PRODUCT INNOVATIONS


the cleaned wash water in a closed loop system for reuse in further impregnation cycles. “Certain chemicals that are com-


monly discharged today will absolutely not be acceptable to discharge tomor- row,” said Bob Remler, vice president of sales, Ultraseal America. “In the 1970s, there was a saying that ‘dilu- tion is the solution to pollution.’ Tat concept is gone now.” Rexeal 100 updates Ultraseals’


original recyclable sealant, MX2, which has been used by Honda, BMW, Delphi, Hyundai, Sanden, Toyota, Valeo and VW. The new sealant is designed to have higher thermal resistance and greater hy- drophobic qualities and be easier to wash away after impregnation. The new sealant is suited to


impregnation of small batches as required, or Ultraseal’s front load- ing impregnation equipment can be incorporated into an automated


Rexeal 100 impregnating sealant, shown here in blue in a cross-section of a casting, has been devel- oped for components operating in temperatures between -58F and 428F.


production line for those who wish to impregnate all parts as a quality enhancement rather than on a selective basis. In tests determining the sealant’s


ability to withstand thermal cycling, aluminum test rings were impreg-


nated with Rexeal 100 and sub- jected to cycles of heat from -105F to 320F (-76C to 160C) at hourly intervals. At the end of the test, the rings were subjected to pressures of


290 psi and remained sealed. Visit www.ultraseal.co.uk for more information.


Hitachi Metals Reduces Marginal Blasting Costs by 33% Ductile iron caster Hitachi Met-


als Automotive Components USA LLC (HMAC), Lawrenceville, Pa., recently switched from W Abrasives’ S550 steel shot to the supplier’s HPG 6 material. Although the company was not experiencing any operational challenges within the blasting phase of its operations, switching to the new shot resulted in a 33% reduction in marginal blasting costs (including abrasives, common costs, management, manpower maintenance, spare parts, wear parts and energy), reaching tens of thousands of dol- lars in savings. HMAC is an


automotive casting facility with a manu- facturing/machining location in Wellsboro, Pa., and an addi- tional manufacturing/ machining plant in Effingham, Ill. Its product mix consists of safety suspension components and


brackets for customers like Ford, Chrys- ler, General Motors, BMW, Mazda, Nissan, Subaru, Mitsubishi, Honda, VW and others. HPG is a soft, high-carbon steel


Switching to the new shot


resulted in tens of thousands of dollars in savings.


46 | MODERN CASTING June 2011


grit with sharp, angular grains and narrow size distribution. With techni- cal support provided by W Abrasives, HMAC began an HPG 6 trial in one of its seven-wheel Disa blast- ing machines at its casting facility. W Abrasives technical experts analyzed the conditions of the machine, the operating mix, the efficiency of the process, the results achieved and the to- tal cost of the opera- tion. With the new high performance grit, HMAC found it could operate the machine with five wheels, shutting down the other two, and achieve better efficiency than with the S550 steel shot. In addition to the


HPG is a soft grit with angular grains and narrow size distribution.


shutdown of these two wheels, the life of each blasting wheel was extended by one week. “HMAC is an industry leader in


providing ductile iron safety critical castings to the automotive market, and our relationship with W Abrasives has enhanced that position,” said Robert Harter, vice president of manufacturing. Following the trial of HPG 6,


HMAC has fully converted one blast- ing machine to this operating mix and is in the process of introducing HPG


into its second blasting machine. Visit www.wabrasives.com for more information.


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