Ultraseal International is living up to its global reputation for being at the forefront of vacuum impregnation technology with its new two-stage process that will be unveiled at GIFA 2015 in Düsseldorf, Germany.
Scientists at the company have revolutionised the design and eliminated one of the three stages of the Vacuum Impregnation process entirely without in any way compromising the quality of the impregnation process.
Called the R-FL-Duplex+, it has a much smaller footprint on the factory floor than a conventional casting impregnation process; it uses less energy, produces less waste and is fully automated with the use of robotics. The machine is ideally suited to single-part processing but, with some configuration, multi-parts can also be processed.
Gary Lloyd, Managing Director of Ultraseal International, said: “Once again Ultraseal International is delivering more benefits to customers with an exciting advance in the fight against porosity in cast metal parts.
“Our latest innovation is truly ground-breaking – our two-stage impregnation process offers all of the quality of Ultraseal’s recycling sealant technology with added advantages in space and cost.”
Visitors to GIFA 2015 can see the new R-FL-Duplex+, complete with robotic handling, at the Ultraseal stand in Hall 11 F26 at the exhibition in Düsseldorf, Germany from June 16-20.
Vacuum Impregnation with porosity sealants is an important post-casting process for diecasters because it offers a reliable and permanent solution to the problem of porosity in cast metal parts. Porosity – microscopic holes that form during the casting process itself – can create serious problems if leak paths are formed.
Typically, impregnation is carried out in three stages: firstly, parts are placed in an autoclave and a vacuum applied that will draw air out of any porosity before a liquid sealant is introduced; secondly, parts are washed in a cold wash cycle and finally they are moved to the ‘hot cure tank’ where the heat transforms the liquid within the porosity into a solid, flexible plastic.
The success of the R-FL-Duplex+ depends upon the innovation of the chemistry developed at Ultraseal’s headquarters in Coventry, UK, where all of its Research and Development is carried out. The twin-module machine works with Ultraseal’s market-leading recycling sealant, Rexeal 100™.
Kevin Siviter, Technical Manager of Ultraseal International, explained: “Traditionally after impregnation there is a dedicated wash module to ensure that components are clean before the last stage of impregnation.
“This is different. There is no wash station – parts go straight from the autoclave to the hot cure tank. The R-FL-Duplex+has a new hot cure recycling process.
“Customers will get the same impregnation quality as they would achieve with a three-module machine in regard to sealability and cleanliness but the machine would take up one-third less space, less energy is required to run it and it has increased production throughput.
“It is a continuous, real-time process that is very robust and offers all the advantages of our recycling sealant technology.”
Ultraseal has led the way for decades and is once again transforming the face of vacuum impregnation.
The company has its headquarters in the UK, Joint Ventures in China and India, an operation in the United States, an office in Japan and a network of 22 agents/distributors around the world, as well as the renowned jobshop Sterr & Eder Industrieservice GmbH, based at Velden, Germany.
It is exhibiting at GIFA alongside Sterr & Eder and Lubrolene – a series of water-free die release agents developed by the Aoki Science Institute of Japan and for which Ultraseal has been granted exclusive European distribution rights.