In today’s fast-growing automotive landscape, vehicle manufacturers are focused on improving sustainability in ways that extend beyond electrification. Automakers are rethinking every aspect of vehicle design and production, including how to make internal combustion engines (ICE) more reliable, efficient, and environmentally responsible. As manufacturers look to balance performance with cost-effectiveness and sustainability, trusted processes such as vacuum impregnation have an increasing role to play.

At Godfrey & Wing, we deliver advanced vacuum impregnation solutions that eliminate porosity-related defects in critical ICE components. This process not only improves product quality but also contributes to sustainability by minimizing wasted materials and extending component lifespan.

Porosity Challenges in ICE Components

Vehicle manufacturers require optimal performance from every component in an internal combustion engine. Die cast parts like engine blocks, cylinder heads, transmissions, compressors, and powertrains must pass stringent quality testing to ensure they will perform as needed. Porosity—microscopic voids that result from the die casting process—can compromise these parts, leading to failures and costly rework.

Porosity is almost impossible to avoid during die casting due to variables such as molten material flow, pressure, trapped gases, and the presence of die release agents. For example, compressors are particularly vulnerable to porosity. These components are typically required to be pressure-tight up to 18 bar and operate at internal temperatures as high as 150 °C (302 °F). However, a single leak caused by undetected porosity can render the unit unusable. If a leak is discovered post-assembly, manufacturers face the costly option of disassembly and scrapping high-value, precision-matched components like seals and pistons.

Godfrey & Wing’s Vacuum Impregnation Solution

Godfrey & Wing’s vacuum impregnation technology is designed to prevent ICE component failures by sealing internal leak paths and voids before they lead to downstream issues. Using a specially formulated polymer capable of withstanding harsh chemical and thermal conditions, this process permanently seals porosity in molded and cast parts, allowing auto manufacturers to use components that would otherwise be scrapped.

The Vacuum Impregnation Process

The vacuum impregnation process follows these core steps:

  • Phase 1: Dry Vacuum. Preheated parts are placed in a sealed pressure vessel where a vacuum removes air from all internal voids.
  • Phase 2: Wet Vacuum. The sealant is introduced to the impregnation chamber while under vacuum to ensure deep penetration into any porosity.
  • Phase 3: Pressure. The vacuum is released, and pressure is applied to force the sealant into all voids and leak paths.
  • Phase 4: Recovery. Any excess sealant is returned to the holding tank for reuse, minimizing waste.
  • Phase 5: Wash/Rinse. To remove remaining sealant from the surface of the part and machined passageways, tapped holes, etc.
  • Phase 6: Cure. Parts are heated to 90°C, curing the sealant to form a permanent seal.

Vacuum Impregnation Benefits for ICE Components

Godfrey & Wing’s vacuum impregnation solutions deliver long-term reliability and performance for ICE components. Key benefits include:

  • Eliminates Porosity-Induced Leaks. The vacuum impregnation process eliminates voids and air gaps, reducing the risk of failure from leaks and thereby extending engine lifespan.
  • Improves Aesthetics. In addition to sealing porosity, vacuum impregnation can prevent cosmetic defects in powder coating. If not sealed, air in pores can expand and out gas during the curing phase. This air can escape through the powder, leading to unattractive holes and bubbles that can later cause moisture and corrosion damage.
  • Reduces Costly Scrap and Rework. Vacuum impregnation helps to decrease the rate of scrap and rework. This not only reduces waste but also lowers overall production costs.
  • Enhances Thermal Performance. By filling all voids, vacuum impregnation improves heat dissipation, allowing the engine to run cooler and with more efficiency.
  • Improves Overall Product Quality. This process enhances overall component quality and helps manufacturers meet rigorous customer and regulatory standards.

Automotive Vacuum Impregnation Solution from Godfrey & Wing

As a trusted partner for the world’s leading automotive OEMs, Godfrey & Wing brings unparalleled expertise to vacuum impregnation technology. With a strong understanding of repeatability, manufacturing, and sustainability, we can deliver high-performance solutions that meet the unique needs of the automotive industry.

By integrating Godfrey & Wing’s vacuum impregnation systems, automakers can reduce production costs and waste, streamline quality control, and enhance the safety and reliability of critical ICE components. To learn more about how our vacuum impregnation equipment and services can support your automotive application, contact us today.