "
Last October, Scotchmer, received the 2022 Innovaion and
Synergy Award from the Natural Sciences and Engineering
Research Council of Canada for its ESD innovations and patents
related to the process. Huys partnership with Dr. Norman Zhou at
the University of Waterloo also included ArcelorMittal Dofasco
and the International Zinc Association. This partnership has
resulted in the Centre for Advanced Materials Joining (CAMJ),
an innovation hub for Canadian research and development, which
has grown into one of the largest research groups in materials
joining in North America.
Tim LeCrone is the director of manufacturing engineering at
PBC Linear.
PBC Linear round rail and ball bearing pillow blocks support the
oscillating linear motion required on the cross-axis, which propels
the ESD heads back and forth. PBC Linear application engineers
suggested the simple yet effective linkage solution.
http://www.cfcm.ca
Canadian Finishing & Coatings Manufacturing Magazine Jan/Feb 2023

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