Application: Spray dry-film lubricant coatings and dry lubricants in a controlled manner
What this application is about
In practice, solutions range from flexible manual workstations to indexed, robot-assisted series-production systems. The spray equipment, material supply and movement sequence must be suited to the coating material and the workpiece.
Functions of dry-film lubricant coatings
The application mainly concerns metal, elastomers, plastics and pre-treated composite parts. The required effect occurs only when coating material, substrate, layer thickness and subsequent drying or curing fit together. The spraying process must therefore be adapted to the concrete material system and the real production conditions.
Alongside surface quality, material consumption, cleaning effort, system availability and reliable repeatability also matter. A sound technical solution therefore combines controlled atomisation with a stable material supply that is easy to regulate.
Typical requirements for the spraying process
Even small fluctuations in material pressure, viscosity, distance or movement control can change the coating visibly or functionally. Typical requirements include:
- thin and uniform functional layer
- Avoiding sedimentation in solid media
- constant friction values over the entire component area
- good edge and geometry cover
- wear-resistant and well flushable material paths
- Reproducible drying and curing
Reproduce thin sliding and dry lubricant films reproducibly
Sliding coatings often contain solid lubricants and are used as a thin, dry functional layer. The friction and wear properties depend heavily on an even distribution of the solids and the intended layer thickness. Sedimentation in the container or in pipes can change the composition of the spray film.
Agitator, material pressure and nozzle selection are therefore considered together. Functional and contact surfaces must be fully wetted without unnecessary overloading of threads, sealing areas or joints.
- Stable suspension of solid lubricants
- thin, closed layer
- precise limitation of functional surfaces
- Avoidance of rough or powdery areas
- coordinated drying or heat curing
Krautzberger solutions for spray application and material supply
Krautzberger treats application and material supply as a connected system. Depending on the task, manual and automatic spray guns, suitable air and material nozzles, material pressure tanks, diaphragm pumps, pump and lifting stations, and material pressure regulators can be combined.
In automated processes, spray guns can be integrated into mounts, lifting devices, axes or robots. Material changeover valves and flushing equipment support applications with several colours or media. The specific selection depends on viscosity, solids content, application quantity, cycle time and component geometry.
For fine surface finishes, various XLINE nozzle combinations and spray patterns are available. With highly viscous, abrasive or sedimenting media, sufficiently large flow cross-sections, suitable material combinations, agitators and pressure-stable delivery become more important.
The focus is on finely adjustable hand or automatic spray guns, agitators for sedimentating media, material pressure vessels or pumps as well as material pressure controllers for a constant application. The technically and economically suitable combination is selected for the specific medium, components and required production output.
Components, industries and fields of application
The application is used in different industries and component groups. Typical examples are:
- Seals and guide profiles
- Screws, springs and connecting elements
- Sliding surfaces and bearing components
- Automotive and mechanical engineering parts
- Assembly aids for pressing and joining operations
- components with anti-squeak and stick-slip requirements
Manual, partially automated or fully automatic
Small parts can be coated individually, on workpiece carriers or as bulk material in suitable rotary systems. The spray technology is adapted to the solid content, desired layer thickness and component movement.
In addition, component feed, extraction or ventilation, cleaning, media change and accessibility for maintenance work must be taken into account during the system integration. This keeps the process stable not only in the pattern run, but also in everyday production.
Result for quality and economy
- Uniform friction and sliding properties
- less wear and noise
- clean dry lubricating film
- reduced material consumption due to thin application
- Reproducible values in series production
- suitable for individual parts and mass small parts
Tests with original material and sample components
Liquid media and coating materials with similar names can differ considerably in viscosity, solids content, solvent base, wetting and drying. A reliable choice of spray gun, nozzle and material supply should therefore be made using the original material and a representative component.
The decisive factors are sedimentation behaviour, nozzle selection, stirring, layer mass and drying; these parameters are matched with the concrete dry-film lubricant coating.
On this basis, the spray pattern, material quantity, pressure, distance, movement and cleaning sequence can be defined. The result is an application solution suited to the medium, the geometry and the intended production process.
Trials at the Krautzberger technical centre
At the Krautzberger technical centre, the process can be tested with the original medium and representative sample components. Conveyability, spray pattern, application quantity, material pressure, distance, movement and cleaning are coordinated during these trials.
The trials provide a reliable basis for selecting the spray gun, nozzle, material supply and degree of automation. Final functional and process approval is issued by the operator together with the material manufacturer.
Related products
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Contact for your application
Looking for a spray gun, an automatic spray gun or a complete material supply for this process? Krautzberger helps you select and design suitable spray technology, nozzle configurations, delivery and regulation.
Contact Krautzberger to discuss your medium, component, production volume and desired result. Together, we assess how the process can be implemented safely and economically.
Industries for this application
Where oils or greases are unsuitable, dry-film lubricant coatings can provide defined friction coefficients. Application of the layer depends on the component, its loading and the requirements of the respective use.
