Development and characterization of foundry refractory coating and validation through factorial design of experiment

Foundry Refractory Coatings are used to improve surface finish of grey iron castings and reduces the re-work cost that covers the surface defects. Present research was concentrated on qualitative and quantitative analysis of commercial coatings through X-ray Diffraction and Energy Dispersive Spectroscopy respectively. A number of coating compositions were prepared by means of refractory fillers, binders and particle size as most concern parameter and validated through Design of Experiment. Ultimately, three types of coating formulation were developed by coating constituents and characterized using X-ray Diffraction. Fe2O3 and SiO2 were determined as major phases in all coating samples. Particle size of 75 microns was used for smooth surface finish. Gray iron casting had been produced without disturbing the mechanical properties and graphite distribution. Surface defects were covered by one of the best refractory coating recipe.