lighter alternatives, especially aluminium. This can be used onmany components, including drive and powertrain. The net result is that battery range is greater, and vehicles go further. However, during the die casting process,
ales of battery electric and hybrid vehicles are being driven by increased demand and the rapidly increasing availability of
EV-models. Automakers launched 143 new electric vehicles in 2019 (105 BEVs and 38 plug-in hybrids) and are accelerating their EV launch plans, partly to comply with increasingly stringent regulations in Europe and China. Based on current EV-model launch plans, by 2022 there will be over 500 different EVmodels available globally. Policymakers are pushing the auto market
towards lower emissions. Fuel economy regulations, quota systems and city policies all play a growing role. China, for example, has introduced New-Energy Vehicle (NEV) regulations, among others, to increase efficiency and reduce emissions. The UK has set a new goal of banning sales of conventional fossil fuel vehicle by 2030, and only allowing zero-emission vehicles from 2035. In addition, Arriva announced the first UK trial of its electric buses will take place later this year. A study by the Boston Consulting Group estimates that by 2030, the sale of electrified vehicles – including all versions of hybrids as well as all BEVs – will have 51%ofmarket share. Vehiclemanufacturers are understandably fully
focused on sustainability. This takes in many aspects beyond just the way their vehicles are powered. It’s about making all of their vehicles more efficient – and that means their internal combustion engines too. It also means looking at ways to increase the efficiencies within their operations, including the supply-chain and production. In each of these areas, vacuum impregnation, a long accepted technology in the automotive sector, has an increasing role to play.
Some 75%of fuel or energy consumption is directly correlated with weight, so the lighter the vehicle, themore efficient. Newmaterials are being explored, including composites and carbon- fibre, but while these are all predicted to grow, they’re far from proven or established just yet. Metal remains the material of choice. One of the main ways to achieve ‘lighter’ is
by using structural die cast components and replacing heavier metals such as steel with far
microscopic holes are formed in the metal, resulting in tiny imperfections (porosity) which can cause structural weaknesses. More commonly, it forms leak paths which could affect the functionality of the component, especially in applications that need to be pressure or fluid tight. A consequence of die casting, it ismore likely to be an issue with thinner walled castings. So, while die cast components offer big
opportunities to reduce weight, the potential risks need to be managed effectively. This has always been the case for internal combustion engines. In hybrid and electric vehicles, it’s especially so for such critical components as electronics, the powertrain or complex cooling systems. For the automotive industry, vacuum
impregnation is the accepted and OEM approved method for solving the problems of porosity in metal castings, sintered metal parts and electrical components.
With this, components are placed in an autoclave, a vacuumis applied, then after a period of time the components are immersed in sealant. The vacuum is used to draw the sealant into the micro-porosities and leak paths. This is then effectively sealed in a hot cure process which turns the liquid into a chemically and thermally resistant polymer. The result is amore reliable component, whatever themetal or its weight. Vacuumimpregnation therefore improves the
performance of components and helps contribute to lighter andmore efficient vehicles. But, it also makes a significant difference to operational efficiency in terms of scrap and waste. This is an issue in allmanufacturing, but in automotive – with the sheer volume and the pressures and complexities of supply-chains – it’s particularly acute. The cost of scrapping fullymachined parts is always expensive. However, if that part is used within an assembly which subsequently failed, the knock-on effect and costs aremagnified. At its extreme, this could affect brand
reputations. By eliminating the problems of porosity, manufacturers are helping improve component performance, reduce waste, enhance production efficiency and also protect their business. In the quest for zero waste and continuous improvement, vacuum impregnation has a clear and definite role. Another sustainable consideration relates to
wastewater and the use of chemicals, especially in the face of increasingly stringent environmental
legislation. In a traditional impregnation process, a cold wash is used to remove excess sealant. In fact, as much as 98% of the sealant disappears down the drain, along with water. State-of-the-art equipment, such as that
provided by Ultraseal International, a Quaker Houghton company, overcomes this problemwith recyclable sealants. Rather than being flushed away, these are collected fromthe wash tank and processed in a special sealant recycling system. In addition to using less sealant, the process also uses considerably less water. There’s also no need to change the wash-water
tank. These benefits reduce cost and downtime while contributing tomore sustainable production efficiency. For manufacturers with existing traditional impregnation technology, Ultraseal can oversee conversion, helping them reduce waste and comply with regulations.
Vacuum impregnation requires dedicated equipment, but the benefits it delivers are considerable. Ultraseal has a wide variety of equipment and can tailor a solution to suit the customers’ requirements, which could be delivered on or off site. In terms of equipment, the company’s front-
loading impregnation systems have a small footprint and deliver fast cycle times. They also offer best-in-class sealing performance and are ideal formanufacturers interested in establishing andmanaging their own impregnation plant. Where high volumes are required, the process
can be automated, reducing labour costs and operator involvement even further. Automated systems have fast, consistent cycle times, ensuring consistent output quality. Ultraseal even has the capability to monitor this equipment remotely, providing data and insight to help optimise system performance. Ultraseal can also offer a fully managed
on-site solution; and it has a global network of impregnation outlets, many based near major automotive manufacturing centres.
Manufacturers today need tomaximise the efficiency of internal combustion engines while ensuring electric vehicles are as light and efficient as possible – and all this with the additional pressures of driving sustainability into their operations. By adopting state-of-the-art impregnation technology from Ultraseal, they can take a small but significant step towards achieving all three objectives.
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