GMNA - 9986539
Resin, Impregnation, Heat Cured (Catalyst Ultraseal DB42 with a 1.5 minute to 3 minute Resin Gel Time)
|Publication Date:||1 July 2017|
Note: The words must, shall or will as used in this document mean a mandatory requirement.
Material Description. This specification describes requirements and tests for a thermocure resin intended for the impregnation of porous metal castings and powdered metal components for transmission and engine applications. See 7.1.2.
Symbols. Not applicable.
Application Limit. Intended as a single application to components that do not initially pass final leak test due to porosity in the metal. Multiple applications, three (3) or more, of any sealant typically indicates large porosity. For engine blocks and transmissions usually up to two (2) impregnations are allowed. In stating this we assume the impregnation system is being operated within specification and operates a modern process - dry vacuum, correct vacuum level, good chemical control, etc.
Usage and Temperature Limits. After impregnation, under no circumstances should the continuous or excursion product temperatures of the material manufacturer be exceeded. This is a Class B product suitable for components operating in the continuous temperature range (see Table 1, Class B). Discuss with the resin supplier the nature and frequency of the excursions before making a selection. See Table 1. Do not confuse this with storage shelf life, 3.9.4.
Note 1: Excursion time at temperature is determined by the resin manufacturer. Consult with manufacturer regarding the specific application before selecting the product.
The product is applied after all heat treatments and before or after final machining.
This product is only intended to seal porosity and no other process defect.
Use of impregnation product is strictly a temporary measure to resolve a porosity condition. The condition limits, under which use is allowed, are defined in the Component Technical Specifications (CTS) or the Statement of Requirements (SOR) for the part or component. If no provisions are stated, no impregnation is permitted.
Precautions. Resin use is recommended only as a temporary preventative measure to fill porosity contributing to air or fluid leak(s) until a metal forming process solution to eliminate porosity leakage is satisfactorily completed. The long term durability of this impregnation product is not known because it is rarely used. GMW3155 testing of impregnated parts is highly recommended to assist in defining long term sealing performance.
Expired Product. Even if properly stored (see 3.9.4) do not use this product past its expiration or use before date. Do not contact GM Materials Engineering and request permission to use expired product.
This material is introduced into a clean and dry part by a vacuum and/or pressure process. It reaches a cured state with the addition of heat.
Air leakage of the part or component determines before and after if the impregnation process is suitable. Consult the Statement of Requirements or Component Technical Specifications for the part or component.
Resin discoloration may occur after impregnation. This is normal and shall not be cause for rejection of the component.
Normally pressure penetration testing (126.96.36.199) occurs on non-machined specimens, however, since machined parts are impregnated, the testing requires machined and etched surfaces.
For Aluminum Military (MIL) rings (see 188.8.131.52) order several thousand at a time. The alloy specified in the MIL specification is 99% aluminum, however 95% or higher is acceptable to manage cost. 1.4.6 For Iron MIL Type II rings order a small number as they are rarely used. The Ultraseal test ring produced by Oilite (Beemer) is acceptable. It is within the porosity limits defined by MIL (around 20%) and is suitable not just in a laboratory but also through an impregnation line.
Impregnation MIL Standard Limitations. MIL specifications listed in Section 2 are not maintained/updated. Just because an impregnant is on the MIL-I-17563C approval list doesn't mean it will pass the requirements in this document. MIL-I-17563C is a supply specification, meaning the approval is tied to the location of manufacture at the time of approval. Over time locations are added, move and equipment changes, so old approvals may not be relevant. A number of the referenced material specifications in MIL-I-17563C have been superseded resulting in considerable time finding specified materials or identify valid alternatives and requiring confirmation from Naval Sea Systems Command (NAVSEA) that the selected material is allowed. One or both of the materials needed for the environmental conditioning tests is not available and NAVSEA must supply the material. Our 998 ignores the MIL irrelevant parts, e.g., weight per gallon, etc., which are not in any way related to performance.