Application Area Details

What Is Porosity
  • Porous defines a structure that contains small holes or pores,
  • More critically, one that can be permeated by a fluid or gas,
  • Occurs in metals, especially castings, as they change state from liquid to solid,
  • Also prevalent in powder metal industry during manufacture,

SEALANT – The History
  • Weathering - traditional method for cast iron,
  • Linseed oil - early method of impregnation,
  • Sodium silicate - cheap but poor performance,
  • Polyesters - better but not production friendly,
  • Methacrylate - the “modern” sealant.
The Ultraseal History
  • First to develop methacrylate sealants commercially,
  • Introduced PC504-66 with improved qualities,
  • Worlds first recycling sealant Ultraseal MX2 (1987),
  • Further recycling advances through Rexeal 100.
Methacrylate Sealant
  • Blend of monomers formulated to achieve required combination of physical properties after curing,
  • Thermo curing through an initiator (catalyst) that is temperature sensitive,
  • With temperature rise polymerisation starts,
  • The higher the temperature the faster the change,
  • At 90ºC sealant will gel in 2 – 3 minutes.
Ultraseal Equipment Focus
  • Quality enhancement process,
  • Fit for purpose sealed parts,
  • Productivity through faster cycle times,
  • Lean manufacturing (minimum WIP),
  • Good parts handling,
  • Pollution free for use in factory,
  • Minimised effluent for environment,
  • Man - machine friendly interface.
Rotational Processing
  • Faster cycle times & cleaner parts,
  • More effective draining,
  • Aggressive washing action,
  • Filtered solutions,
  • Less contamination,
  • Better heat transfer in cure cycle.
Ultraseal Recycling Sealant & SRS
  • Technical challenges,
  • MX2 first introduced by Ultraseal in late 1980’s,
  • SRS used to return sealant to autoclave,
  • Cold wash water never needs changing,
  • Environmental & cost benefits.
Porosity in Die-castings
  • Flow Porosity – surface or internal porosity from poor pressure conditions,
  • Gas Porosity – internal porosity from trapped gases of various kinds,
  • Shrink Porosity – porosity from the volume change as the metal changes state.
Effects of Porosity in Castings
  • Leaks through casting wall,
  • Defects in subsequent surface treatment,

    Leading to:

  • Reject or scrap parts,
  • Failure in service,
  • Reduced operational life,
  • QUALITY ISSUES!
What Is Impregnation
  • A permanent solution to porosity,
  • Process that causes no dimensional change or contamination of the component,
  • Fills any interconnected voids with a stable yet flexible material,
  • Impregnated part is resistant to attack from heat, oils, chemicals, or other external influences such as vibration.
What Does Impregnation Do
  • It is a process that brings increases in productivity and reductions in cost:
  • By reducing waste & therefore, costs,
  • By reducing manufacturing time,
  • By enhancing quality,
  • Thereby adding value.
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