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Case Study: Ensuring EV Battery Performance with Vacuum Impregnation

amarin@godfreywing.com (Andy Marin) — Mon, 10 Apr 2023 13:50:00 GMT

It is expected that there will be 134 electric vehicle (EV) car models available by 2024. Both well-established industry leaders and startups are debuting new car models and redesigning well-known models to be EVs. In addition, these companies are announcing investments to shift from internal combustion engines (ICE) to EVs. This competitive landscape rewards companies that can identify opportunities to adapt appropriately.

The Challenge

One example is a multinational automotive manufacturer developing an EV model for one of its sport utility vehicles (SUV). This SUV model has a passionate customer base. These customers view themselves as a community that loves adventure and is environmentally conscious. An electric SUV would align with their values.

The electric SUV model requires two batteries per vehicle (Image 1). During testing, the OEM discovered coolant leaking from a high percentage of the battery tray die castings. This threatened to be disastrous, affecting the assembly of thousands of vehicles. If the OEM could not find a solution quickly, they would need to shut down production and would lose revenue.

Image 1: The OEM discovered coolant leaking from a battery tray casting for a new SUV.

The OEM contacted Godfrey & Wing, having used its vacuum impregnation technology as part of its manufacturing of die cast aluminum parts and components. But while vacuum impregnation is a viable solution for sealing die castings, it didn’t seem to be viable for these battery assemblies. While the process could indeed seal the discovered leak paths, multiple complications would arise.

Sealant contamination. Excess cured sealant would affect assembly and part quality.
With traditional vacuum impregnation processes, an entire part is submerged in sealant and water. Some electrical components would be incompatible with the sealant, water, or heat that are part of the impregnation process (Image 2). This would result in part damage.

Image 2: Some electrical components would be incompatible with the sealant, water, or heat from traditional vacuum impregnation process

Disassembly and reassembly of the batteries—needed for the vacuum impregnation process—would delay production and risk damaging fragile electrical components.

The Solution

To determine how impregnation could be most effective, Godfrey & Wing conducted controlled tests with sample batteries. The testing discovered leak paths that had formed in the battery’s die-cast aluminum housing. The company tested multiple processes and sealants to determine the best seal rates without damaging any components.

Godfrey & Wing's research determined that the best process and sealant would be:

Single-point Impregnation— Godfrey & Wing developed a patent-pending process called single-point impregnation. The process is in accordance with MIL-STD-276A Method A. Single-point impregnation comes in contact with only the leak path. The rest of the battery’s components are untouched, which eliminates the risk of sealant contamination.

Image 3: Only the leak path encounters the sealant.
This eliminates the risk of sealant contamination since no other components are touched.

Internal Pressure Process— All openings are plugged, except for the ports used in the leak path. Sealant is then impregnated with pressure into the part through the port (Image 3).

95-1000AC sealant—This sealant is anaerobic, meaning it cures in the absence of air with no heat or water. Using this sealant protects battery components that are incompatible with heat and water.

The testing and development of the process was done expeditiously, in less than two weeks. With a proven solution, the OEM moved forward with sealing its production parts.

Godfrey & Wing processed the parts inside of shipping containers. This expedited the production process and removed the risk of handling damage. The operator connected an inlet and outlet tube to each battery (Image 4). The sealant flowed through the tube to impregnate any leak paths. A pulsating rinse then flowed through the tube to wash excess sealant out of each part.

Image 4: The operator connected an inlet and outlet tube to each battery while the parts are in the shipping containers.
This expedited the production process and removed the risk of handling damage.

The Results

Once the process was developed and approved, Godfrey & Wing built the system and began processing production in two weeks. The solution answered the manufacturer's challenges:

Seal leak paths—Godfrey & Wing’s solution sealed 99.98% parts. This allowed the manufacturer to return parts to production without losing productivity.

Achieve part performance—The internal pressure impregnation and anaerobic sealant protected critical features, allowing the batteries to function as designed.

In Summary

As the demand for EVs continues, so too will the demand for innovative and adaptive manufacturing processes. By working with Godfrey & Wing, this manufacturer found a solution to a potentially catastrophic problem in four weeks. Through research, Godfrey & Wing's single-point impregnation process is the best and most economical option to meet the OEM’s quality and production demands.

The EV market has unprecedent competition. By having a partnership with Godfrey & Wing on sealing leak paths, this manufacturer has an advantage over its competition.

Preparing Parts for Vacuum Impregnation

amarin@godfreywing.com (Andy Marin) — Thu, 30 Mar 2023 12:44:00 GMT

When it comes to vacuum impregnation, it's essential to ensure that the parts being impregnated are dry beforehand. This is because any surface impurities can interfere with the impregnation process, leading to subpar results.

If any residual fluids or debris are on the parts prior to impregnation, then the following problems may occur.

Parts Not Being Properly Sealed

The fluids in the leak path will prohibit the process from fully sealing the leak path (Image 1). The parts may not pass the leak test since the leak path is not properly sealed. Any parts that fail the leak test will be unusable and possibly scrapped.

Image 1: The oil left on this part will prohibit it from fully being sealed.

Increase TAKT time

Any residual fluids will need to be boiled off in the vacuum chamber. When water boils, it expands approximately 1,700 times. That expansion means there is more volume for the vacuum pump to evacuate from the vessel, which takes time. In addition, if the water is in the part’s porosity, then the evaporation process could take several seconds more than evaporating from the surface. A few additional seconds may not sound like a lot of time. But this additional time compounds and can cause an increase in production time and costs.

Improper Assembly

Debris in tapped holes or blind passages can cause assembly issues or prevent fluid flow (Image 2). If the debris is not removed, then the parts will not function correctly. Cleaning the debris will require additional steps, which may create production delays.

Image 2: the debris in the blind passage (highlighted in red) will lead to assembly issues.

Inhibits Part Rinsing

Debris remaining on and part will inhibit the rinsing during the impregnation process. The debris will prohibit the sealant from fully being washed from the part's internal passages, taps, pockets and features where sealant is undesirable. Inadequate rinsing will lead to sealant being cured in undesired features that will affect the part's assembly and quality.

Sealant Contamination

Residual fluids and debris on the part can contaminate the sealant (Image 3). The contamination will affect the sealant's chemistry causing it to lose chemical properties and significantly reduce the recovery rate. The contamination will also require maintenance to replace the contaminated sealant with pure sealant. This will cause production delays and unforeseen costs.

Image 3: The machine chip left on the part will be dragged into the sealant. This will contaminate the sealant, rendering it less effective.

Best Way to Dry Parts

The best way to dry parts is with a vacuum drying system. The equipment allows for efficient and effective sealing, resulting in fewer production delays and costs (Image 4). Using vacuum drying equipment ensures parts are properly prepared for vacuum impregnation.

Image 4: Vacuum drying equipment dries parts prior to vacuum impregnation, allowing them to be efficiently and effectively sealed.

Understanding How Vacuum Pressure Impregnation (VPI) Works

amarin@godfreywing.com (Andy Marin) — Tue, 31 Jan 2023 14:46:09 GMT

Vacuum Pressure Impregnation (VPI) is a method to insulate wound electro-mechanical parts thoroughly with a resin or varnish. VPI is a critical process to insulate and seal the porosity of the parts. VPI is essential to ensure that parts function correctly and improve the longevity of the equipment (Image 1). This blog is a guide that will explain the process, advantages and applications of VPI.

Image 1: Vacuum Pressure Impregnation (VPI) is an essential process to insulate wound electro-mechanical parts thoroughly with a resin or varnish.

VPI Process Explained

1. Pretreatment: The part is preheated in an oven.

2. Dry Vacuum Step: The part is placed in the pressure vessel, and the cover is closed. The vacuum is pulled to remove air or until a specified vacuum is achieved. This is the most critical step to ensure the part is fully encapsulated (Image 2).

3. Wet Vacuum Step: The transfer valve is opened, and the resin or varnish fills the impregnation chamber while under vacuum.

4. Pressure: The vacuum is released, and pressure is applied for the resin or varnish to penetrate the voids in the part entirely.

5. Release Pressure: Return unused resin or varnish to the holding tank.

6. Cure: The part is removed and placed in the customer's oven for curing.

Image 2: The second step of the VPI process is when the part is placed in the pressure vessel, and the cover is closed.
The vacuum is pulled to remove air or until a specified vacuum is achieved. This is the most critical step to ensure the part is fully encapsulated.

Advantages of VPI

Without VPI, a component will deteriorate over time, leading to a failure in the product. This will increase costs and reduce quality. Here are the main advantages of using VPI.

1. Improve power output
A fully enclosed part leads to good heat transfer, keeping the electricity within the wires. This results in better part performance.

2. Contamination resistance
Contamination penetrates small openings in the unsealed insulation and produces a conducting path between turns or to-ground. Since VPI fully encloses the part, VPI ensures no risk of contamination.

3. Reduce coil vibration
The most common failure in motors is abrasion. Vibration causes wear and chaffing, leading to a part no longer being able to withstand voltage. Having a part enclosed with VPI serves as an adhesive between the motor strands as it turns. This reduces the risk of coil vibration.

VPI Applications

Typical applications of VPI are divided into two main categories (Image 3).

1. Electric Motors: Rotors, Stators

2. Electricity Delivery Equipment: Transformers, Capacitors, Super Capacitors

Image 3: Typical applications that use VPI include stators.
Image source: Electric Motor Engineering

In Summary

Vacuum Pressure Impregnation is the most efficient and effective way to enclose and insulate electro-mechanical parts. Using VPI ensures part performance while eliminating failure modes.

Inspect Casting Porosity with Nondestructive X-Ray

amarin@godfreywing.com (Andy Marin) — Wed, 09 Nov 2022 13:35:00 GMT

The phrase aluminum die casting porosity is used extensively when talking about any void in an aluminum casting, but it does not describe the actual problem. It can take many different shapes and forms, but it is often described just as “porosity”. When analyzing a casting’s porosity, it is important to describe specifics like size, shape, location, and frequency (Image 1). Since porosity is within the casting’s walls, the best way to analyze it is through Nondestructive Testing.

Image 1: Die casting porosity can take many different shapes and forms. The best way to analyze it is through Nondestructive Testing.

What is Nondestructive Testing?

Nondestructive Testing (NDT) is the process of inspecting and evaluating components for discontinuities or differences in characteristics without destroying the part. Bottom line, after NDT the part can still be used in production.

Radiographic Inspection

While there are various types of NDT testing the most effective for porosity is radiographic inspection (X-Ray). This is because porosity is within the casting walls. In this method, the casting is exposed to radiation from an x-ray tube. Dense material withstands the radiation penetration, giving these areas a darker appearance. Less dense materials, such as porosity, allow more penetration and are shown as a lighter appearance (Image 1).

In addition, X-Ray testing serves as a permanent record to the casting’s porosity. The testing allows for tractability throughout the manufacturing process.

Image 1: The porosity (highlighted in green) is shown in a lighter appearance, while the rest of the casting has a darker appearance.

Four Reasons to Inspect Casting Porosity with X-Ray

From the design stage through production, there are three main reasons why X-Ray inspection is done:

1. Diagnostics
The term porosity alone does not determine if it is a defect. Porosity only causes casting defects when it creates a leak path or structural problem in the part. X-Ray identifies if the porosity causes the defect by showing the porosity’s type, location, and frequency.

2. Determine Repair Criteria
X-Ray allows manufacturers to define acceptance rates. The customer can then integrate acceptable parts into production, and seal the porosity of rejected parts though vacuum impregnation.

3. Prohibit Contamination of Noncompliant Parts
X-Ray allows the manufacturer to remove non-conforming parts from production. This prevents the risk of failure downstream in the production cycle.

4. Preventative Tool
Porosity in castings is inevitable, but it can be minimized. X-Ray can be used during the R&D stages to help part and tooling design to reduce porosity as much as possible.

In Summary

Porosity is inherent in casting manufacturing. With OEM specifications becoming ever more rigorous, this porosity often leads to greater waste, increased costs, inhibited capacity and delayed production. Because porosity is an internal defect, Nondestructive X-Ray is the best inspection method to measure casting porosity while still being able to use the parts in production. Nondestructive X-Ray testing enables companies to identify areas of concern before porosity causes defective parts.

Sealing Motors with Vacuum Pressure Impregnation vs. Varnish Dip

tjuday@imprexusa.com (Tim Juday) — Mon, 24 Oct 2022 14:20:00 GMT

One component that engineers are designing in electric vehicles (EVs) is the electric motor. This component is one of the main driving-forces behind EVs. Per IDTEchEx, over 100 million electric motors will be required by 2032. The EV market is constantly evolving with new designs and higher performance requirements to meet these consumer demands. These requirements can result in more parts being rejected and scrapped. Leading to increased costs, and delayed production.

In an electric motor, insulated copper wire is wound around a core to create or receive electromagnetic energy, transferring that energy by induction to another coil. Once an electric motor is wound, it must be insulated with a varnish (Image 1). This step is critical to ensure the part's integrity. Vacuum Pressure Impregnation (VPI) and Varnish Dip are the two most common methods to insulate electric motors.

Image 1: Copper wiring must be insulated to ensure the motor's performance.

Vacuum Pressure Impregnation Process

During the VPI process, the part is lowered into a pressure vessel, and a vacuum is drawn. As that occurs, a varnish is drawn into the chamber until the unit is completely submerged (Image 2). Pressure is then applied, and the inside and outside of the part becomes thoroughly impregnated with the varnish. Afterward, the part is removed and then cured in an oven.

Air is a critical element that will cause quality and performance issues. Therefore, the vacuum step is crucial to remove the air. This ensures complete varnish penetration.

Image 2: The part is lowered into a pressure vessel, and a vacuum is drawn.
Removing the air is critical to ensure complete varnish penetration.

The Varnish Dip process dips the part into a varnish tank. Afterward, the part cures in an oven. The Varnish Dip process does not have a vacuum component. This means that air is not entirely removed, resulting in the inside and outside of the part not thoroughly impregnated.

Benefits of Vacuum Pressure Impregnation

While both processes have been used for over 60 years, VPI has three significant advantages over Varnish Drip (Image 3).

Improve power output
Because of the vacuum step, VPI varnish has a complete penetration. A fully enclosed part leads to good heat transfer, keeping the electricity within the wires. This results in better motor performance.

Contamination resistance
Contamination penetrates small openings in the unsealed insulation and produces a conducting path between turns or to-ground. As previously stated, VPI fully encloses a part because of the vacuum step. Therefore, VPI ensures no risk of contamination. Air not removed from a part creates microscopic openings that increase contamination risk.

Reduce coil vibration
The most common failure in motors is abrasion. Vibration causes wear and chaffing, leading to a part no longer being able to withstand voltage. Having a part fully enclosed with VPI serves as an adhesive between the motor strands as it turns. This reduces the risk of coil vibration.

Image 3: The VPI process will ensure a parts power output,
improve contamination resistance, and reduce coil vibration.
Image source: Car and Drive

In Summary

Electric motors in EVs offer cutting-edge technology and performance. As the surge of electric motors continues, so too will the need for VPI. Vacuum Pressure Impregnation is the most efficient and effective way to enclose motors. Using VPI ensures part performance while eliminating failure modes.

Three Reasons to Seal Electronics with Vacuum Impregnation

amarin@godfreywing.com (Andy Marin) — Thu, 01 Sep 2022 14:15:00 GMT

Electronics play a crucial role in electric vehicles (EVs). In 2000 automobile electronics were responsible for 18 percent of the cost of a car. Twenty years later, electronics accounted for 40 percent of a car's cost. The use of electronics will continue to meet fuel efficiency, safety regulations, and consumer standards. However, while the use of electronics will grow, manufacturers must ensure their parts' quality, safety, and their bottom line's integrity.

Source: Car and Driver

Metal pins and wires are embedded in the plastic housing in these parts. When the parts experience heat during manufacturing, the plastic and metal expand at different rates, creating microscopic leak paths between the materials.

One example are the overmolded pieces in this EV battery. The part needs to be pressure tight, while the leak path is unavoidable, it will result in the part being rejected and scrapped (Image 1).

Image 1: The leak path in this EV battery needs to be sealed so the part can work properly.

The rejected parts will cause a field failure, with an unforeseen increase in cost and loss of production. As a result, the massive expansion of electronics in automobiles has made sealing the leak paths critical. Vacuum impregnation is the most common and preferred method by OEMs to seal electronics.

Here are the three main reasons why:

Seal Leak Paths
Vacuum impregnation is a subsurface process that seals leak paths by filling the void between the two dissimilar materials. If not sealed, then fluids may penetrate the connector. Vacuum impregnation prevents fluids from leaking by sealing the leak paths.

Prevent Corrosion
From either oxidation or galvanization, corrosion reduces current-carrying capacity and causes the part failure. Vacuum impregnation prevents corrosion by sealing the leak path that oxygen and moisture can follow(Image 2).

Image 2: Vacuum impregnation will prevent the metal prongs from corrosion.

Enable Design Freedom
Vacuum impregnation does not change the part's dimensions, allowing engineers to design and make parts to the net shape. Since the process does not leave any sealant on the part's surface, an engineer does not need to incorporate dimensional allowance.

In Summary
The surge in electronics in EVs has made leak path sealing crucial. Properly sealing the porosity ensures the component's quality meets its performance requirements. Vacuum impregnation is the most effective solution for sealing leak paths and preventing corrosion while enabling design freedom.

The Ultimate Guide to Sealing 3D Printed Parts

amarin@godfreywing.com (Andy Marin) — Mon, 15 Aug 2022 19:45:28 GMT

When 3D printing was first developed in the 1980’s, it was primarily used for a product’s proof of concept or initial prototypes. The limits of the technology and material did not allow one to use the process for field testing, or production. The past decade has seen a surge in 3D printing use. The rapid developments in 3D printing technology and materials has accelerated areas like product development, offer customized product, and eliminate design restrictions.

3D printing has streamlined the product development cycle in industries like die casting. The process is commonly used to test a working model for fit and function prior to die casting production. The technology helps die casters bypass costly and time-consuming aspects of creating and testing dies.

However, parts created through the process are susceptible to the same porosity that plagues those created through more traditional processes. The porosity is inherent to the properties of the material and technology. And, although it may not be fully eliminated within the 3D print process itself, it can be effectively sealed through vacuum impregnation.

This blog will discuss common materials, applications, and misconceptions related to impregnating 3D printed parts.

Common 3D Materials Vacuum Impregnation Seals

The two primary materials that vacuum impregnation seals are plastic and sintered metal.

Acrylonitrile butadiene styrene (ABS) and Nylon are the most commonly used plastic materials. ABS is ideal for low-cost prototyping, developing mechanical parts. Nylon is ideal for functional parts, complex models with intricate design, and assemblies.

Sintered metals are ideal for functional prototypes, and end-use parts. The material is also used for complex designs that cannot be machined by traditional machining methods.

Common Applications for Sealing 3D Printed Materials

The two common reasons why vacuum impregnation is used in 3D printing is to seal leak paths, and improve part integrity.

Seal Leak Paths
The laser, or nozzle, of the 3D printing machine creates a part by melting or fusing material, layer by layer. While a finished part is 98 – 99 percent dense, the process can leave a small number of micro-cavities within the part. This porosity is an almost unavoidable effect of the 3D printing process.

Certain applications require the part to be pressure tight, with 100 percent density. In order for parts to be pressure tight, the porosity needs to be sealed. If the porosity in 3D printed parts is not sealed, then fluids or gasses will leak. Vacuum impregnation seals the porosity within the part, allowing it to be pressure tight.

Improve Part Integrity
A 3D printed part is not as dense — and thus not as strong — as a part made from traditional manufacturing processes. Vacuum impregnation can be used to strengthen the material. As the vacuum impregnation sealant cures within the perforations, it creates a bond between the part layers (Figure 1). This strengthens the part by increasing the density.

Figure 1: The vacuum impregnation sealant will cure within the perforations, and strengthen the part by increasing the density.

Eliminate the Risk of Blooming
A common problem of 3D printed parts is blooming. The part features bloom, or swell as the layers absorb fluids. This risk of blooming is eliminated with vacuum impregnation. As previously written, the vacuum impregnation sealant cures within the perforations. After vacuum impregnation, fluids cannot be absorbed within the part's walls.

Misconceptions for Sealing 3D Printed Parts

The three most common misconceptions of applying vacuum impregnation to 3D printing are:

1. "Does vacuum impregnation remove build lines?"

Vacuum impregnation does not remove build lines (Figure 2). Build lines are a concern if the part is used for cosmetic purposes. Vacuum impregnation does not remove the build lines, because the process is done within the part’s walls and not above the surface.

Figure 2: Vacuum impregnation will not remove these build lines.

2. "Does vacuum impregnation seal surface defects?"

Vacuum impregnation only seals micro-porosity only within the part, and not visual defects on the part's surface (Figure 3). If applied to visual defects, then the sealant will not cure because there is little material for the sealant to adhere. Only the impregnation sealant that has been drawn into the walls by the force of the vacuum and pressure remains in the part.

Figure 3: Vacuum impregnation will not fill in these visual defects.

3. "Does vacuum impregnation increase part thickness?"

Because the process occurs subsurface, it does not add any thickness to the overall part dimensions. Impregnation allows engineers, designers and parts manufacturers complete freedom to design and make parts to their actual net shapes with no dimensional allowance to add or incorporate the impregnation process.

In Summary

3D printing is being used for more rigorous prototyping and even in certain production applications. This enables manufacturers to streamline the production process. Vacuum impregnation helps make this possible by making the 3D printed part pressure tight and improving its integrity.

Case Study: Tailored Solution to Seal Powder Metal Porosity

amarin@godfreywing.com (Andy Marin) — Thu, 30 Jun 2022 12:45:00 GMT

The increased use of turbochargers has become an important trend in car manufacturing. This trend has been driven by requirements to design smaller, more powerful engines that also reduce fuel consumption.

One example is a new powertrain from a global automotive component manufacturer. The company manufactures key turbocharger components through powder metallurgy, which produces precise and net-shaped parts.

But porosity is inherent to powder metallurgy. Any interconnecting porosity forms a leak path that will affect the part's structural integrity and performance. A common and effective way to address this issue is to seal powder metallurgy parts through vacuum impregnation.

The Challenge

The manufacturer expected an annual volume of 1.6 million parts with a leak rate specification of 215 psi for two minutes. Because of these stringent standards, the manufacturer determined that 100% of the parts would need to be sealed with an in-house vacuum impregnation system.

Vacuum impregnation is a proven technology for sealing leak paths; a technology that the manufacturer was well versed in. It used vacuum technology, including thermal cure sealants, to seal aluminum die castings in earlier programs.

However, upon testing, the manufacturer determined that using its established impregnation processes would create the following issues when sealing parts made with the powder metallurgy process:

Poor recovery—The thermal-cure sealant would bleed out because its viscosity is too thin to adhere to the powder metal leak paths.
Corrosion—The hot water used to seal die castings would cause its powder metal parts to corrode.

Based on these challenges, it was realized that a new impregnation process was needed.

The Solution

With engineering operations in Europe and manufacturing in Asia, the manufacturer needed a global partner with international resources and process development. The manufacturer turned to Godfrey & Wing, whose sealing technologies are trusted by OEMs worldwide.

The manufacturer met with Godfrey & Wing's European division to discuss their needs; they included an extensive review of their parts' pressure testing requirements, critical features, and production flow.

Godfrey & Wing explained its various impregnation processes sealants, This included how sealants' viscosity, adhesion, and properties vary, and how sealant selection allows a manufacturer to address their part's porosity. The manufacturer was unaware of the sealant variety. Having previously only used thermal-cure sealants for die castings, it assumed sealants were an interchangeable commodity.

Godfrey & Wing tested multiple processes and sealants to determine what would work best for the manufacturer’s needs. This research resulted in the following recommendations:

Dry Vacuum & Pressure (DVP) process—Demonstrated to be the most effective vacuum impregnation process in the world, DVP incorporates a fast, deep vacuum to evacuate air from the part's porosity. The system applies high pressure to allow the sealant to penetrate deep into the powder metallurgy walls.
95-1000AC sealant—This sealant is anaerobic, meaning it cures in the absence of air with no heat. This sealant will eliminate the risk of corrosion.
Lean-top loading system—Godfrey & Wing designed a lean-top loading vacuum impregnation system to accommodate the manufacturer’s production demand. The modular footprint of 104 square feet would allow the customer to integrate the system into their production easily. Its fixtures were designed to process 240 parts per cycle, enabling the customer to meet production demand while ensuring sealant is flushed from blind holes and critical features are protected.

The manufacturer agreed that the proposal seemed to offer a viable solution, but rigorous testing would be needed to prove its effectiveness. Godfrey & Wing processed 2,000 parts with a first time-through (FTT) rate of 99%. The results demonstrated that the DVP process and 95-1000AC sealed the leak paths. The customer concluded that the combination of sealant and process delivered superior outcomes compared to any other combination.

Godfrey & Wing built the system based on the research and results. Having a tailored system would allow the manufacturer to properly seal parts and maximize production.

The Results

Godfrey & Wing installed the equipment in the company’s production facility in China. Since the installation, the combination of the DVP impregnation process and anaerobic sealant has eliminated the company's challenges.

Improve recovery—Scrap caused by porosity has been eradicated. The equipment is delivering a First Time Through (FTT) rate of nearly 100%.
Eliminate corrosion and surface flaws—The anaerobic sealant has eliminated the risk of internal corrosion and surface flaws.
Capital Expense (CAPEX) recovery—Having a system tailored to its parts enabled the manufacturer a fast CAPEX recovery of less than 12 months.

In addition, the customer subsequently changed their prints and specifications to identify 95-1000AC as the exclusive and only sealant permitted for their parts.

In Summary

Growth for automotive turbochargers will continue due to stringent emission regulations and customer preferences. As this happens, manufacturers will continue to use vacuum impregnation to meet these standards and ensure product effectiveness. This manufacturer found great value in having a vacuum impregnation strategy tailored to meet its specific challenges of powder metallurgy. It can now effectively make long-lasting turbochargers that meet stringent standards.