Tag Archive: Vacuum Impregnation

  1. Vacuum Impregnation for Electronics: How to Seal Components and Prevent Leaks

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    Modern EV architectures, industrial automation, and high-reliability aerospace assemblies depend on delicate circuitry that must operate flawlessly under aggressive moisture exposure and severe vibration. At Godfrey & Wing, we manufacture advanced vacuum impregnation equipment, specialized resin sealants, and processing lines engineered to seal internal voids across sensitive electronic applications. Learn more about the advantages of vacuum impregnation for electronics and how to implement effective strategies for sealing electronic components against environmental degradation.

    What Is Vacuum Impregnation in Electronics?

    The vacuum impregnation process seals internal air gaps, micro-porosities, and leak paths within electrical connectors, sensors, and power distribution modules. The process begins by pulling a deep vacuum to evacuate trapped air from internal voids.

    Once evacuated, liquid resin enters the chamber and penetrates microscopic voids. Positive pressure then drives the sealant deep into every internal cavity. Excess resin washes away from external surfaces before curing transforms liquid sealant into a permanent polymer barrier. Using vacuum impregnation with electronics establishes an internal seal without altering external dimensional tolerances or adding excess assembly weight.

    Why Electronics Require Sealing in Manufacturing

    Unsealed micro-porosities in cast housings, overmolded connectors, and terminal pins act as pathways for moisture, dust, and corrosive fluids. This can compromise the insulation’s electrical resistance. Uncontrolled moisture migration can also lead to oxidation in battery terminals and power modules.

    Preventing battery corrosion in electronics means using the right method to effectively seal leak pathways before fluid reaches active circuits. Thoroughly sealing electronic components preserves system integrity in the given operating environment.

    Three Reasons to Seal Electronics with Vacuum Impregnation

    Vacuum impregnation technology is used to seal electronics for several key reasons, including its ability to effectively seal leak paths, shield internal parts against moisture, and meet quality demands.

    Seal Leak Paths

    Overmolded parts and electrical winding systems can develop microscopic air gaps during cooling due to differing thermal expansion rates. Applying vacuum impregnation completely seals hidden leak paths to create a solid, uniform mass.

    Prevent Corrosion in Electronics Manufacturing

    Moisture that migrates through voids can accelerate wear and lead to premature failure in electronics. The vacuum impregnation process seals these voids to shield internal contacts from harsh automotive fluids, chemicals, and humidity.

    Support Quality and Design Flexibility

    Traditional insulation methods can add bulk to electronics or restrict compact layout designs. Utilizing a precise vacuum impregnation process provides robust environmental protection to seal internal leak paths without compromising on weight or space constraints, allowing engineers to maintain dimensional and layout requirements.

    Applications and Benefits of Vacuum Impregnation in Electronics

    Using vacuum impregnation supports effective sealing and reliability across critical electronics applications. Examples of its use cases and benefits are shown below:

    Application / Component Primary Failure Mode Addressed Core Benefit of Vacuum Impregnation
    Wire/Wire Harnesses Voids between stranded wires Seals leak paths
    Overmolded Connectors Pin-to-plastic leak paths sealing the pin-to-plastic leak path
    Power Inverters Thermal shock & condensation Enhances dielectric isolation and heat transfer
    EV Battery Enclosures Fluid/coolant leakage and moisture ingress Seals leak paths to prevent fluid ingress

     

    Advanced vacuum impregnation techniques like single-point impregnation can be used with specific sealants to fill air gaps without exposing sensitive components to full immersion.

    Vacuum Impregnation Solutions for Electronics from Godfrey & Wing

    At Godfrey & Wing, our team provides vacuum impregnation equipment and high-performance resin chemistries tailored to modern electronics manufacturing. Our vacuum impregnation systems integrate directly into assembly lines, delivering rapid cycle times and dependable processing.

    Contact our team today via our contact page to consult with an impregnation specialist about your specific application.

  2. How to Seal Die Casting Porosity?

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    Die casting is a metal casting process that involves injecting molten metal into a die using high pressure. Die casting facilitates the production of hundreds or thousands of pieces with high dimensional accuracy and a good surface finish, making it highly economical; however, maintaining quality and consistency at such high volumes comes with its own challenges. Manufacturers need to account for porosity, or the tendency for die castings to have voids or holes that cause surface-level flaws. Read on to learn more about die casting porosity, problems it can cause, and how vacuum impregnation seals die casting porosity.

    Die Casting Porosity

    What Is Die Casting Porosity?

    Die casting porosity refers to specific defects found within the casting. Two of the most common types of porosity in completed metal goods are gas porosity and shrinkage porosity. Gas porosity is often caused by trapped air or other gases during solidification. It is always buoyant, meaning the resulting bubbles are typically found near the top of the casting (as seen below).

    Shrink Porosity

    Shrinkage porosity, on the other hand, refers to internal voids that can form as the metal cools. This is because the solid metal volume is less than the volume of liquid metal at higher temperatures. Shrinkage porosity has a linear or jagged appearance and tends to occur in either the drag or cope portion of the casting (below the surface).

    Gas Porosity

    In addition to the above, having too much die lube can also contribute to porosity in die casting. While die lube is essential for removing cooled goods from the molds, too much can interfere with solid formation and create surface-level flaws. 

    Why Is Porosity a Problem?

    While porosity is inherent in die casting manufacturing, it can impact part performance, especially in applications where pressure integrity is a vital characteristic. Far from just being an aesthetic or durability problem, die-cast porosity can lead to early breakdowns or even failures. Consider the following examples: 

    Blind Porosity

    Blind porosity creates gaps that sit along the surface, pushing slightly into the interior but not creating uninterrupted passages for liquid to seep in. Manufacturers can expose blind porosity during the finishing stages. While it doesn’t make goods mechanically weaker, it does increase the risk of corrosion. The pores can also hold onto cleaning chemicals from powder coating or anodizing pre-treatments and then leach out after treatment, causing blemishes on the surface.

    Through Porosity

    Through porosity creates a leak path that runs through casting walls, or can be exposed after machining. This can weaken the metal and make it unsuitable for applications that require excellent pressure tightness, such as automotive and marine applications. Through porosity may make components weaker, create failure points, and prevent parts from reliably holding fluids.

    Fully Enclosed Porosity

    These pores are completely enclosed and don’t create leak paths. However, fully enclosed pores can become problematic if they’re exposed during surface finishing.

    Casting Sectioned Porosity Rev1

    How to Fix Die Casting Porosity

    Manufacturers can significantly reduce or completely eliminate failures due to die casting porosity with the right equipment and processes. One of the most effective methods is vacuum impregnation. With this controlled method, manufacturers use vacuuming and pressure to introduce the impregnating material into the voids, sealing the voids to make the casting fit for pressure-sensitive applications. 

    Benefits of using die casting vacuum impregnation include: 

    • A fast, cost-effective seal that doesn’t impact the component’s physical properties or functionality
    • No residual contamination or leaching

    Manufacturers can use vacuum impregnation for castings of any size, creating a permanent seal as well as a more consistent look, feel, and functionality in finished products.

    Why Godfrey & Wing Is the Trusted Solution for Die Casting Porosity

    At Godfrey & Wing, we specialize in closing the gaps left by die casting processes. Our equipment can provide fast, cost-efficient, and thorough vacuum impregnation processes to address porosity in die casting manufacturing. We’re committed to building systems that create effective, reliable seals that meet or exceed OEM requirements, and our team has decades of experience researching and improving solutions for die cast porosity. 

    Contact us today to learn more about our products and services.

  3. Preparing Parts for Vacuum Impregnation

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    When it comes to vacuum impregnation, it’s essential to ensure that the parts being impregnated are dry beforehand. This is because any surface impurities can interfere with the impregnation process, leading to subpar results.

    If any residual fluids or debris are on the parts prior to impregnation, then the following problems may occur.

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  4. Three Reasons to Seal Electronics with Vacuum Impregnation

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    Electronics play a crucial role in electric vehicles (EVs). In 2000 automobile electronics were responsible for 18 percent of the cost of a car. Twenty years later, electronics accounted for 40 percent of a car’s cost. The use of electronics will continue to meet fuel efficiency, safety regulations, and consumer standards. However, while the use of electronics will grow, manufacturers must ensure their parts’ quality, safety, and their bottom line’s integrity.

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  5. How Vacuum Impregnation Enables Lightweighting

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    Recent decades have seen a surge in the use of aluminum castings in car manufacturing. Aluminum has been a critical material in car manufacturing since the beginning. The first sports car featuring an aluminum body was unveiled at the Berlin International Motor Show in 1899. Carl Benz developed the first engine with aluminum parts two years later. Since then, aluminum has become the leading material used in various components and car models. Aluminum use now ranges from mass-market to luxury vehicles.  

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  6. Cost of Vacuum Impregnation

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    Manufacturers are constantly faced with either scrapping castings that leak or sealing the castings through vacuum impregnation. Some may perceive vacuum impregnation as a non-value added cost and assume it is less expensive to scrap die castings that leak. In this simplified yet real-world example, we will review the costs of die casting scrap compared to vacuum impregnation.
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  7. Vacuum Impregnation for Electronics: How to Seal Components and Prevent Leaks

    Comments Off on Vacuum Impregnation for Electronics: How to Seal Components and Prevent Leaks

    Modern EV architectures, industrial automation, and high-reliability aerospace assemblies depend on delicate circuitry that must operate flawlessly under aggressive moisture exposure and severe vibration. At Godfrey & Wing, we manufacture advanced vacuum impregnation equipment, specialized resin sealants, and processing lines engineered to seal internal voids across sensitive electronic applications. Learn more about the advantages of vacuum impregnation for electronics and how to implement effective strategies for sealing electronic components against environmental degradation.

    Wire Harness Vacuum Impregnation

    Image 1: The different materials in electronics contract at different rates causing porosity. Moisture or corrosive agents can seep into the porosity, causing a part to be ineffective.

    What Is Vacuum Impregnation in Electronics?

    The vacuum impregnation process seals internal air gaps, micro-porosities, and leak paths within electrical connectors, sensors, and power distribution modules. The process begins by pulling a deep vacuum to evacuate trapped air from internal voids.

    Once evacuated, liquid resin enters the chamber and penetrates microscopic voids. Positive pressure then drives the sealant deep into every internal cavity. Excess resin washes away from external surfaces before curing transforms liquid sealant into a permanent polymer barrier. Using vacuum impregnation with electronics establishes an internal seal without altering external dimensional tolerances or adding excess assembly weight.

    Seal Electronics Porosity

    Image 2: The image on the left is sealed through vacuum impregnation. The part is sealed since no air bubbles appear when submerged in water. The part on the right is not sealed since air bubbles (highlighted in red) appear.

    Why Electronics Require Sealing in Manufacturing

    Unsealed micro-porosities in cast housings, overmolded connectors, and terminal pins act as pathways for moisture, dust, and corrosive fluids. This can compromise the insulation’s electrical resistance. Uncontrolled moisture migration can also lead to oxidation in battery terminals and power modules.

    Preventing battery corrosion in electronics means using the right method to effectively seal leak pathways before fluid reaches active circuits. Thoroughly sealing electronic components preserves system integrity in the given operating environment.

    Three Reasons to Seal Electronics with Vacuum Impregnation

    Vacuum impregnation technology is used to seal electronics for several key reasons, including its ability to effectively seal leak paths, shield internal parts against moisture, and meet quality demands.

    Seal Leak Paths

    Overmolded parts and electrical winding systems can develop microscopic air gaps during cooling due to differing thermal expansion rates. Applying vacuum impregnation completely seals hidden leak paths to create a solid, uniform mass.

    Prevent Corrosion in Electronics Manufacturing

    Moisture that migrates through voids can accelerate wear and lead to premature failure in electronics. The vacuum impregnation process seals these voids to shield internal contacts from harsh automotive fluids, chemicals, and humidity.

    Support Quality and Design Flexibility

    Traditional insulation methods can add bulk to electronics or restrict compact layout designs. Utilizing a precise vacuum impregnation process provides robust environmental protection to seal internal leak paths without compromising on weight or space constraints, allowing engineers to maintain dimensional and layout requirements.

    Applications and Benefits of Vacuum Impregnation in Electronics

    Using vacuum impregnation supports effective sealing and reliability across critical electronics applications. Examples of its use cases and benefits are shown below:

    Application / Component Primary Failure Mode Addressed Core Benefit of Vacuum Impregnation
    Wire/Wire Harnesses Voids between stranded wires Seals leak paths
    Overmolded Connectors Pin-to-plastic leak paths sealing the pin-to-plastic leak path
    Power Inverters Thermal shock & condensation Enhances dielectric isolation and heat transfer
    EV Battery Enclosures Fluid/coolant leakage and moisture ingress Seals leak paths to prevent fluid ingress

    Advanced vacuum impregnation techniques like single-point impregnation can be used with specific sealants to fill air gaps without exposing sensitive components to full immersion.

    Electronics Fixture

    Image 3: Fixtures enable a large amount of parts to be sealed at the same time.  This allows companies the benefit of economies of scale.

    Vacuum Impregnation Solutions for Electronics from Godfrey & Wing

    At Godfrey & Wing, our team provides vacuum impregnation equipment and high-performance resin chemistries tailored to modern electronics manufacturing. Our vacuum impregnation systems integrate directly into assembly lines, delivering rapid cycle times and dependable processing.

    Contact our team today via our contact page to consult with an impregnation specialist about your specific application.

    Guide to Seal Electronics

  8. How Vacuum Impregnation Supports Environmental Responsibility

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    Automotive manufacturers realize that being environmentally responsible and profitable are not mutually exclusive. Being environmentally responsible can achieve better growth, cost savings, improve brand recognition, and increase profitability. The environmental impact of the responsible use of resources is beneficial to everyone, and automotive manufacturers play a leading role.

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  9. Correcting Three Vacuum Impregnation Myths

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    In some die casting applications, components must also be pressure-tight to hold pressurized fluid or gases. Companies use vacuum impregnation to meet these requirements by sealing the internal leak paths caused by interconnected porosity.

    Misconceptions and lack of information about the vacuum impregnation process can hinder its implementation, which may increase unforeseen costs and negatively impact part quality. This piece demystifies vacuum impregnation by correcting three common myths.

    Myth: Vacuum Impregnation is a CoatingFact: The process occurs subsurface, with no residual sealant remaining on the part’s surfaces, machine features, blind holes, and taps. Only the sealant drawn into the leak path by the force of the vacuum and pressure remains in the casting.

    Vacuum Impregnation Not a Coating

    Myth: Vacuum Impregnation Causes Dimensional Changes to CastingsFact: Vacuum impregnation does not change the casting’s dimensions, thus allowing engineers the freedom to design and make parts to the net shapes. Since the vacuum impregnation process occurs subsurface, an engineer does not need to incorporate dimensional allowance.

    Vacuum Impregnation No Dimensional Changes

    Myth: Vacuum Impregnation is a Cork or PlugFact: Vacuum impregnation seals porosity deep within the leak path; it is not a cork or plug. In the case of visible or open porosity, low viscosity sealants will most likely be washed out of pits or holes. Thus, a casting with surface porosity or blemishes before the process will exhibit the same surface porosity and blemishes after the process. However, the leak path below the part’s surface is fully sealed.

    Vacuum Impregnation Seals Porosity

    In Summary A clear understanding of how vacuum impregnation works can help companies maximize their production results. As the preferred method to prevent fluids or gases from leaking under pressure, the vacuum impregnation process seals casting porosity that forms during manufacturing. When done properly, the casting will function so that fluids or gasses will flow only where needed while physical characteristics, simply stated, will not be different in any manner. Vacuum impregnation helps manufacturers decrease the rate of scrapped parts, increase productivity, and ultimately increase their profitability.

  10. Can Vacuum Impregnation Seal Cracks?

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    In some die casting applications, components must also be pressure-tight to hold pressurized fluid or gases. Companies use vacuum impregnation to meet these requirements by sealing the internal leak paths without impacting any other features of the casting. A commonly asked question is in addition to leak paths, can vacuum impregnation seal cracks?

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