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Visitors to CastExpo 2016 keen on cost and environmental benefits

More foundries are exploring the benefits of using recycling porosity sealants in their post-casting processes – a trend that was apparent at CastExpo 2016 according to Ultraseal America.


They are turning away from using conventional (non-recycling) porosity sealants because modern recycling impregnation technology offers cost and environmental benefits that give them an edge in a competitive market.


Recycling impregnation technology uses less water, less chemicals and produces less waste water than conventional porosity sealants, while exceeding the first-time sealing rates of many conventional sealants.


Ultraseal America, a subsidiary of the UK-headquartered company, Ultraseal International, noticed an upsurge of serious interest in recycling technology when it exhibited at the show in Minneapolis, Minnesota, in April.


Stephen Hynes, Marketing Director of Ultraseal International, said: “Recycling sealants have become the sealant of choice in many markets, including the United States which in the past has been very conservative.


“Foundries and manufacturers are now seeing the advantages of turning to modern recycling equipment and sealants such as Rexeal 100™ as a solution to the problem of porosity in cast metal parts.”



Casting impregnation offers a reliable and permanent solution to the problem of porosity – microscopic holes in a cast metal part - creating a leak path and causing the part to leak. Automotive foundries and suppliers were among the first to adopt the process as a routine quality enhancement.


Ultraseal International has produced a revolutionary two-stage casting impregnation machine, the R-FL-Duplex Plus that is transforming casting impregnation. It works with recycling sealant, takes up a fraction of the floorspace of a conventional unit, and can process up to 45 units an hour.


Bob Remler, VP Sales, Ultraseal America Inc., said after CastExpo 2016: “Companies were very interested in Ultraseal’s recycling technology in general and the R-FL-Duplex Plus in particular because it produces so very little wastewater and can cut their costs.


“There was also a trend towards companies wanting to carry out casting impregnation in-house, rather than outsource it, in order to reduce their lead times and avoid transportation costs.


“They can also substantially reduce their own lead times by eliminating the need to truck parts off-site for processing.”


The R-FL-Duplex Plus casting impregnation machine has reduced the process to two stages – eliminating the drain and cold wash modules. Parts go straight from the autoclave to the hot cure tank. It uses Ultraseal’s global benchmark recycling sealant Rexeal 100™ and both the water and sealant are recycled from the hot cure tank to ensure that a fully closed loop system is achieved.  The process is fully automated and can run round the clock with minimal downtime.


Ultraseal International is a global leader in its field, with headquarters in Coventry, UK, Joint Ventures in India and China, an office in Japan, operations in the Germany and the United States and 22 agents/distributors around the world. It also has a range of jobshops and associated jobshops in Europe, the United States, China and India.


Visitors to CastExpo 2016 came from Canada, India, Mexico, Turkey, China and the UK as well as the United States.