Ultrasonic Spray for Silicon Steel Inorganic Protective Coatings
In the manufacturing of power equipment such as motors and transformers, silicon steel sheets, as the core magnetic substrate, directly determine the energy efficiency, stability, and service life of the equipment due to their surface protection performance. To address the pain points of silicon steel sheets being prone to oxidation and having insufficient corrosion resistance, inorganic protective coatings, with their advantages of high temperature resistance, excellent insulation, and environmental friendliness, have become the preferred solution for surface treatment of silicon steel sheets. Ultrasonic spray coating machines, with their precise coating control capabilities, are perfectly suited to the preparation requirements of 300mm wide silicon steel sheets and 1μm (maximum not exceeding 1.5μm) inorganic protective coatings, achieving the dual goals of substrate protection and performance optimization, and driving the upgrading of silicon steel sheet processing technology towards refinement and efficiency.
The core advantage of ultrasonic spray coating machines lies in precise atomization and uniform deposition, which highly aligns with the stringent requirements of inorganic coatings for silicon steel sheets. Its working principle involves converting high-frequency electrical signals into mechanical vibrations using a piezoelectric transducer. This causes the inorganic solution to form micron-sized droplets at the nozzle, which are then guided by a directional airflow to uniformly deposit on the surface of the silicon steel sheet. The entire process is contactless and pressure-free, effectively preventing damage to the substrate. Compared to traditional spraying processes, ultrasonic spraying machines can precisely control the atomized particle size within 5-50μm, achieving a coating uniformity CV value of <5%. It can easily prepare ultra-thin coatings of 1μm with thickness deviations controlled within ±0.1μm, strictly meeting the technical requirement of “maximum not exceeding 1.5μm,” fundamentally solving the industry pain points of uneven coatings and excessive thickness in traditional spraying.
For silicon steel sheets with a substrate width of 300mm, the ultrasonic spraying machine achieves efficient and uniform spraying of wide substrates through customized nozzle design and an automated conveying system. The equipment uses adjustable wide nozzles, combined with a synchronous and uniform conveying mechanism, to ensure consistent coating thickness from the edge to the center of the silicon steel sheet, avoiding the problem of excessively thick edges and thinner centers. Meanwhile, ultrasonic spraying machines boast a material utilization rate exceeding 95%, significantly reducing inorganic solution waste and production costs compared to the 50%-70% utilization rate of traditional spraying. Furthermore, they eliminate environmental pollution caused by excessive spraying, aligning with environmentally friendly production requirements under the “dual carbon” target.
The compatibility of the inorganic solution’s properties with the ultrasonic spraying process is crucial for achieving an ultra-thin, uniform coating. The inorganic solution used in this application, with silica sol and phosphate as core components and optimized with rare earth additives, exhibits excellent fluidity, stability, and film-forming properties. It requires no harmful solvents, meets industry standards for VOC content, and combines environmental friendliness with protective performance. During ultrasonic spraying, precise control of parameters such as solution viscosity and atomization frequency ensures uniform adhesion of inorganic solution droplets to the silicon steel sheet surface. Subsequent drying and high-temperature curing processes form a dense inorganic protective coating, providing excellent insulation properties to reduce motor iron loss and effectively blocking corrosive media such as air and moisture, delaying the oxidation and aging of the silicon steel sheet, and extending equipment lifespan.
In actual production, the ultrasonic spraying machine, through its intelligent control system, achieves precise control of spraying parameters, ensuring the stability of coating quality. For the requirement of 1μm ultra-thin coatings, the equipment can precisely adjust key parameters such as atomization frequency, spraying height, and moving speed: the atomization frequency is controlled between 60-120kHz to ensure fine and uniform droplets; the spraying height is set between 50-100mm to avoid droplet aggregation affecting coating thickness; and the moving speed is precisely adapted to the coating thickness requirements, combined with real-time feedback from laser thickness measurement, to achieve closed-loop control of coating thickness, preventing thicknesses exceeding 1.5μm. Simultaneously, the modular design of the equipment facilitates maintenance, significantly reducing downtime and improving the mass production efficiency of 300mm wide silicon steel sheets.
The application of the ultrasonic spraying machine in the preparation of inorganic protective coatings for 300mm wide silicon steel sheets not only meets the stringent requirements of ultra-thin coatings but also promotes the upgrading of silicon steel sheet surface treatment processes. The 1μm inorganic protective coating prepared by this process not only ensures that the magnetic permeability of the silicon steel sheet is not affected, but also significantly improves its corrosion resistance and high-temperature resistance, making it suitable for the use of high-end equipment such as industrial motors and transformers, and helping the equipment to develop towards high efficiency and long service life. With the advancement of intelligent manufacturing technology, ultrasonic spraying machines will further optimize parameter control precision and achieve unmanned operation in combination with automated production lines, providing strong support for the high-quality development of the silicon steel sheet processing industry and promoting the green upgrading and technological innovation in the power equipment manufacturing field.
About Cheersonic
Cheersonic is the leading developer and manufacturer of ultrasonic coating systems for applying precise, thin film coatings to protect, strengthen or smooth surfaces on parts and components for the microelectronics/electronics, alternative energy, medical and industrial markets, including specialized glass applications in construction and automotive.
Our coating solutions are environmentally-friendly, efficient and highly reliable, and enable dramatic reductions in overspray, savings in raw material, water and energy usage and provide improved process repeatability, transfer efficiency, high uniformity and reduced emissions.
If you have any technical questions, customization demands, or procurement inquiries about ultrasonic atomization nozzles, feel free to contact our professional sales and technical team for detailed parameters, customized solutions, and industry application support.
Email: market2@cheersonic.com
