Customer Gains with Reduced Service Calls and Field Complaints

Arempee Compressors is a manufacturer of air compressors in India. They were using metallic gaskets to seal the valve plate assembly to cylinder head in top block assembly of the compressors. Metallic gaskets are conventionally used in high temperature conditions. However, metallic gaskets do not create 100% sealing between mating surfaces and are expensive. Arempee Compressors were receiving field complaints of air amd oil leakage. This required frequent visits by their service engineers to attend to the complaints. ]]>

CUSTOMER & END PRODUCT

• Arempee Compressors, India manufactures Air Compressors

SITUATION

• Metallic gaskets were used to seal the valve plate to cylinder head in top block assembly

• Field complaints of air & oil leakage after long running hours

• Inconsistent performance

LOCTITE® SOLUTIONS

• Loctite® 596 high temperature silicone gives 100% seal; resists to 315℃

• Compressor assembly tested for high pressure & temperature -> 40 bar @ 240℃

BENEFITS

• 100% sealing: fills voids and surface imperfections

• Withstands back pressure and temperature

• No field complaints – Savings on service cost!

• Lower cost of assembly -> 40% savings in gasket costs

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Makes Process More Reliable

AOD, India makes ophthalmic devices. The ophthalmic incision knife that they make has a SS blade that needs to be bonded on to PC handle. AOD was using a 2 Part epoxy for this process however it was time consuming and depended largely on operator skill. Customer wanted to increase production to 1.2 million units / annum and the process time with a 2-k epoxy was a constraint. Using a 2-k epoxy involved mixing both parts and was time consuming. The mixed epoxy also had limitations on pot life and resulted in wastages of mixed epoxy ]]>

CUSTOMER & END PRODUCT

• AOD, India makes ophthalmic devices

SITUATION

• The ophthalmic incision knife has SS blade to be bonded onto PC handle

• AOD was using a 2 Part epoxy

• This process was time consuming and depended largely on operator skill

• Customer wanted to increase production to 1.2 million units / annum

LOCTITE® SOLUTIONS

• Loctite® 3321 Medium viscosity Light cure adhesive

• Loctite® WWE 97017 Semi Automatic Reservoir & Controller + 98009 UV dispense valve + 7700 LED UV Light source

BENEFITS

• Loctite® 3321 cures in 10 seconds with bond strength of 6.5 kgf

• Automation with dispense & cure equipments – higher productivity, improved reliability

• Loctite® 3321 is ISO 10993 certified

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Withstands Autoclave Sterilization

Bio-Rad Medisys, India manufactures Urological & Gynecology catheters. Bio-Rad required to bond a variety cannulae (SS, PU & PVC) to hubs (ABS, Nylon & PVC). In some cases with a radial clearance of 0.2mm. They tried a competitive cyanoacrylate but it could not withstand autoclaving* process and de-bonded.]]>

CUSTOMER & END PRODUCT

• Bio-Rad Medisys, India manufactures Urological & Gynecology catheters

SITUATION

• Bio-Rad required to bond SS, PU & PVC cannulae to ABS, Nylon & PVC hub with a radial clearance of 0.2 mm

• Competitor’s cyanoacrylate could not withstand autoclaving and de-bonded

LOCTITE® SOLUTIONS

• Loctite® 4014 Instant Adhesive – specially developed for Medical Applications

BENEFITS

• Increased strength (from 2.1 kgf to 7.2 kgf)

• Joints withstand Autoclave process

• Medical grade adhesive conforms to ISO 10993 standards

Figure 1

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Clear Bond Line Enhances Component Aesthetics

Kasturi Machine Builders is a manufacturer of special purpose machines in India. Kasturi also assembles oil filters made of polycarbonate fo their machines. They were using a competitive cyanoacrylate to bond lower and upper casing parts of the filter – however, the casing was stress cracking and causing leaks. The cracked casings needed to be replaced - adding to their costs. Also the blooming caused by cyanoacrylate affected the aesthetic appearance of the transparent casing.

Strengthens Assembly, Prevents Moisture Ingress

Train bogie wheels are assembled utilising a heavy interference fit of 0.001” per inch of axle diameter, (typically 0.009” for a 9” diameter shaft). In addition, press-on tonnage of between 65-110 tonnes must be achieved and documented to ensure optimal assembly strength. This can be an extremely difficult task, and the consequences of poor assembly can be expensive or even catastrophic. Therefore if metal pick-up occurs during assembly, the components will be scrapped, and if the tonnage is not achieved within specification, the wheel and axle must be separated and re-matched.

Henkel Engineer Provides Solution after Analyzing Process Considerations

A multinational customer manufactures high voltage integral horse power motors of 150 to 3000 HP rating in India. Customer used a rtv silicoone sealant to seal the end shield of the motor. However, the seal failed to perform consistently and failed to withstand IP 65* tests. During a plant survey, Henkel Application Engineer analyzed that the operator takes close to 15 min to dispense the silicone on the flange area, by which time the silicone would have started to skin over this leads to insufficient bonding on the mating flanges and improper sealing.

Saves on Production Time and Costs, Boosts Productivity

Bright Burnishing Tools is a manufacturer of burnishing tools in India. They were using silver brazing process to join the tool shaft to the holder. The silver brazing material is expensive and the process needs very skilled operator and is time consuming. Additionally, the process involves heat and brazing flame that might bring safety concerns for the operators.

Outperforms Expensive Nyloc nuts, Maintains Clamp Loads under Severe Conditions

Nifty Lifts, Australia makes Hydraulic Lifts for forestry, mining and construction use. Base turn table of the lift holds boom & bucket and is subjected to severe vibrations, impacts & shear loads. 16mm structural bolts on the turn table loosened under these conditions. Nifty used nyloc nuts to prevent vibrational loosening of these bolts but even nyloc nuts failed to retain clamp load over long periods. Bolts had to be retorqued frequently; any premature failure can result in accidents.

Eliminates Shredding and Customer Complaints

A leading Indian OEM of electrical switchgear manufactures used PTFE tapes to seal the drain valve and plug threaded joints in their single-phase and three-phase electrical distribution transformers. However they received field complaints of leakage, shredding of PTFE tape & clogging.

Eliminates Need for Expensive Machining or Brazing

A leading tool manufacturer in Australia was launching new model of pliers for electronic components. Customer considered press fits or brazing the pliers hands to the jaw. They found that all these methods were undesirable. Press fit involved expensive machining to maintain very tight tolerances. Brazing needed expensive brazing machines, was very much dependant of operator skills and was expensive too.