Metal castings do not always guarantee perfect impermeability against gases and liquids.
During the casting process, micro-porosities—small cavities within the material—can form. These are often invisible to the naked eye and may only become apparent during subsequent machining processes.
To effectively and definitively resolve sealing issues in components, a technique called vacuum metal impregnation, performed in an autoclave, is used.
This process involves filling the micro-cavities in the casting with special resins, thereby sealing any internal porosities.
After impregnation, a series of thorough washes is carried out to ensure the complete removal of residues, such as silicate deposits, leaving the components perfectly clean.
In many cases, impregnation is an essential step in the production cycle of components.
At CO.ME.R, this operation is performed directly on-site, eliminating additional logistical transfers and providing significant advantages in terms of efficiency and process quality.

Technologies Used in the Impregnation Process

Comer employs advanced impregnation technologies in its facilities, utilizing different types of resins selected to meet the specific needs of each client.
Currently, the company has two separate systems, each optimized for the use of a particular type of resin.

The first system is based on the use of sodium silicate resins, known for their excellent sealing properties and widely used for specific industrial applications.
The second, recently introduced system uses methacrylate resins, recognized for their ability to penetrate micro-porosities and their greater flexibility in various production contexts.

Both processes require a rigorous sequence of operations, including:
● Careful loading of processing baskets, ensuring optimal arrangement of parts to guarantee uniform treatment.
● Impregnation phase under vacuum or controlled pressure, where resins are forced to penetrate the micro-cavities of the components.
● Thorough post-treatment inspection and cleaning of the parts, using specific washing cycles designed to remove silicate or methacrylate residues and ensure maximum component cleanliness.
● Continuous monitoring of process parameters, including resin viscosity and composition, as well as the quality and purity levels of the washing water.

The system dedicated to methacrylate resins is equipped with an innovative centrifuge integrated into the autoclave, a technological solution that allows for the recovery and reuse of part of the applied resin, reducing waste and improving operational efficiency.
This system also effectively removes excess product from treated components.
With over 30 years of experience in the mechanical industry, CO.ME.R. goes beyond standard impregnation process management, offering customized services such as the study and design of tailor-made processing baskets to optimize the treatment of high-volume components.
This personalized approach ensures maximum production efficiency, adapting to the specific needs of clients and their products.

Silicate Impregnation

The impregnation of metals or polymers with sodium silicate is a technique that allows the sealing of component micro-porosities, improving their resistance to gases and liquids.
This process utilizes a sodium silicate-based resin, which is made to penetrate cavities under vacuum or pressure.
Once the impregnation is complete, the parts undergo specific washing treatments to remove residues and ensure a clean, ready-to-use surface.
This treatment is ideal for applications requiring durability and cost-effectiveness, making it particularly suitable for components intended for industrial use.
The parts can be retested for sealing 24 hours after the process.

Methacrylate Impregnation

Methacrylate resin impregnation is an advanced technology used to permanently seal the micro-porosities of metal components.
This resin, known for its excellent fluidity and penetration capability, is applied under vacuum or pressure, ensuring optimal resistance to gases and liquids.
After the impregnation process, the parts undergo thorough washing to remove any residues, leaving a clean surface ready for further processing.
This method is particularly suitable for high-precision components, thanks to its ability to provide long-lasting and high-performance sealing.
The parts can be retested for sealing immediately after the process.