Vacuum Impregnation of Automotive Casting Parts

Prevent Porosities from Thinner Castings in Vehicle Engine Components

Reducing vehicle weight means increasingly thinner castings for engine components. Because thin walls are at risk of porosity, the need for vacuum impregnation is more important than ever before.

In this segment of On the Road with Henkel, we take a closer look at the growing need for impregnation at our facility in Muncie, Indiana.

VIDEO TRANSCRIPT

Speaker 1: [00:00:00] As automakers reduce vehicle weight, they use increasingly

thinner castings for ending components. But thin walls are at risk of being too

porous, which can cause leaks and reduce durability and performance. So we're on

the road with Henkel in Muncie, Indiana, not far from Indianapolis, at one of their

nine regional processing centers, to see how Henkel's vacuum impregnation

process can protect against leaks.

Speaker 2: Ferocity and porosity sealing has evolved as where we used

to have a lot of iron castings, ferocity wasn't that relevant in those castings and as

we move to aluminum, ferocity is. A large percentage of the cast components of an

automobile are aluminum. I would guess over 50%. As it evolves, there will be more

and more aluminum content in a vehicle.

Some of these castings will get additional machining after impregnation.

There has actually been a transition in the industry in the last few years, moving

towards 100%. Impregnation before final machining ensures that any ferocity is

there won't be opened up and fail later. Therefore, 100% upfront seems to be a

more viable option. Henkel's involvement in the casting impregnation industry

creates a number of new opportunities, from beginning to end.

It helps reduce inventory. It helps with loss due to scrap. One of the new

opportunities in the market is battery cases for the electric and hybrid

vehicle. Each battery is encased in aluminum casting. That casting has to be

pressure tight, therefore, impregnation will become a part of that process. We also

have electronics sealing here in this facility. We do that at three locations. That's a

whole another avenue, mainly automotive, similar to the castings.

We provide a couple of types of impregnation systems. One is called the CIS, which

is Circle Impregnation System. It's automated. It runs recycling resin,

which is good for the environment. We also have a linear system and it's adjustable

to the customer size. What we've designed into our new equipment are several

advantages. They include ease of maintenance and access to the equipment, water

usage, and water management.

Quality standards in the industry continue to rise. Oil on the floor is not acceptable.

Something leaking out of an engine is not acceptable. Worn tissues are

unacceptable. Casting impregnation helps with that to allow the auto

manufacturer to provide that higher quality standard.

[00:02:44] [END OF AUDIO]

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