Optimization of Lost Foam Coating Performance: Effects of Blade Shape, Stirring Speed, and Drying Temperature on Viscosity, Coating Weight, and Surface Morphology

Abstract

The current investigation focuses on the viscosity, coating weight, and surface characteristics of lost foam casting coatings, examining the effects of blade shape, stirring speed, and stirring time. A systematic analysis was conducted to determine how different stirring speeds and durations influenced coating weight and viscosity. The results indicate that the blade shape has a considerable impact on the uniformity and efficacy of the coating, with some designs being far more effective in reaching the optimal viscosity and coating weight through uniformly distributed mixing. Results were consistently obtained when stirring at 800–1200 rpm. It was demonstrated that while stirring speed significantly impacts coating deposition, it has small effect on viscosity. A stirring time of 30 min was found optimal for stabilizing coating weight and viscosity without significant variations. Drying at room temperature produced smoother surfaces with fewer cracks, whereas higher drying temperatures (50 °C) were associated with increased surface roughness and cracking. Crack analysis after drying revealed that coatings mixed with the tri-blade had the lowest tendency to crack, demonstrating its superior capability for even and thorough mixing.