• امروز Friday 21 Sep 2018
  • آوا رسیس

    Farsi/Persian (Iran)English (United Kingdom)

    Impregnation

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    What is Impregnation?


    The lexicological meaning of Impregnation is saturation. However, in the casting and metallurgy it means filling the emptied cracks and porosity of the parts with suitable filling material. In other words, it means saturation of porosity in the metal parts with suitable filling material to make it sealed and impermeable.

    Since the beginning of casting industry the micron-sized cracks and porosity has been one of the problems of the industry; this is more relevant when the metal parts are used for storage or duct for compressed fluids or gasses including valves and pipes, engine cylinders, and other automotive parts, body of pumps, different compressor parts, piping fittings, water counters, parts used in CNG, KPG industries etc.
    This problem emerges in the form of collection of materials inside the metal parts, formation of bubbles inside the parts, micron-sized oxidized layer especially in aluminum, zinc, bronze and manganese parts.

    For the purpose of removing these problems and assisting the state industries, Ava Rasis Chemicals Company decided to introduce the solution for fixation of this problems based on the most advanced technology and international standards as well as standard requirements of US Army and introduce it to the state industries.

    Advantages of the Solution:


    •    Elimination the need for renewal melting of metal;
    •    Making the produced parts competitive with the similar foreign ones by means of decreasing the production expenses and costs;
    •    Assurance of favorable results;
    •    Assurance of customer satisfaction;
    •    Saving in time;
    •    Faultless process and guaranteeing long service life of the parts;
    •    Acceleration of the new production and market development;
    •    Competition with the similar foreign goods and possibility of export;
    •    Decreasing the pollution by means of elimination the need for renewal metal melting and decrease of wastes;
    •    Decrease of fuel consumption and saving the national resources, expenses, energy and labor by elimination of renewal melting process;
    •    Decrease in pollution and fuel consumption by means of sealing the leakages from micron-sized cracks and porosity existing in fuel and energy transmission vessels;
    •    Promotion of physical and mechanical properties of parts by sealing the cracks and porosity which will result in shorter service life following vibration and strokes.

     

     

    Impregnation چیست؟


    Use of Most Advanced Global Technology in Removing the Defects of Parts:


    Some of the industries have a false understanding of this technology due to the fact that they have already used unsuitable and non-standard methods. We decided to eliminate such a misunderstanding by introduction of correct and standard methodology which entails the full guaranteeing of the products and their long service life.
    Since long ago, the saturation has been used in Iran but the used methodology has been incorrect and out of standard by using silicate resins and unsuitable machinery in absence of any standard method. Consequently, a false and unfavorable understanding has been formed in regard of impregnation in some of the industries and specialists.
    Due to use of unsuitable machinery and resins in the traditional method, the material could not penetrate the micron-sized cracks and porosity and impregnate them well. Therefore the physical, chemical and mechanical properties of parts impregnated by use of the traditional method will not significantly improve because the sodium silicate resin does not have the needed properties to enable it to impregnate the parts and improve their properties and, on the other hand, the resins are easily dissolved by other materials and substances.
    Unfortunately, due to use of false and non-standard methods, a misunderstanding has been formed about impregnation technology among the manufacturers and specialists.
    Presently, the developed countries use resin thermoset acid metacrilic and special machinery based on the most advanced methodology and standard requirements, e.g. standards applied by US Army for impregnation of the metals parts and this has led them to the most optimum results.
    Therefore, the specialists who used the new methodology and resin thermoset acid metacrilic instead of old resins are surprised of the favorable results they obtained from impregnation and use it with the maximum possible assurance. We suggest all manufacturers to use this methodology and enjoy the optimum results.


    The Necessity of Impregnation:


    As we stated earlier, we can outline several advantages for this methodology including decrease in fuel use and labor, decrease in environmental pollution, etc. But the important fact with the use of impregnation is increase in the service life of the parts without any leakage, their higher quality, lesser cost and acceleration in production process. As a result, as the produced parts are capable to compete with the similar foreign parts, it will result in prevention of importation of the similar goods because the advantage of most of the foreign parts is utilization of this new and advanced technology. Presently, the most of the manufactured parts pass through impregnation process and this process has been become as one of the essential parts of the production.
    The use of this technology seems to be more essential when the casting parts are used as vessels for compressed fluids like engine cylinders, different pump parts, compressors, valves, counters, fittings, etc.
    Therefore the most outstanding manufacturers in the world have launched some impregnation lines in their factories including BOEING, NISSAN, BMW, FORD, GENERAL MOTORS, BRITISH AEROSPACE, TOYOTA, etc.
    The use of impregnation technology seems inevitable if we decide to produce some parts capable to compete with the products of the said leading manufacturers.

    Quality, Guaranteed Economic Profit and More Competitive Cost Price:


    The chemical properties of the parts impregnated by use of this technology will not change and their physical and mechanical strength will be promoted due to filling of their cracks and porosity and their service life is increased considerably.
    The hidden porosities will result in leakage and cracks in the future following the stresses that the part is exposed. Therefore, despite the higher cost of the resins used for impregnation in this new methodology, as the used resin is in lower quantity the total resin costs is very low when compared with the renewal melting and the resulting economic profit justifies the initial cost of the impregnation.
    Also, in some cases, we can use the materials of lower quality instead of higher purity and more qualitative – hence most expensive – ingots if use this technology and can produce more qualitative products even by use of the relative less qualitative raw materials. This will also open our way to the global market.
    The economic profit of this technology is favorable in such a degree that the manufacturers, who became acquainted with this methodology, prefer to apply it into all parts before mounting.

    It should be also pointed out that the impregnation does not change the appearance of the parts and there is no different between the appearance of impregnated parts with the parts without application of this process.


    Uses:


    All micron-sized cracks and porosity of iron and non-iron alloys produced by use of die casting, sand casting, pressure casting, powder casting, forging, etc. are fully filled by use of impregnation process and become sealed against any probable leakage in the future.

     

     

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