69th Porcelain Enamel Institute Technical Forum 69th Porcelain Enamel Institute Technical Forum A Collection of Papers Presented at the 69th Porcelain Enamel Institute Technical Forum September 17-20, 2007 Indianapolis, Indiana Conference Director Holger Evele Assistant Conference Director Peter Vodak Editor William D. Faust WILEY- INTERSCIENCE A John Wiley & Sons, Inc., Publication Copyright © 2008 by The American Ceramic Society. All rights reserved. Published by John Wiley & Sons, Inc., Hoboken, New Jersey. Published simultaneously in Canada. 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ISBN 978-0-470-19641-0 Printed in the United States of America. 10 9 8 7 6 5 4 3 21 Contents Preface vii 2007 PEI Officers ix 2007 Technical Forum Committee xi Past Chairs of PEI Technical Forums xiii Surface Tension and Fusion Properties of Porcelain Enamels 1 Charles Baldwin and Sid Feldman Status of Porcelain Enameling Steel Market 11 Kim Frey Gage Reduction and the Impact on Porcelain Enamel Parts 13 Larry Steele Cast Iron Process Control in a Developing Market 19 Liam O'Byrne Recycle-Friendly Aqueous Cleaners 23 Elizabeth J. Siebert, William G. Kozak, and William E. Fristad Cost Driven Development of New Cleaners 33 Kenneth R. Kaluzny 2C/1F Enamelling Process—A Growing Demand 35 Hans-Juergen Thiele Powder Coating Colors: Porcelain Enamel Versus Paint 43 Holger F. Evele Powder Enameling Control Systems 49 Phil Flasher Advanced Porcelain Enamel Coatings with Novel Properties 53 Charles Baldwin and Jim Gavlenski Absorption and Emissivity of Radiant Energy by Porcelain Enamels 59 William D. Faust New Product Design, Development, Validation, and Launch: Getting 65 it Right the First Time! Kara Joyce Kopplin Update on Current EPA and OSHA Issues that Will Impact 69 Your Industry Jack Waggener Case Study: Benefits of a New High Efficiency Furnace 75 Jason Butz Chemical Bonding of Concrete and Steel Reinforcement Using a 81 Vitreous Enamel Coupling Layer Larry Lynch, Charles Weiss, Jr., Donna Day, Joe Tom, Philip Malone, and Cullen Hackler Importance of Rheology in Enamel Application 95 Michael Sierocki Author Index 103 vi · 69th Porcelain Enamel Institute Technical Forum Preface The Porcelain Enamel Institute Technical Forum Committee is pleased to present the proceedings of the 69th Annual PEI Technical Forum. This volume culminates a year's worth of work by the committee and our presenters. The three day's of meetings, seminars and presentations was held in the Indianapolis Convention Cen- ter September 17-20, 2007 in conjunction with the FIN-X'07 International Expo and Conference for Industrial Finishers. Work has already started on the 70th Tech- nical forum to be held in Nashville, TN June 9-12, 2008 at the downtown Double- tree Hotel. I would like to thank the entire committee, especially my vice-chairman and in- coming chairman Peter Vodak (Engineered Storage Products) for their time, efforts and support in making this forum as successful as the previous 68. Without the par- ticipation of everyone the forum could not be the success it was. Each year we strive to bring to the industry reports of new technology available and other techni- cal presentations to support our industry, mission accomplished. As the Technical Forum brings new timely information to the industry our Back to Basics seminar provides a training opportunity for both industry newcomers and individuals seeking refresher training the chance to learn from industry experts. This year was again well attended and well received. Thanks to all the faculty for their efforts in preparing and presenting fundamental information to wide range of eager students. I and the committee would like to thank the authors and presenters of the may topics covered during the technical forum. We and the industry are thankful for the time and effort in researching, preparing and presenting their informative papers. We also want to thank those who took time off their busy schedules to attend the Technical Forum. Their attention and discussion increased the value for everyone at the forum. Our final thanks goes to William "Darry" Faust, our compiler and editor of these proceeding for many years. Darry has chosen to retire. It will difficult to find some- one as resourceful and dedicated to put future proceedings together. Peter Vodak, as the incoming Chairman, along with Mike Horton, new Vice- vii Chairman, and the entire committee has already begun preparations for the next Technical Forum. It promises to be another informative and worthwhile meeting. HOLGER EVELE Ferro Corporation Chariman 2007 PEI Technical Forum Committee and Back-to-Basics Seminar viii · 69th Porcelain Enamel Institute Technical Forum 2007 PEI Officers Chairman of the Board JACK MCMAHON Pemco Corporation President BOB HARRIS Hanson Industries Vice Presidents BILL GANZER Mapes & Sprowl Steel KEN KREEGER Nordson Company DON MCCORMICK Electrolux Home Products TIM SCOTT Henkel Surface Technologies NICK SEDELIA Whirlpool Corporation MILES VOLTAVA Ferro Corporation PAT WALSH Porcelain Industries ix Executive Committee Members PETER DORITY Coral Chemical Company PHIL FLASHER ITW-Gema ROBERT GUIDICE US Borax MIKE HORTON KMI Systems GLENN PFENDT AO Smith Corporation DEBRA VOGES Roesch, Inc. Treasurer JIM STADLER Ferro Corporation Assistant Treasurer JOHN MCBRIDE Porcelain Metals Corporation Executive Vice President CULLEN HACKLER PEI x · 69th Porcelain Enamel Institute Technical Forum 2007 Technical Forum Committee Chairman: Holger Evele, Ferro Corporation Vice Chairman: Peter Vodak, Engineered Storage Products Peter Dority, Coral Chemical Company Cullen Hackler, Porcelain Enamel Institute Mike Horton, KMI Systems Ken fCreeger, Nordson Corporation Liam O'Byrne, O'Byrne Consulting Services Tim Scott, Henkel Surface Technologies Larry Steele, Mapes & Sprowl Steel Dave Thomas, American Trim Miles Votava, Ferro Corporation Jack Waggener, URS Corporation Mike Wilczynski, A O Smith Protective Coatings Ted Wolowicz, Electrolux Home Products Jeff Wright, Ferro Corporation David Latimer, Whirlpool Corporation Porcelain Enamel Institute PO Box 920220 Norcross, GA 30010 Phone:770-281-8980 E-mail : [email protected] www.buyporcelain.org www.porcelainenamel.com XI