Atlas Revolutionizes Galvanizing Pot Maintenance with Innovative Ceramic Coating and Robotic Application
Atlas's breakthrough technology is redefining efficiency in the steel industry.
Innovating Galvanizing Solutions
In a groundbreaking development, Atlas has successfully addressed the persistent issue of dross buildup in the galvanizing pot for a prominent player in the steel industry. The challenge, which led to manual scraping of pot walls and posed both quality and safety concerns, was tackled through the application of an innovative ceramic coating. What sets this solution apart is not only the cutting-edge material but also the utilization of advanced robotic equipment for precise application.
Through ingenuity and problem-solving, Atlas has harnessed cutting-edge technology to resolve the long-standing issue. The formidable challenge was met with a groundbreaking solution that showcases the innovation capabilities of Atlas' engineering team.
Dross Buildup Issues
A steel fabricator out of Ohio initially sought a non-stick coating to be applied to a dross shield in their zinc pot. The challenge lay in the recurrent dross buildup on one of the pot walls, necessitating manual intervention. This labor-intensive process not only posed safety risks but also led to turbulence in the pot, causing quality issues in the final product. Previous attempts with generic solutions had proven unsuccessful, underscoring the need for a truly innovative approach.
Advanced Coating & Robotics
Upon receiving the customer's challenge, Atlas proposed a novel coating solution – Silicon Carbide and Yttrium Aluminum Garnet (SiC-YAG). This unique coating, applied using High-Velocity Oxygen Fuel (HVOF), proved to be the key to addressing the non-stick requirement effectively. The SiC-YAG coating, a 100% full ceramic material, is the first commercially viable solution of its kind. Developed in collaboration with a Norwegian partner, this proprietary coating is exclusive to Atlas in the North American steel industry.
Not only does this unique coating technology set Atlas apart, but even more innovative was the use of a FANUC robot equipped with the HVOF gun to apply the coating, allowing for precise and uniform coverage even on complex shapes such as angled plates.
Quality & Efficiency Boost
The implementation of this innovative coating not only met the customer's non-stick requirement, but also delivered far-reaching benefits. The project significantly improved the quality of the customer's end product, increased operational uptime, and reduced maintenance efforts. These improvements directly contribute to the enhanced profitability for the steel company.
Atlas Going Above and Beyond: Engineering Excellence
The success of this project is attributed to the collaborative efforts of Thermal Spray Technician Jamie Stevenson and R&D Engineer Alex Borchers. The deployment of the new robotic system, coupled with the application of an innovative thermal spray material, showcased Atlas' commitment to pushing technological boundaries to meet customer needs.
Leading Protective Coating Innovation
Atlas's revolutionary approach to addressing dross buildup in galvanizing pots signifies a significant leap forward in protective coating technology. The synergy of advanced ceramic materials, robotic precision, and collaborative engineering has not only solved a persistent industry challenge but has also positioned Atlas as a leader in innovative solutions for the steel industry. The successful application of the SiC-YAG coating marks a milestone in the company's commitment to excellence and customer satisfaction.
Atlas's engineering and innovation teams have not just resolved a persistent industry challenge; they've redefined the possibilities within protective coating technology and have set the example for innovation and engineering excellence in the field. Atlas, a showcase of ingenuity, is providing tailored solutions that go beyond meeting client needs – they are setting new industry standards.