A FEM model of conventional hot dipping coating process by using a fluidized bed

A FEM model of a conventional hot dipping fluidized bed (FB) coating process on a low carbon steel rod using a PPA thermoplastic powder was developed. Two computational domains, the former for the metal substrate and the growing coating and the latter for fluidized bed emulsion nearby the metal substrate were set. A novel recursive procedure was employed to solve the 'coupled' thermal problem. Besides, realistic values of polymer thermal properties according to temperature as well as the whole curve of polymer enthalpy were input to the model so as to increase its reliability. As a result, consistent trend of coating thickness and growth rate according to dipping time with experimental data and theoretical considerations were calculated. Moreover, the calibration procedure of FEM model took to realistic values of heat transfer coefficient according to preheating temperature of substrate as the comparisons with available experimental data confirm. At last, dimensionless analysis stated once more the FEM model reliability by comparing the numerical findings with those of pioneer models available in literature. © 2005 Elsevier B.V. All rights reserved.