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Casting impregnation

A porosity sealing solution

Casting impregnation is the leading solution to porosity – the voids in metal components which occur during the casting process.

What is Casting Impregnation?

Casting impregnation is a post-casting process which seals porosity and leak paths in castings that would render components that need to be pressure or fluid-tight unusable. For the most effective quality enhancement results, the impregnation process can be integrated within the production facility or even inline with the manufacturing process.

How does casting impregnation work?

The component is put in a vacuum impregnation system, air is removed from the voids (known as porosity) under vacuum. Leak paths and porosity in the component are then filled with a chemically and thermally resistant polymer sealant. Excess sealant is then drained and washed from the component and the sealant within the porosity is then cured to provide a permanent seal…

1. Impregnation.

Components are subjected to a dry vacuum in an autoclave, removing the air from the porosity. The components are then immersed in liquid sealant and the vacuum is released, filling the voids with the sealant.

2. Drain.

3. Cold Wash.

Next, a cold wash removes excess sealant from external component surfaces.

4. Hot Cure.

Finally, a hot cure cycle is used which polymerises the sealant, turning it from a liquid state to a solid polymer.

To find out more about the impregnation process and watch our video in which each stage of the process is detailed, visit our vacuum impregnation process explained page.

First, components are subjected to a dry vacuum in an autoclave, removing the air from the porosity. The components are then immersed in liquid sealant and the vacuum is released, filling the voids with the sealant. Next, a cold wash removes excess sealant from external component surfaces. Finally, a hot cure cycle is used which polymerises the sealant, turning it from a liquid state to a solid polymer. 

To find out more about the impregnation process and watch our video in which each stage of the process is detailed, visit our vacuum impregnation process explained page.

Which impregnation sealants can be used?

Ultraseal International offers two types of sealant; non-recycling and recycling sealant.

Our recycling sealant delivers exceptional performance and the lowest cost of operation, while helping tackle the challenges of effluent and waste water, making it the ultimate sustainable solution to sealing porosity in cast components. Rexeal 100 and MX2 recycling sealants continue to keep millions of cast components leak free and reliable.

We offer three types of non-recycling sealant – PC504/66, Sinterseal and Electroseal. They provide a complete solution to sealing porosity in metal castings, electronic leads and connectors, and sintered components.

We also provide a range of detergents and inhibitors developed to work specifically with Ultraseal sealants and equipment. These chemicals enhance performance and ensure consistent Ultraseal quality across both your impregnation equipment and manufacturing process. Find out more about our detergents and inhibitors.

Applications for Vacuum Impregnation

The applications of vacuum impregnation for porosity sealing span many industries, as porosity can be present in a wide range of components and materials. Examples of applications include:

Automotive Powertrain Components e.g. cylinder head, cylinder block, transmission housing, BEV and Hybrid Power Electronics housings and Electric Motor Housings.

Braking systems.

Air Conditioning Compressors.

Electrical Components.

Sintered Components.

Additive Manufactured/3D Printed Components.

casting-impregnation-applications

Casting impregnation services, sealants and equipment from Ultraseal International

Ultraseal International is the global leader in porosity sealing, providing casting impregnation services, sealants and equipment to meet all manufacturing requirements.

Outsourcing casting impregnation to one of our worldwide impregnation service centres is a popular solution for manufacturers with lower production volumes. Those with higher production volumes may wish to consider investing in vacuum impregnation equipment or opting for our fully managed onsite service.

There are many considerations when making an investment in equipment, such as:

Component dimensions and available system floor-space;

Whether the system is to be integrated into the existing production process or an off-line system;

Operator involvement; choice of component handling method;

Operating and environmental cost factors.

For more information about vacuum impregnation, casting impregnation or guidance on the best porosity sealing solution for your business, please get in touch with the Ultraseal team.

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