Self Penetrating Sealers for Porosity Defect in Casting

Introduction

When it comes to metal-polymer systems that include products based on polymers as well as coatings, Diamant Triumph provides top class and innovative solutions for industrial use.

In the world of metal casting, achieving flawless, defect-free components is a major challenge. One of the most common and costly defects found in castings is porosity. Porosity in castings leads to reduced strength, poor surface finish, and leakage issues — all of which can compromise the performance and reliability of the final product. To overcome these challenges, industries today rely on self-penetrating sealers, and one of the most advanced solutions available is Dichtol.

What is Porosity in Casting

Porosity refers to small voids or air pockets trapped within the metal during the casting process. These can be caused by:

1. Gas entrapment during solidification
2. Shrinkage during cooling
3. Inadequate venting or mold design
4. Poor gating system or metal turbulence
5. While porosity may not always be visible to the naked eye, it significantly affects the integrity and performance of the part, particularly in pressure-tight or fluid-carrying components.

The Need for Sealing Porosity

When porosity exists in cast components, it allows air, oil, or water to pass through the microscopic holes. This not only causes leakage but also leads to corrosion and premature failure. Traditional mechanical repair methods like welding or impregnation with resins can be costly and time-consuming.

That’s where self-penetrating sealers come in. They provide an effective, fast, and economical solution to seal porosity — ensuring leak-tightness and enhanced durability without the need for high-pressure impregnation equipment.

The Advanced Self Penetrating Sealer

Dichtol is a high-performance self-penetrating polymer-based sealer designed to impregnate and seal porosity in metals, ceramics, and composites. It is manufactured by Diamant Metallplastic GmbH, a global leader in polymer systems for industrial applications.

Unlike traditional vacuum impregnation methods, Dichtol works through capillary action, meaning it penetrates deeply and seals micro-porosity without requiring pressure or vacuum systems.

How Dichtol Works

Dichtol utilizes low-viscosity polymers that flow into the finest capillaries and microscopic pores in cast materials. Once applied, it cures to form a tough, invisible, and permanent seal inside the pores, preventing any gas or fluid leakage.

The process is simple

Clean the surface – Remove contaminants like oil or dust.

Apply Dichtol – By brushing, dipping, or spraying.

Allow penetration – The sealer automatically seeps into pores through capillary action.

Cure – At room temperature or slightly elevated temperatures for complete sealing.

The result is a hermetically sealed casting ready for finishing, machining, or coating.

Key Features and Benefits of Dichtol

Self-Penetrating Action
No need for pressure or vacuum equipment — seals even the smallest pores automatically.

Room Temperature Application
Simple application by immersion, spraying, or brushing.

High Temperature Resistance
Withstands temperatures up to 250°C (depending on grade).

Chemical and Corrosion Resistance
Provides protection against water, oil, fuel, and other aggressive media.

Improves Coating and Painting Quality
Sealed surfaces result in better adhesion for paints, coatings, or plating.

Non-Dimensional Change
No alteration in component size, shape, or tolerance.

Environmentally Safe
Solvent-free and VOC-compliant options available.

Applications of Dichtol

• Dichtol is widely used across industries such as:
• Automotive – Sealing aluminum castings like engine blocks, gearboxes, and cylinder heads.
• Aerospace – For critical components requiring pressure-tight performance.
• Hydraulics & Pneumatics – To ensure leak-proof housings and valves.
• Foundries – For sealing die-ca
• Additive Manufacturing (3D Printing) – To seal porous 3D-printed metal or polymer parts.

Dichtol Variants

Dichtol is available in multiple formulations to meet different industrial needs:

Product Type Description Key Features
Dichtol WFT Water-thin sealer for fine porosity Fast-curing, solvent-free
Dichtol AM For Additive Manufacturing parts Seals 3D printed metal & polymer surfaces
Dichtol UMF Universal metal sealer Suitable for ferrous & non-ferrous metals
Dichtol HP High-performance, high-temp variant Thermal resistance up to 250°C
Dichtol CFS Colorless and food-safe Ideal for sanitary or food-grade applications
Why Choose Dichtol Over Conventional Impregnation?
Aspect Dichtol (Self-Penetrating) Vacuum Impregnation
Application Simple brushing, dipping, or spraying Requires vacuum chamber
Equipment No special tools needed High-cost equipment
Cycle Time Few minutes to complete Several hours
Dimensional Stability No change No change
Cost Efficiency Highly economical Expensive setup
Portability On-site application possible Not feasible on-site
Environmental and Safety Advantages

Dichtol products are environmentally friendly and user-safe. Many formulations are:

• Solvent-free
• VOC-reduced
• Non-flammable
• Compliant with RoHS and REACH standards
• This makes them suitable for use in sensitive environments, including food processing, medical, and marine applications.

Conclusion

Porosity defects in castings can seriously impact product quality and performance — but with Dichtol Self Penetrating Sealers, manufacturers can achieve reliable, cost-effective, and permanent sealing solutions. Whether it’s aluminum, cast iron, or 3D-printed components, Dichtol ensures leak-proof integrity, extended component life, and superior surface finishing.

If your manufacturing process involves cast metal parts and you face porosity-related challenges, Dichtol offers a proven solution — combining simplicity, efficiency, and durability.

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