Impregnation

The process is remove air from the voids of a casting (Porosity) and replace with a material
that will effectively seal the porous casting and enable it to retain fluids or gases under
pressure
To provide some clarity during purchasing a casting impregnation system, three factors must
be specified
1. What impregnation process is to be utilized
a. Dry vacuum and Pressure (DVP)
b. Dry vacuum (DV)
c. Wet vacuum and Pressure (WVP)
d. Wet vacuum (WV)
2. What manufacturing system is to be used:
a. Offline (Batch System)
b. Online (Continuous / Integrated)
3. What acylic sealant is to be used
a. Thermosetting
b. Thermosetting recyclabel
c. Anaerobic
Filled sodium silicate (Water Glass) sealants have been referred to as first generation
sealants.
First generation equipment
The steps in the process were generally:
1. Remove the air from the pores.
2. Fill the pores with liquid sealant.
3. Wash excess sealant from outer surfaces of
the parts (without removing sealant from
the pores).
4. Cure the sealant within the pores.

Second generation equipment:

The steps in the process were generally:
Pack part into baskets
Using an overhead crane, place baskets into pressure vessel, close lid and draw vacuum
Transfer sealant from reservoir to cover parts, release vacuum, apply pressure
Open lid, move parts to wash tank
Wash parts (Possibly two tanks)
Cure parts (generally heated water tanks)
Unpack parts from baskets

Dry vacuum systems resolved many of the shortcomings of batch technology by:
Continuous manufacturing environment
Reducing batch size
Automation
Use of recyclable sealants

Third Generation equipment:

Reduced the vacuum vessel size to accommodate casting only. It reduced volume of sealant

required for impregnation. Third Generation equipment, continuous flow impregnation was
made.
Processing parts in one at a time quantities vs batching parts has many significant
advantages
WET VACUUM/PRESSURE (VP)
This process method requires only one tank. Parts
are submerged in the sealant, which remains in
the process tank at all times.
Process Steps:
1. Place parts in process basket and load into
process tank.
2. Draw vacuum in process tank to remove air
from pores of parts.
3. Release vacuum and pressurize tank
with air.
4. Release pressure.
5. Remove parts. Wash and complete other
process steps.
VP processing is more common for production
processing of castings with very fine porosity and
for high density PM parts.

 WET VACUUM (V)

It is similar to the VP
method, except that the tank is not pressurized.
Instead, the tank is simply vented to atmosphere
after establishing the vacuum. Penetration of the
resin into the parts takes place at atmospheric
pressure. The resin flows in to fill the vacuum
created inside the porosity of the parts.
Wet vacuum impregnation is the most widely
used application method by far. The simplicity
and rapid processing, along with lower
equipment cost, make this the method of choice
in many impregnation system installations.

Process Steps:
1. Place parts in baskets and load into
process tank.
2. Draw vacuum in process tank to remove air
from pores of parts.
3. Release vacuum and vent tank to
atmospheric pressure.
4. Allow parts to soak briefly while sealant
penetrates.
5. Remove parts. Wash and complete other
process steps.
PRESSURE IMPREGNATION
used to treat parts
individually and can be a very effective way to
seal porosity in some situations. Typically, the
parts are not placed inside a tank. Instead, each
part is fixtured so it can be filled internally with
the liquid sealant. The sealant is then pressurized,

usually with compressed air, to force it to flow

through any porosity leaks. The part is then
drained, washed and processed further as in a
tank method.
Process Steps:
1. Position part in fixture and close all
open ports.
2. Fill part with liquid sealant.
3. Pressurize to force sealant through any
leaking pores.
4. Release pressure and drain liquid sealant
from part.
5. Remove part from fixture. Wash and
complete other process steps.
Pressure impregnation in a highly automated
system requires only seconds to process each part.

PROCESSING DETAILS FOR

HOT WATER CURING
Place the basket of parts into the hot water
cure tank and allow sufficient soaking time
for the sealant to cure within the parts. The
sealant will cure in four to 10 minutes at
90C (194F), but time must be allowed
for the parts to reach that temperature
throughout. Twenty minutes of soak time
in the hot water tank is usually sufficient.
Note: Parts must be allowed to cool after
removal from the hot water. They can be
leak tested as soon as they are cool. A
corrosion inhibitor can be added to the hot
water tank to provide protection for parts
that might rust or corrode easily.

CHRYSLER ENGINEERING STANDARD No: MS-9543

This standard covers the chemical, physical, source approval, and quality
control requirements for three types of organic resin impregnating material:
Class 1 - Aerobic/thermal cure, suitable for service temperatures up
to 300 degrees Fahrenheit (F) 149 degrees Celsius (C).
Class 3 - Aerobic/thermal cure, for use where air pollution
requirements apply. Suitable for service temperatures up to 300F
(149C).
Class 4 - Anaerobic/ion cure, suitable for service temperatures up
to 300F (149C).
MILITARY SPECIFICATION
MIL-I-17563C
IMPREGNANTS FOR CAST OR POWDER METAL COMPONENTS
Classification. The impregnants shall be of the following classes (see
6.7):
class 1 Class la class 2 class 3 Suitable for service temperatures up co 300 degrees

Fahrenheit (F) (149 degrees Celsius (C)).

Suitable for use on mortar shell castings up to 300F
(149C)
Suitable for service temperatures up to 500F (260C).
Suitable for use where air pollution requirements apply
and compatible with acrylic -nitrocellulose lacquer paint
system up to 300F (149C)
I NOTE: Classes 1, la, and 2 may or may not contain volatile photo1 chemically reactive solvents and should not be used where
air pollution requirements are enforced.
Material. Material meeting the requirements of this specification shall
be nonmetallic resins capable of being cured to a hard, dense structure which when
cured shall produce a solid seal throughout a casting containing 15 percent
porosity.
3.3 Volatility. The impregnant shall not contain inert liquids, nor react
to produce gaseous or liquid by-products, either alone or in contact with
materials present. The volatile content of class 3 sealant shall consist of
nonphotochemically reactive solvents. A nonphotochemically reactive solvent is
any solvent with an aggregate of not more than 20 percent of its total volume
composed of the chemical compounds classified below or which does not exceed any
of the following individual composition limitations, referred to the total volume
of solvent:
(a) A combination of hydrocarbons, alcohols, aldehydes, esters, ethers,
or ketones having an olefinic or cycloolefinic type of unsatura tion: 5 percent.
(b) A combination of aromatic compounds with eight or more carbon atoms
to the molecule except ethylbenzene: 8 percent.
(c) A combination of ethylbenzene, ketones having branched hydrocarbon
structures, trichloroethylene, or toluene: 20 percent.
3.4 Weieht loss. This material shall not exhibit a weight loss exceeding 3

percent nor a volume loss exceeding 10 percent after curing.

3.6 Pot life. When tested as specified in 4,3.1.1; the activated impregnant
shall have a pot life of not less than 1 month at 75 t 5F (24 f 2.8C) except fOr
anaerobic ion cured impregnants which shall have a pot life of not less than 1
month at 65 + 5F (8 I 2.8C).
3.7 storage life. Materials in unopened containers shall be usable and meet
the manufacturers original specification at the end of one year.
3.8 ~. The impregnant shall cure to a hard firm mass when in contact
with aluminum, copper, iron, magnesium, and zinc alloys (see -4.5.4.1). TIM cured
material sha

Reference:
Casting Impregnation for Light weight material www.godfreywing.com