Electric Vehicles (EVs)

A primary method manufacturers use for reducing the weight of an EV is to utilize die cast parts constructed of lighter metals. Aluminum has an impressive strength-to-weight ratio, so selecting this lightweight material over heavier alternatives like steel won’t mean sacrificing strength in powertrain, drive, or cooling system parts, for example. By reducing the weight of individual components and, by extension, the EV itself, manufacturers can enhance the battery range of their EVs so that the vehicles can travel greater distances.

However, microscopic holes develop within the metal material of a part during die casting, leaving behind small flaws. The chances of this porosity occurring increase for die cast parts with thinner walls. While porosity won’t always impact EV part performance, it may weaken a part’s overall structure. It can also lead to the formation of leak paths for liquids or gases. Porosity is a particular problem when an application requires pressure-tight parts.

For these reasons, EV manufacturers can use die cast components as an ideal solution for vehicle weight. However, they first have to address the risk of porosity to ensure high-quality, long-lasting parts.

Vacuum impregnation is an effective way to combat porosity and enable die casters to create lighter, thin-walled EV parts with confidence. This method has become increasingly common in recent years as the EV market has continued to expand.

The process uses liquid sealant under vacuum conditions to fill in any tiny holes resulting from the die casting process. Under heat, this sealant becomes a solid polymer with good thermal and chemical resistance. It eliminates any potential leak paths for pressurized gases or liquids, which not only enhances EV efficiency but also equates to cost savings as it reduces the need for manufacturers to scrap defective components.

At Godfrey & Wing, we design and manufacture our vacuum impregnation solutions to deliver better results, safer operations, enhanced control and efficiency, and simplified integration for our clients’ operations. Read our EV performance case study for a real-world example of our equipment and problem-solving skills in action.

Using our vacuum impregnation equipment, our customers benefit from the following:

• Reliably sealed leak paths. The sealant applied through vacuum impregnation will last for the full life cycle of a part, delivering lasting leak path prevention and protection against fluid leakage.
• Enhanced flexibility in EV part design. As discussed, die casters can create thinner-walled EV parts without having to worry about the negative effects of porosity. Also, the vacuum impregnation process doesn’t have any impact on the dimensions of a component because it doesn’t leave sealant remnants on the part surface. As such, design engineers don’t have to account for any changes to their design’s net shape.
• Corrosion prevention. Safeguarding against corrosion is important for EV components because degradation from galvanization or oxidation would limit their ability to carry current, potentially resulting in component failure. The process effectively seals the leak paths through which moisture and oxygen could otherwise escape.

At Godfrey & Wing, our team will work closely with you to help you find the ideal impregnation process and sealant variety for your unique needs. Our company has a proven track record in ICE sealing, and now we’re assisting our OEM clients in the EV market. We maintain a global network of vacuum impregnation service centers, strategic partners, and resources for your convenience. We also support your company’s environmental initiatives with compliant solutions, using non-toxic, eco-friendly sealants.

As the EV industry continues to evolve, so, too, will Godfrey & Wing’s porosity sealing solutions. Learn more about our innovative vacuum impregnation capabilities for reliable porosity sealing and contact our team today.