- Globally automotive manufacturers are reducing vehicle mass for bringing a greener solution for Electric Vehicles, for better battery management
- Vacuum Impregnation enables EV manufacturers to manufacture thinner and lighter designer without any imperfections caused by porosity
- High-tech vacuum impregnation without compromising quality is now a possibility, to reduce cost and save time during the manufacturing process
Vacuum impregnation has become relevant in eliminating the porosity in aluminium castings which has witnessed a spike in demand for its potential to enhance automotive performance. Since the advent of vacuum impregnation in the 1940s, various industries have been adept to incorporate it into their manufacturing process. Porosity that was earlier sealed off with sodium silicate and styrene-based resins was streamlined by the 1980s when flexible and easily adaptable resins arrived at the market as sealants.
Significance of Vacuum Impregnation for Sustainability
The automotive industry has integrated vacuum impregnation to lower down defects, waste and introduce enhanced hybrid and battery electric vehicle manufacturing. It has transformed the old-school manufacturing process sustainably thereby reducing carbon emission that is associated with blasting, machining, trimming and washing of substitute parts.
Around the globe, manufacturers are reducing vehicle mass for bringing a greener solution for electric vehicle (EV) manufacturing since heavy vehicles deplete the battery faster than their lighter counterparts. However, the shift towards thin-walled castings to reduce vehicle weight is not simple either. Manufacturers deal with an increased risk of porosity. Interconnected porosity leads to surface defects, microscopic holes and other imperfections. Vacuum impregnation, a low-impact technique of sealing the internal leaks of porosity, acts as a sealant without altering the casting dimension or functional traits.
Why vacuum impregnation has gained traction in the Electric Vehicle industry?
Assuring liberty of design: In EV manufacturing, vacuum impregnation has allowed for thinner and lighter designs without any hassle of imperfections due to porosity. Previously, diecasting porosity would discard parts to meet rigid requirements.
Maximizing part use: With the vacuum impregnation technique, manufacturers are more at ease with using castings that otherwise would have been scrapped off leading to a subsequent drop in profit. Vacuum impregnation allows 100 per cent use of the spare parts in the production line.
Reducing melting and re-manufacturing: Vacuum impregnation renders redundant the expensive melting and re-smelting besides removing carbon waste costs. The feasible business model has made viable a constructive way for capping costs.
To cater to surging demands, OEMs have now installed an in-house vacuum impregnation system using a batch system wherein workers would load parts into caskets for processing. The Batch system was vulnerable to quality issues with excess labour and maintenance charges. Additionally, many parts were rejected as unusable. The Batch system was eventually replaced with front-loading that strives to cut down on sealant contamination and increase seal rate. Improved production today is synonymous with a smaller system that lessens cycle times and works on the production volume.
Today, robotic handling of the parts scrutinizes each part for perfection before they are moved further in production. Furthermore, with a PLC-integrated system, manufacturers can easily resort to data acquisition to quality check the plant’s production system. Data on each parameter are stored which is later accessed with the audit.
Vacuum Impregnation- The Future of Defence, Oil and Gas
Make in India initiative attempts to reduce cost production in high-tech impregnation without compromising the quality. Manufacturers are inching towards a reliable R&D process and indigenous technology to meet domestic and international demands. Today, the anticipated rise of vacuum impregnation in the aerospace, oil & gas industry is too probable given how cost-effective and eco-friendly the technique is.
Impregseal & Teknoseal from Sen Group is one of the top five players worldwide in vacuum impregnation technology and equipment with the complete package of impregnation equipment supplies, impregnation resin supplies and impregnation services all under one group. Through our commitment to the industry and high-quality delivery earned an international reputation with global approval from international bodies and auto majors.
To find out how vacuum impregnation can bring benefits to your industry, do write to me at probalsen@impregseal.com