42nd Porcelain Enamel Institute Technical Forum

206 Pages·2008·23.743 MB·English

by  William Smothers

Proceedings of the
42nd Porcelain Enamel Institute
Technical Forum
George B. Hughes
Conference Director
A Collection of Papers Presented at the
42nd Porcelain Enamel Institute
Technical Forum
October 29, 30, and 31, 1980
University of Illinois
Urbana, Illinois
ISSN 0196-6219
Published by
The American Ceramic Society, Inc
65 Ceramic Drive
Columbus. Ohio 43214
@ The American Ceramic Society
and the Porcelain Enamel Institute, 1981
The page is intensily left blank
Proceedings of the
42nd Porcelain Enamel Institute
Technical Forum
George B. Hughes
Conference Director
A Collection of Papers Presented at the
42nd Porcelain Enamel Institute
Technical Forum
October 29, 30, and 31, 1980
University of Illinois
Urbana, Illinois
ISSN 0196-6219
Published by
The American Ceramic Society, Inc
65 Ceramic Drive
Columbus. Ohio 43214
@ The American Ceramic Society
and the Porcelain Enamel Institute, 1981
The page is intensily left blank
Executiue Dlrector & Publisher Associate Editor
Arthur Friedberg Susan Stock Means
1.
Director Pub/lcatlons Graphlc hoduction
of
Donald C. Snyder Carl M. Turner
Editor CfrculatfonM anager
William J. Smothers Gary W. Panek
I
Commlttee on Publlcatlons: J. Lambert Bates, Chairman; Robert J. Beak;
H. Kent Bowen; William C. Mohr; Richard M. Spriggs; Louis J. Trostel, Jr.,
ex ofpclo;W illiam J. Smothers, ex ofpcfo;A rthur L. Friedberg, ex oflclo.
EdftorfalAduisoryBoard: L. J. Trostel, Jr., Chairman; R. Berger; W. G.
1.
Coulter; R. T. Dirstine; R. A. Eppler; E. J. Friebele; F. A. Hummel; W. J.
Lackey; T. D. McGee; G. W. Phelps; D. W. Readey; and W. R. Wale.
Edltorlal and Subscrfptlon Ofpces: 65 Ceramic Drive, Columbus, Ohio
Subscription $60 a year; single copies (postage outside U.S.
43214. $12 $2
additional). Published bimonthly. Printed in the United States of America.
Allow six weeks for address changes. Missing copies will be replaced only if
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Replacements will not be allowed if the subscriber fails to notify the Society of a
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of
CESPDK VOI. pp.
2, NO.3 -4, 143-336,1981
Foreword
A Message from the Technical Forum Chairman
It has been a real pleasure to serve as chairman of the 1980 PEI Forum Com-
mittee. The many individuals who contributed so much to make the meeting
another highly successful one have made my task especially easy and plea-
sant.
While it is impossible to acknowledge everyone, I do want to express my
appreciation and that of the officers and staff of the Porcelain Enamel In-
stitute to everyone connected with the University of Illinois for being such
fine hosts. Again this year, as they have been doing in alternate years since
the first PEI Forum in 1937, they amply provided for our every need. Coor-
dinator of the university arrangements was Dr. Clifton Bergeron, the new
head of the Ceramic Engineering Department at Illinois. We all owe him a
special thanks for his efforts.
This year’s Technical Forum program proved to be another successful
one in our long series of outstanding technical meetings. With a banner atten-
dance, we were pleased to have James D. Sullivan open the Forum with his
excellent A. I. Andrews Memorial Lecture. Directing his lecture to the sub-
ject of “Glass-Metal Reactions and Physical Properties of Enamels,” he
presented a substantive paper in which he discussed some fundamental
metallurgical and chemical factors involved in glass-metal reactions. Follow-
ing his lecture, the Forum audience heard two informative papers on the role
of porcelain enamel in microcircuitry applications. Next was a report on
research in specialized ceramic coatings and a summary of several industry
programs involved with government research efforts. The first afternoon ses-
sion concluded with an informal panel presentation on the status of govern-
ment environmental actions that threaten the porcelain enamel industry.
Thursday’s session led off with five papers touching on various aspects
of base metals and metal preparation techniques. The rest of the morning ses-
sion was devoted to a series of papers and panels on the subject of furnace
improvements and modifications. Thursday afternoon saw a variety of topics
receiving attention-several papers on the latest processing advances, others
on the subject of no-nickeVno-pickle systems, and a final group dealing with
low-cobaltho-cobalt ground coats. On Friday the session began with a series
of papers related to energy conservation. These were followed by individual
papers and two separate panels devoted to material utilization and waste
disposal.
As I conclude my remarks, I want to thank each of our speakers and the
individual session chairmen. Of course, I don’t want to forget the work of
the Technical Forum Committee that planned the program and contributed
in so many other ways. Looking ahead, we hope to see you at the 1981 PEI
Technical Forum at The Ohio State University in Columbus. The dates are
October 6 and 7, and we urge you to begin now to make plans to attend.
George B. Hughes, Chairman
Technical Forum Committee
...
111
Table of Contents
A. I. ANDREWS MEMORIAL LECTURE
.......
Glass-Metal Reactions and Physical Properties of Enamels 143
James D. Sullivan
PORCELAIN ENAMEL IN MICROCIRCUITRY
Industry Experience with Porcelain-Enameled Steel Substrates
................................
for Electronic Applications 160
Robert B. Schabacker
Developments with Porcelain Enamel Steel Substrates
................................
for Electronic Applications 166
Lubomyr Onyshkevych
GOVERNMENT INVESTIGATIONS AND PROGRAMS
Some Thermal Stress Problems in Porcelain
....................................
Enamel-Coated Rods 178
Glenn McDonald and Robert C. Hendricks
Some Current Government Activities Relating to the Porcelain
........................................
Enamel Industry 188
Howard F. Smalley and Richard I. Moss
Current Environmental Programs Impacting the Porcelain
.............................
Enamel and Related Industries 192
(A Panel Presentation)
BASE METAL AND METAL PREPARATION
Properties and Enameling Characteristics of Sheet Steels for
Porcelain Enameling ..................................... 193
Donald A. Toland
....................................
Identifying Steel Soils 199
Patrick J. Crilley
Practices in Porcelain Enamel Plants That Cause Production
..........................
Difficulties and Enameling Defects 205
Fred Allenbaugh
..................
Low-Temperature Cleaning- A Case History 210
Alfred H. Pope
Mechanism of Nickel-Flash Coating in Porcelain
.................................
Enamel-to-Steel Bonding 214
Yong-Wu Kim
FURNACE INNOVATIONS
Energy-Efficient Furnace Systems .......................... 228
Louis C. Kolar
.......
Energy Savings in Furnaces Using Ceramic Fiber Modules 232
Ronald L. Allen and Lester N. Smith
V
Plant Experiences with Ceramic Fiber Modules as a
.................................
Veneer Lining in Furnaces 238
Thomas E. Penisten
Industry Experiences with Furnace Modifications:
......................................
APanel Discussion 244
Oscar A. Jeude, James Marcotte, Edward L. Macoicz, and
W. Charles Bennight
ADVANCES IN ENAMEL APPLICATION
...........................
Two-Coat/One-Fire Alternatives 249
Werner Joseph
......
Analysis of Two-Coat/One-Fire Powder System Adherence 256
William D. Faust, Holger F. Evele, and James W. Smith
Study of Bond Development and Cobalt Replacement in Frit
........................................
Powder Systems 270
Gary F. Howorth and R. Stephen Barr
......................
The P/E Plant of 1990-A Look Ahead 281
Jeffrey F. Wright
.........
A Decision to Move to P/E Powder-A Progress Report 290
Donald R. Sauder
........
Experiences with Porcelain Enamel Powder in Production 295
Hans W. Hoffman and Jorn Drake
Quick Color Change Capabilities with Porcelain
.........................................
Enamelpowder 301
Gunter J. Lissy
NO-NICKEL/ NO-PICKLE SYSTEMS
.....
Production Experience with a Pickle-Free Enameling System 304
Alfred G. Carter and M. George Sinkovec
LOW-COBALT/NO-COBALT GROUND COATS
Observations on Industry Experiences with Low-Cobalt/
......................................
No-Cobalt Systems 310
Archie E. Farr
Industry Experiences with No-CobaltlLow-Cobalt Systems:
.....................................
A Panel Presentation 313
Daniel R. Yearick, Lester N. Smith, and Narayan M. Sedalia
ENERGY CONSERVATION
Industry Looks at Energy Conservation: A Panel Presentation ..... 316
Bobbie G. Stewart, G. Thomas Cavanaugh, and Gordon Shippy
MATERIALS UTILIZATION AND WASTE DISPOSAL
.............
Responding to the Hazardous Waste Requirements 321
James J. Carleton
.............
Role of Eight Selected Metals in Porcelain Enamel 322
Thomas L. Stalter
vi
Concepts and Experiences in Using Reclaimed Enamels:
.....................................
A Panel Presentation 325
Frank Vondracek. Thomas L . Stalter. and Bernard Borowski
Plant Programs for Materials Reclamation:
.....................................
A Panel Presentation 329
Daniel R . Yearick. Rush S . Dale. and W . Roland Verchota
......................................
A'lTENDANCE 333
LIST
vii
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