HEAVY DUTY SEALING SOLUTIONS

Transcription

1 HEAVY DUTY SEALING SOLUTIONS

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3 WHERE CAN WE FIND HEAVY DUTY APPLICATIONS Trucks Power Generation Equipment Agricultural Machinery Transport - Bus & Coach Construction Machinery (e.g. Demolition and Scrap etc.) Marine Applications Military Applications Mining & Quarrying / Forestry Equipment Rail Applications Recreational Vehicles Materials Handling Equipment (eg. Fork Lifts, Crain's etc.)

4 WHERE CAN WE FIND SOFT FLAT GASKETS IN HEAVY DUTY APPLICATIONS Air Cleaner Gasket Distributor Gasket Valve Cover Gasket Water Outlet Gasket Timing Cover Gasket Water Pump Mounting Gasket Water Pump Cover Gasket Fuel Pump Gasket Oil Pan Gasket Oil Pump Gasket

5 WHERE CAN WE FIND SOFT FLAT GASKETS IN HEAVY DUTY APPLICATIONS Disc Mowers Carter flat flange gasket

6 PRODUCT CONSTRUCTION CHARACTERISTICS FOR FLAT GASKETS MATERIAL CHARACTERISTICS ALLOWS FOR SINGLE THICKNESS AND NESTING SOLUTIONS. ADHESIVE BACKING FOR FAST ASSEMBLY IS OPTIONAL DIE CUT Sheets Frame Sheets Splitted Roll Sheets Frame sheets BLOCKS ROLLS MOULDED FRAMES FORMULATED COMPOUND

7 PRODUCT RANGE FOR FLAT PRODUCTS TechSeal products are designed to withstand the application needs, while providing our customers with manufacturing options that will assure it s profitability. TS1400 (Nitrile - NBR) TS1800 (Nitrile - NBR) TS1308 (Nitrile - NBR) TS7100 (Nitrile - NBR) TS7110 (Epichlorohydrin - ECO) TS7000 (Silicone - VMQ) TS1711 (Hypalon - CSM)

8 PRODUCT RANGE FOR FLAT PRODUCTS Recomended service conditions regarding temperature and sealing stress are represented in the graph above.

9 PRODUCT RANGE 3D PRODUCTS TechSeal 3D products cover a wide range of diverse applications. A099 (Silicone - VMQ) Up to 170ºC A041 (Nitrile - NBR) Up to 125ºC

10 LOAD TO SEAL TechSeal products typically require a low load to seal value which suggests that economical hardware designs can be used instead of structured and tight tolerance surface finishes. Load to Seal The Diferential in load to seal leads to hardware gains such as optimized hardware design, including lower grade or smaller size fasteners. Lower torques also benefit lower distortion issues, and safer fastener working ranges. Costly hardware required when designing with competitive materials can be replaced with TechSeal products and more efficient designs (TechSeal needs less than ¼ of load to seal than fiber materials). 0 Fiber Material TechSeal

11 LOAD TO SEAL A key advantage of our products in the application is conformability to flange distortion. TechSeal products have fewer and lower stress peaks due to a more uniform load distribution as well as a greater contact area, therefore proving the better conformability. This fact is one of the reasons that explains the lower load to seal seen with our products. Dynamic stress images taken with Tekscan stress sensors on a hardware flange with a distortion of 0.1mm between bolt spans. Competitor materials have difficulty in accomodating the distortion and consequently decrease the sealing stress between the bolt span. TechSeal Medium Density Fiber

12 LOAD TO SEAL High load to seal materials such as fibers, impact hardware distortion upon assembly due to their impossibility to flow and the need for higher loads (torques). On plastic covers, because of their strength, excessive distortion can lead to fracture of the hardware and failure of the entire sub-system. FEA distortion images of a PA66 plastic cover simulated with TechSeal and a medium density fiber. Warmer colours indicate increased distortion. TechSeal Medium Density Fiber

13 CRUSH OUT Embossments in the flange hardware, are typical hardware solutions for fiber sealing systems used to increase stress due to the high load to seal of these materials. Due to TechSeal s low side flow, the crush-out loads are well above the recommended materials application loads, ensuring that this failure mode does not happen. COMPRESSIVE STRENGTH Concentrated loads under bolt heads are common in bolted joints. TechSeal products have a compressive strength that exceeds 70MPa (10000 psi), distributing concentrated loads to areas with lower stress levels.

14 ENGINE ENVIRONMENT FLUID TRENDS GASOLINE DIESEL CNG LNG LPG METHANOL MTBE ETHANOL ETBE BIODIESEL Methyl E./Ethyl E. < Sulphur Content < PM Oxygenation min. 2% MTBE < Sulphur Content < PM M85 E5 Ex E85 E Diesel B20 Bx B100 CNG LNG LPG HYDROGEN (Fuel Cells)

15 ENGINE ENVIRONMENT FUEL SYSTEM Low Sulphur Diesel Biodiesel & Blends ENGINE Sub-Systems COOLING SYSTEM MEG OAT Coolant MEG Regular Coolant MPG Coolant LUBRICATION SYSTEM Mineral Engine Oil Synthetic Engine Oil Mineral Gear Oil Hydraulic Fluids

16 CHEMICAL RESISTANCE OF FLAT PRODUCTS TS1400 TS1308 TS1800 TS7100 TS7110 TS7000 TS1711 B-100 Bio-Diesel Suitable Suitable Suitable Acceptable Suitable Unsuitable Unsuitable Diesel (low sulfur) Suitable Suitable Suitable Suitable Suitable Unsuitable Unsuitable Engine oil (15W40) Suitable Suitable Suitable Suitable Suitable Suitable Suitable Gear oil (75W90) Suitable Suitable Suitable Suitable Suitable Suitable Suitable Hydraulic Fluids Suitable Suitable Suitable Suitable Suitable Suitable Suitable MEG Coolant Suitable Suitable Suitable Unsuitable Suitable Suitable Unsuitable OAT Coolant Suitable Suitable Suitable Unsuitable Suitable Suitable Unsuitable PEG Coolant Suitable Suitable Suitable Unsuitable Suitable Suitable Unsuitable Our product range is suited to the application environment conditions where contact with engine oil, Bio-Diesel & blends are required.

17 CHEMICAL RESISTANCE OF 3D PRODUCTS A099 A041 B-100 Bio-Diesel Unsuitable Suitable Diesel (low sulfur) Unsuitable Suitable Engine oil (15W40) Suitable Suitable Gear oil (75W90) Suitable Suitable Hydraulic Fluids Suitable Suitable MEG Coolant Suitable Suitable OAT Coolant Suitable Suitable PEG Coolant Suitable Suitable Our product range is suited to the application environment conditions where contact with engine oil, Bio-Diesel & blends are required.

18 CASE STUDIES

19 CASE I Perkins Oil Pump The oil pump has two gaskets of different sizes. A bigger gasket at the oil intake pipe (#1), which is torqued with two 5/16 bolts (27 N.m), and a smaller gasket (#2) is located in the outlet of the oil pump, which is torqued with two 1/4 bolts (13.8 N.m). A short but severe thermal cycle test performed on the fibre gasket vs. the TS1400 gasket, +130ºC, 2h -40ºC, total 120 hours with 15W40 mineral oil pressurized to 60PSI internal pressure 2 1 Oil Pump Assembly Oil Pump Assembly Gasket Location Oil Pump Assembly in Thermal Cycle

20 CASE I Perkins Oil Pump Fibre Gasket 1 After 24 hours testing, the fibre gaskets presented an oil film on the graphite side. Some adhesion was noticed on the non-graphite side. 2 TS1400 Gasket 1 2 After 120hours of testing both gaskets presented no leakage, with low adhesion to the flanges

21 CASE II Perkins Rear Oil Seal Housing The hardware in question had a critical stress riser configuration that could promote crush-out on certain materials. The stress riser all round the flange compresses the material to 70%. Torque is applied through 12xM8 bolts (25 N.m) and 2xM5 bolts (6 N.m). Testing composed of a vibration conditioning in two planes (4 hours; 2,55g axial,4 hours; 4,95g transverse), preceded by a thermal cycle in air +130ºC, 2h ramp, -40ºC for 72 hours. Gaskets assembled : 0.8mm Rear Oil Seal Housing

22 CASE II Perkins Rear Oil Seal Housing Rear oil seal housing in axial and transverse vibration test TS1400 with stress riser imprints but no splitting

23 CASE III Oil Pan Stamped steel pan with 20x 5/16 bolts (torqued to 20N.m) and high hardware distortion. A 1,6mm thick TS1400 gasket was proposed. Critical characteristics considered was hardware distortion promoting leakage and localized crush-out. The short thermal cycle testing was composed of, ºC, 2 hours ramp, 2 -40ºC, for a total of 50 hours TS1400 Gasket Oil Pan Assembly Gasket sample after thermal cycle testing TS1400 showed some adhesion to the pan due to the pan coating (paint) but no adhesion to the metal plate. No leakage was verified.

24 CASE IV Rocker Cover SUBSTITUTION OF ALUMINIUM ROCKER COVER SEALED WITH A VITON O-RING SISU Fortius Series 3 Cylinder Diesel Engine Rocker Cover SISU Fortius Series 4 Cylinder Diesel Engine Rocker Cover SISU Citius Series 3 Cylinder Diesel Engine Rocker Cover SISU Citius Series 4 Cylinder Diesel Engine Rocker Cover

25 CASE IV Rocker Cover ROCKER COVER FLATNESS MEASUREMENT ROCKER COVER DISTORTION MEASUREMENT ROCKER GROOVE DEPTH MEASUREMENT STRESS MAPPING VOID / VOLUME CONSIDERATIONS The proposed gasket section permits a gain in % compression overcoming the hardware distortion and compensating for groove tolerance. Specially designed pads for assembly purposes

26 CASE IV Rocker Cover FEA Analysis

27 CASE IV Rocker Cover Validation Testing Validation Thermal Cycle test, static soak 2h ramp, total 1000h. Dynamic Stress measurement (Tekscan). Dynamic Stress Measurement

28 ENVIRONMENTAL RESPONSABILITY

29 ENVIRONMENTAL RESPONSABILITY TechSeal products ensure conformity with all present regulations for hazardous substances. TechSeal products are free of: ASBESTOS HEAVY METALS (Pb, Cd, Hg and Cr(VI)) POLYCYCLIC AROMATIC HYDROCARBONS (PAH) Several Amorim Divisions are FSC (Forest Stewardship Council) certified. Recent studies in the Iberian Peninsula state that cork oak forest contributes with more than 20 Millions tons of CO 2 sequestration, making it a significant world resource for the environmental balance. Each time cork is harvested, cork bark regenerates itself. Cork oak trees store CO 2 in order to regenerate, and therefore a harvested cork oak tree absorbs 3 to 5 times more than one which is not harvested, thus benefiting the atmosphere. CORK OAK LIFE CYCLE

30 COMUNICATION & TOOLS

31 COMMUNICATION & TOOLS

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