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Machinists do not need to worry about rejections due to leakages anymore

METAL IMPREGNATION

Porosity is nothing but spongy areas within the material that makes the casting prone to leakages, and mainly after the final machining operations. These porosities cause major rejections and line stoppages and need to be sealed before the castings were sent for further operations or assembly at the customer end. Vacuum Impregnation using Teknoseal’s revolutionary sealant TSP 99 is the answer.

With the advent of the concepts of value-added services and the Supply of assemblies, only casting supply is a thing of the past. Earlier the foundry industry focussed only on castings but now the call of the day is to provide machines and fully finished ready to assemble components.

There used to be processes that did not succeed to take care of a lot of adjoining issues that arose post casting or even machining. One such intrinsic problem for foundry industry was porosity. Porosity is nothing but spongy areas within the material that makes the casting prone to leakages, and mainly after the final machining operations. These porosities cause major rejections and line stoppages and need to be sealed before the castings were sent for further operations or assembly at the customer end. Vacuum Impregnation using Teknoseal’s revolutionary sealant TSP 99 is the answer.

The process is a batch process with a very short cycle of only 20 mins. It involves four steps - • Vacuum Impregnation, • Drain, • Wash,  • Hot cure

The castings even if fully machined have no change in shape or final dimensions.

Why does One Need Impregnation?

As we all know, Casting is a product made from pouring molten metal in a die/ mould. After the casting stage, the component is machined to give it the final finish and precise dimensions. This process of Machining as we all are aware is a very expensive process and often a machined component is almost 300% value added.

The casting sections when machined might open up porosities which would cause leakages. A leaking casting can only be rejected and sent back to the foundry for remelting and recasting. However, in this case, the large portion of value added during the machining stage would be lost and moreover, the new casting that is made may again leak.

Metal ImpregnationVacuum Impregnation is the procedure that seals the porosity and can be applied on a fully machined component. The procedure can either be used directly by the casting manufacturers or by machining jobshops. The cost savings with the use of vacuum impregnation are enormous especially for intricately machined castings like cylinder heads and cylinder blocks of automotive engines and has a wide range of applications right from the automotive industry to the food industry.

Why Teknoseal?

A decade ago, Teknoseal, as a brand, was developed in India for making vacuum Impregnation more affordable. Fighting all the constraints of market, Teknoseal leads to be the global solution for sealing of micro-porosities in castings

Teknoseal is manufacturing in India with international standard compliances. Teknoseal is not a manufacturing unit or a plant alone; it is a research-oriented company. That being said, Teknoseal obviously has the market for selling products but people working there are always inclined towards improving the existing quality and bringing new innovative products on board. The research team is dedicated in developing sealants for various applications. All teknoseal products are approved and tested to international scientific specification.

Today, Teknoseal, is the leading solution provider for all the sealing applications using the cutting-edge and highly recommended technology. Teknoseal is a company that is manufacturing TSP 99 sealant, for better impregnation process. The process is a sealing technique that ensures to eliminate any kind of leakage problems that are noticed in castings.

What is Underpinning Profit?

A company spends thousands to cast a metal and then machining the castings, only to retrieve it back with pores in them. This is not a profitable solution in any way. After machining, the open porosity can cause several issues including leakage which would lead to failure if the components in service. Impregnation is an economic and smart choice in the casting business. Moreover with present trends of achieving 0 ppm vacuum inpregnation is very often used for complete processing of the entire batch of castings. This not only ensures all porosities being sealed but also ensures quality assurance.

Teknoseal has world-class R&D department that works hours together to develop effective and efficient sealants that can help impregnate even the finest of all porosities.

Machining and impregnation go hand-in-hand for casting, use in automotive industries. Normally conventional techniques are used such as Vacuum impregnation. For extremely fine or hidden pores in castings subjected to inert gas applications vacuum and pressure impregnation is used.

The author Probal Sen and his brother Saibal Sen, are pioneers in impregnation casting technology with globally renowned sealant TSP99, manufactured by their Pune based company Teknoseal Engineering Solutions. For more detail please do visit www.teknoseal.in

 

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