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LEAD INDUSTRIES ASSOCIATION *3 MADISON AV KNU8 NSW YORK 7. N. Y. March 7* 1961 SUBJECT: 8UPPIZMEHT TO "LEAP Dt THE CERAMIC DCXISTRIES" To Members of the Lead Industries Association: The attached supplement to our technical data hook, "Lead In the Ceramic Industries,'' has Just been published by the Lead Industries AsbC-'aticn. It Is being nailed to all persons vho now hare this looselcaJ data book, end press releases de 4 scribing it are going to appropriate trade papers. It deals with low-firing porcelain enamels for steel, a new narket which ve believe offers great growth potential for lead. It was prepared by Mr. 8. V. Turner of the Association staff with the assistance of the Ceramics Technical Committee. Very truly yours. RIXtJRH Alt. Secretary JJMHU LIA24A58 te^dlii -wn 3 v'ilAli1iL ftt-v- IHI 1700 f <**4 * '.** pc'ffv-* ~W*'*`* 9*9* j;' o* (>* i !*, "***# f < C * '*4 i* H)4 *3 ( *' ao^t' 41m 09 l'* 2* ***** rC t g> cJ k w *o4 *y y dr**' c* o* cr* Ko f* t4* 94i*'**4 LOW FIRING PORCELAIN ENAMELS FOR STEEL I*"* p*ud-im injniJ o'Ur t*tn pi^nm-os ! tN.- poivsljm cnjnvliip in!.r*;iv ^u-it.i profit m.iffciM ,o h J .'i vAp.iiuk'J pcojisl !m< 1 o*.l pudik- ,*n ^o*u *iih !o* Kni(MV.l u ' fnt* t*il! \*o'J higher profit macin' U* the porcd-n'* vr.invller. F it*c .Uilv :mp**iijni Nih IiIh from imii-; :hoe tuts urc lower !i,m. n1, Iik I. p...mK i)ji\c .on) l.vhos ct**!* L J \n expanded pfoJi^i line * >il N: the io*ull v*f jn ui\jM.-n itux U tffp\-rjirc Inis o| tcftrtoi\ f.-rmjlv .SwlipKsJ c Vw Uims i's H\ orpjnic tinihc* prsJiK.1s wjii row 'x: k '.iu J with tv.miilul. vfurjkk-. \w (cmpcr<<tuiv p*f*LUm \njmcl pfdiM% th.il w*.r< formerls fKt suit. Me Kv j u h 1 eomcn- fni* don't eover eortki* -.nj %hjrp joules jnJ S\j u < ol Ihe incwt.iMv Jisi4*rt*o ol the high tem- pvf.Ture prt\e\v Ih-toMn^t ptt^knis j C pf.k'tk-dt\ n*nc\i'lcnt `Atih live low !.mp\f-.njic IM* jnJ vomers *nd shj<p .ingles get iourjge a\ well. if': 1 ;l : I !; i I1 !l ! f: .i r \ ; i< ij J 4 1000 to 1100 r. PORCELAIN ENAMELS I ow liflifH'tiluiv pt'Kiljm cti^flKiv * n j c^Uh .ill phfjM.* It nejns ^"Mhing that fires lower fhm the ^*n\tniiHtu1 porect.iMi vnjmeU \etu.*IU, there -lie two nu|tf of l** umpsijluic irtt fr sitvl tn use U*U\ thw< mulunng 12*0' !> H*o I. md th.w< tfuf hie j * !<** to I lM I. Ihcn: l.iitvf tui\ jic ejtUJ the v\ti^ to* temper-tun, ctumiK -nd jte tbs' Mthtevl lvt this supplement. Some repress M-tise fot mtiLlhvis *l these portiLin ciumcH tie ^iwn j K*s c Ihctnul v\xitkKnls *4 c\pun%H>n !h itv>e erums-K ^rv Hhm f t 1*1 * ol sled. I 3 *3 U Ml N 1707.01 w L IA24459 r * N p*<il 4t<gA Im*v <ii #rf fe# *< vi'f ifc* 1000 firft fooi>#ft <Kf. p<dk(ti f<xm*r!f w|if &>gon< l>Nibt (** *o* fe* ro*'*d >lA b#v*'ivt. toi& oil p0'C*l0'" AA.t HOW 1000 FRITS CUT PRODUCTION COSTS I ovs cost luriuvc v *mMiu c Ik u and maintenance v*ill undouhtcdlx xield the gic.ifc*sl '.iMnp from the im: <*f these extra low ivmpctjlure frits. K ow tent* pcrjture tiring require forctJ conxeclion healing lor highest pri*duclion rates. Mthongh more complicated than cs*mentH*n.d luinaces. the enormous ddlerencc in firing temperatures 4tm to 500 K. so reduce the design entena that the initial cost ot a turn.ice can he M.*\er.il times lower than a eon\ention.d fur nace. f urnace wear at loot* to t |im |. will also obvHuisk he nucli U*wer. so maintenance e's*sls are reduced. At |i**> to Moo f\ lower <*! furnace hardware can he u%ed - jid it wdt st.md up longer Usv Of ctHirse. fuel cods at the lower temperatures will he lower It is p*>'iblo in vnK' eases to saxe bx using lighter gauge steel, where high strength s*r neuiilv is not essential, became the c \Uj low tem perature tuts can be hied on extiom.-ls thm vis.k withsHil danger ot warpmc In fast, sheets whuh aie HOW 1000 FRITS EXPAND PRODUCT UNES !** thm to be vitista%ton!\ coated with *.on\eniional Appliance cabinets < slo's*s. washing machines, etc * .* enamels can be pouvlam cn.imelsd with the low icm- and the burgoonme new use ot metal curtain wall m peraturc lots architecture aie udax's big markets tor porcelain these extra low icn|Viattuc tuts hast no pteter- ^n..inet lint i bust ,1 i*tber finishing apj'livaton applications lormerlx m the* realm ot organic and cm.e l*f enameling crash* xieeN < old tolleJ steel wj!l do just as weli So a sasmgs is obtjmeJ here as well \n adsJltH'nd advantage is that it other kinds of fin ishing are King carried i m the same plan*. *nlv one kind . j need be puuhased. suiting Jowr. plating finishes soe.M well use the beautitul. durabte finishes js*ssibh- <ulx with porcelain enamel I hose if.- pnvlwvt' wh-^h. bee.h im.* ot .omplieated design. or l-cht eniee met d. would h*pc!cs%!\ distort at the hich tsmiviatuies icquired tor the eon\enth*naJ pfivs>s. mxentorx pr.Wcme Hut with the low temperature ptivcss. this is no U*njjer true. n C*T*O.J b'<**90'4i . 1900 f p&ci'o s i *4 *#! * *'; '* n*cy, \S ith the new Uw temperature Ints a!rrk*st ru* bnnlatKHis exist on ths* shjps*s. tsums and *.'aufs> that can be pfselain enameled llK*re are three* rca>*ns toi this: I inng temperatures are well tvlo* the trans formation temperature ol steel the point at which the steel lranslums lumi ferrite ! atisU*r/le acc*mp.inH*J b a la/^e JirTK*nsmmi chanpe. At H*t to 11< i F. steel has a nnwh hi^hs*T tsusile strength than at the higher cmps*ratures requited for esHisentwmal fcMcvlain enanu'linf I his means that there ts vit little tendency for the to sag during hung. thinner coats of the to* temperature frits are piwsible 2 ts 5 mils compared ti ? to 12 mils. Ihinncr coats result in Uwer stresses during tiring I hesc thice tastors combine to rcdiKC dislortwMi so that mils one side* sf a punJikt ru*ed be exiled. Manx article's which Can he cxuleJ onlx k i one vtde. such Wf W|l|l W!5f ' fmv*- vpir^<|P LIA2AA60 1 EXTRA LOW TEMPERATURE PORCELAIN ENAMELS firing temperature 10005 to MOO* f. ,u* rearpage olmott no Hmitotioot on cemplkottd *hop* thot con be coated coverage excellent coverage on thorp edges ond radii adherence surface finish because of thin coatings and High adhe.enc*, enameled sheet* may be bent without chipping similar to orgonk finishes gtose better control of gloss fhon with conventional porceioln enamels rcflct'tunce 76% In white acid resistance A 1o AA rating -- P.E.I. citric odd test abrasion resistance harder than aluminum porceioln enamels, not so hard os conventional porcelain enamels j \ i i ) as hollow itcftjv like vjsh ana ' frames, can now hate the benefits id porcelain cnamci. -JJ. lion. these liNto | . tritv unlike ciHiventional fritv give excellent coverage im sharp corners and r.Jn. In short, no special enameling design feature need he considered in the design of the produel. WHAT ARE 1000: FINISHES UKE? Ixtra low temperature finishes arc porcelain enamel anJ shate the well-known propound of this tvpe finish with the convcntumal fritv i.e., high cht-mical resis tance. h-rdncNs. ahrasiin and scratch resistance and the l:ke. Vet. there are dillerenccs in Jegree. Because the low temperature enamels Jj not "lav down" os well as the ciwvcntional enamels the soif.ice texture w ill m>t he av snukdh lothecvc. in lad. the low tern* pcralure finishes look a lot like organic finishes. A lull *ange of gloss values, friun matte to high gUss are obtainable by changes in the milling formulaOp-*s*t\ is obtained prunaril) from mill addiUw*. While a givd white with aKmt 7<>' reflectance can he achieved. the high i*pjetv levels of the cietvcn* tkHial ptfidam enamels cannot he matched at pres ent. Future research, it is hoped, will change *htv Chemical Resistance C hcmieal resistance id the extra km temperature coalings is excellent. Surpciv mgh. these Hum finishes rale much higher on the average than the I km I , enamels. A I* F I. (Pifoclam I nantel Institute) citric acid spot test rating *d "A** to "AAM is obtained in white and most colorv Certain sinnvg colors particularly h r - v-J."i**m->elemum reds and oranges, will h.xvc km or resistance fai u.gv u< -c'ei. Weather resistance can he expected to he satisfactory because of the high :teid resistance. Data rs limited because of the newness id the fnts hut. in instJLtk'ns *. |jr. no detertoution has hern observed after socral xears expiKure to the weather. toift end window fromet v>*f m. mi w*4mm t'OMi li <omu4 mm mmtf m*m u4* tOOO t pm+tml+m tA>i mf 4m f4 l**t f>r* tm* mrmfm mm tm4**, M *4 HWUP4UBII tux i iif ii y LI &2AA61 1 HOW ARE 1000- PORCELAIN ENAMELS PROCESSED? t vtra U temperature enamels arc processed just like conventional enamels except that greater cart mu'i he taken in Ihc cleanliness of the steel and more careful control of firing .'cmperaturcs must he mjin* tjined. Shortcuts. particularly in the cleaning opera* tionv arc to he avoided. Even greater care mm! he applied when rum-premium steels are used. The recommended metal preparation is: 1. C leaner hath - Soiling for 20 minutes in pro prietary hath (Oakitc or Wyandotte or equivalent I 2. Water rinse - room temperature .V Acid hath 6-8'. sulfuric acid 15(1 1(1 minutes 4. Nickel dip - 0.0f* to 0.08 gm. sq. ft. 5. Water rnv< - room temperature 6. Neutralize - *: to 'a normal strength is recommended (dilute neutralizer should he used to minimize Misters and similar defects caused hv rosiJu.il salt m the steel surface. I 7. Dry Application Spraying is tf*e recommended method of application. !>ue to the extremely km firing tem peratures of these IriK the use of clay and eleclrsdyic formufatkms in the slip are detrimental. The result is that the hase-coat and finish-coat slips have good suspcnsKHi. hut poor scl. They work well for spray gun applications. hut only to a limited extent for dip applieafkms. Because the low temperature finishes do ru*t \mu>th out v-z "lay down" well during firing, the desired surface texture must he obtained by prsvper spravmg if a slip of the proper consistency. Firing I iring of the l*8l F. porcelain cnamek must he conducted in furnaces with a uniform heal ifistrihutkHt and accurate temperature control. A somewhat shorter firing range of the km temperature porcelain enamels is the reason. Conventional fur* nacev designed to operate at 1400 - 1500* F. fely on radiation for their major heating power. Radiation heating at loot* - 1100 F. is veryinefficient so firing time in a conventional furnace is unnecessarily long. Furthermore, temperature control is very difficult for conventional furnaces at km temperature* although, with care, successful firing can he accsMnplished. Properly, however, a furnace designed (svr Uk mi 1100' use - a forced convection furnace - should he used with these frits. With a forced convection furnace, heat transfer is efficient and high production rates can he maintained. Shell Life these frits must he ground very fine to mature evenly at the low firing temperature*. Hm iv no doubt, the reason for the comparatively short shelf life of these frits. The base coats work well after as much as three weeks id aging at uvm temperature, hut costr coats should he used within one week. Over-grinding must he avoided a* the shelf life can he considerably shortened, Trouble* from aging are fearing, crawling, and rough, gassy texture. I. f S. Talent ;.M',4U tu feme) and Mtmund, IV'* I. litlf V 'V<me ChitalftMKS iZ la*w Tcmreraiwie TtXvrlain fiune'v." i/ fh* Tiatrtdt* tn,t,n,'r \ id. IK. IVA * VI f OIK ON A\ff I Vf>eviik jia<n Sheet. O. Ilommef (Vi. TiMsKiifh. T*. (o'advl Jrrfchen tobinth * #Jm >' ! UMfUt?*** p*ff1MI #**< 0*9 #! #( <(