Métallisation Nord Industrie – rue d’Arcole 51 bis – Lille – Tel: – Fax: – website: KERASIL Dry film lubricant used in the glass manufacture Eliminates the lubrication of molds and metallic parts in contact with hot glass during forming The Kerasil solution Application method Results GLASS INDUSTRY The Kerasil application consists of two primary stages: spraying and curing. The technique for applying the coating is similar to spray paintings for water-based coatings and features a base coat and a top coat. Surface preparation includes sandblasting with glass bead or preferably aluminium oxide grit. This is to ensure the removal of any oils or other hydrocarbons from the surface of the substrate to be coated. Application is effected using a detail-type spray gun (similar to the type used for automotive Touch-up). The spray gun should be held from 6-8” from the surface and the coating applied using parallel motions. This eliminates the likelihood of runs, sags, or uneven coating thickness. Kerasil coating can be cured in a standard type oven, and is effected with a ramp method of 100° C held for 15 minutes, then ramped up to 450°C for one hour. As for coating removal, this is best done by either immersion, or enclosed spray method of a warm alkali solution. Kerasil coating system aims to encourage a radical re-think of common lubrication methods, with an answer that takes the form of a water-based inorganic material with low viscosity. The coating system is a formulation of hard ceramic particles interspersed with organic and inorganic soft elements including, among others, the following elements: graphite, molybdenum, tungsten disulphide and boron nitride. The Kerasil coating brings a four-pronged solution to problems caused by traditional swabbing methods: firstly, the system pays dividends in terms of reduced mould wear; secondly it ensures less lost ware for producers; thirdly makes it easier for operatives to monitor quality and to identify other sources of imperfection in the product and last but not least offers a more ecological approach. A more ecological approach Glass manufacturers have been feeling the heat of environmental regulators in order to reduce the amount of hydrocarbons and other pollutants that are produced in the manufacture of glass, e.g. the pollution produced when blanks and other forming equipment are lubricated. The lubrication, has to date, been done by manually swabbing a doping compound on the blanks as the forming process goes along. This compound usually consists of a mixture that includes graphite and oil. When it comes into contact with the hot molding equipment, hydrocarbons are freely released into the air. These pollutants rise into operator’s face and also settle on the equipment, walls and ceilings of the plant, posing a potential fire hazard.

Métallisation Nord Industrie – rue d’Arcole 51 bis – Lille – Tel: – Fax: – website: KERASIL Caracteristics (Physical properties)) Material: Graphite, molybdenum, tungsten disulphide, bore nitride, … Chemical resistance: Mild acids, mild bases and all solvents Mechanical Bond Strength: psi Operating T° (continous):650° Operating T° (intermittent):815° Coefficient of thermal expansion: ppm/°C Thermal conductivity:12-26 W/km Friction coefficient:0.48 Salt spray test (ASTM B117):1000 hours Abrasion resistance:> 150 liters of sand per mil (.001’) of coating thickness Taber abraser test ASTM 4060:10 mg/1000 cycles Oxidation resistance:No coating defects, slight discoloration after 500 hours at 537° Thermal shock resistance:Cured at 537° and then plunged into ambient water with no effect on coating PERFORMANCES The coated blanks do not need any lubrication and can stay on the machine during 72 to 96 hours. Performance factors contributing to a longer coating life of blank moulds ParametersLengthening factors Rating Glass colorGreen1 Amber1.5 Flint0.8 ProcessBB/SS1 PB/PS0.8 NNPB/NNPS1.5 Blank designShort neck1.25 Normal1 Long neck0.75 IS machine loadingGood1.5 Average1 Bad0.5 IS machine coolingBlankside vertiflow 1.5 Wind cooling adjustable 1 Wind cooling non adjustable 0.75 Dry film lubricant used in the glass manufacture