Specialty gaskets: Metaloseal —metal-elastomer—elastomer. · Temperature up to 350°C Spring steel Resin-stabilized NBR ... (macro sealing) • Adaptation to component roughness

Specialty gaskets:

Metaloseal®—metal-elastomer—elastomer.

Extremely versatile, extremely robust.

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1117_SD_Broschuere_GB_ro.qxd 31.08.2007 17:44 Uhr Seite 1

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4 | At a glance

Metaloseal® specialty gaskets

6 | The sealing system without compromises

7 | Systems expertise

8 | Metaloseal® exhaust gaskets

12 | Metaloseal® for oil, coolant, and fuel systems

Metal-elastomer and elastomer specialty gaskets

14 | Maximum performance—safe and reliable

16 | Examples of uses

20 | Materials expertise

Canada Leamington | USA Livonia · Branchburg | Mexico Toluca | Brazil Piracicaba | Germany Dettingen/Erms · Langenzenn · Runk

Spain Reus | Italy Mazzo di Rho | South Africa Johannesburg | People’s Republic of Chi

ElringKlinger—present in automoti ve m

Cylinder head gaskets Specialty gaskets Transmission

applications

Shielding systemsHousing modules Topographic housing

components


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nzenn · Runkel · Bietigheim-Bissingen · Heidenheim/Brenz · Idstein · Rottenburg/Neckar | Great Britain Redcar · Gateshead

public of China Changchun | South Korea Changwon | Japan Tokyo | India Ranjangaon

moti ve markets throughout the world.

Bipolar plates

for fuel cells

mission

ations

Engine measuring

and testing services

PTFE componentsOriginal

Elring spare parts

Experience mobility—Drive the future:The ElringKlinger group of companies.

ElringKlinger—innovative development partner and series supplier to the

international automotive industry and other industries. We think ahead

and take on responsibility. For more sustainability and environmental

compatibility. Today and tomorrow.

Our trendsetting technologies and sophisticated product solutions con-

tribute to further reduce fuel consumption and emissions, and enable the

use of alternative fuels and the development of new drive technologies.

With comprehensive engineering and production expertise, we allow more

freedom of design for engines, transmissions, exhaust systems, and aux-

iliary aggregates. Together with our customers, we successfully promote

new technologies. To this end, we have around 3,400 employees working

at 21 locations throughout the world.


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At a glance: Specialty gaskets for engine, transmission, and exhaust system.

Reliable from -40°C to +1100°C.


5

Modern sealing systems accomplish a great deal: They guarantee a reliable

sealing of various media (oil, coolant, fuels, fuel gases) both from the out-

side as well as in relation to each other. Furthermore, they act as power

transmission elements between engine components while performing sig-

nificant additional functions.

With Metaloseal® specialty gaskets as well as metal-elastomer and elas-

tomer specialty gaskets, ElringKlinger provides suitable product solutions

for a variety of sealing tasks in the engine, transmission, exhaust system,

and auxiliary aggregates, e.g., compressors and pumps. Materials and

design are matched optimally to the specific requirements.


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A highly efficient sealing system based on elastomer-coated and uncoated

metal carrier materials. The functional principle: line sealing by means of

a bead.

One of its greatest advantages is the ability to combine different metals

with various types of elastomer depending on the application location. The

additionally coined beads can be used to optimally match the properties

of the carrier material to the sealing system. The beads reduce the seal-

ing pressure to a line compression. This helps achieve higher sealing

pressures at constant bolt force, or vice versa a lower bolt force is used

at constant sealing pressures.

The variety of combinations between metallic carrier materials and elas-

tomer materials can cover almost all application locations in engine, trans-

mission, exhaust system, and auxiliary aggregates.

Furthermore, Metaloseal® gaskets can perform additional functions. Thus,

for example, oil baffles or sensors can be

integrated for even more efficient engine

management.

Elastomer-coated Metaloseal®

gasket for the engine/pressure

oil, and compressed air systems.

Metaloseal® multi-layer gasket

for exhaust systems.

Partially coated Metaloseal®

gasket for exhaust recirculation

systems.

Transmission cover gasket

with partial coating.

Met

the

SCR

exh

Metaloseal® sealing systems

can be matched exactly to the

respective requirement profile

due to the variable combination

of the parameters of metal

carriers, coating, and bead.

Full bead

Metal carrier

Coating

Metaloseal® specialty gaskets.The sealing system without compromises.


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Systems expertise.Welcome to the future.

Thermal change test by using

transmission control plates.

Dynamic hot gas test bench.

Metal/soft material

gasket for automatic

transmissions.

Metal gasket with partial

elastomer coating for automatic

transmissions.

Metaloseal® gaskets and

thermal shielding part for

SCR injection systems for

exhaust aftertreatment.

FEM analysis of a distortion

system (engine components,

gasket, bolts).

Testing fatigue strength of

the beads on a servohydraulic

system.

0

Sealing force [N/mm]

0 100 200 300 400 500

100

200

300

Sealing gap [μm]

Elasticity behavior of

Metaloseal® gaskets in

the sealing gap.

FEM analyses and state-of-the-art testing and simulation techniques help

us ensure the readiness of our Metaloseal® sealing systems for series pro-

duction as early as in the prototype phase. Engineering in close coopera-

tion with our customers. Fast, reliable, and economical.

For us, systems expertise also means working consistently on new mate-

rials, technologies, designs, and applications. For innovative product solu-

tions. For the sealing tasks of tomorrow.

Dynamic hot gas test bench

Dynamic hot gas testing of exhaust system components under realistic

conditions.

Test bench componentsReverse bending test bench

Biaxial test bench horizontal and vertical axis

Max. force amplitude 15 kN

Max. half-wave amplitude 150 mm

Hot gas burner

Number of burners 2

Gas temperatures 250 – 1100°C

Max. counter pressure 1 bar

Volume flow rate 300 – 750 kg/h


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Car manufacturers and automotive suppliers are confronted with new and

complex challenges in the form of the increasingly strict emission limit

values worldwide. The resulting downsizing programs and exhaust

aftertreatment systems set partly new and demanding general conditions,

especially for sealing technology. Thus, high requirements are placed

especially on the leak tightness of exhaust systems. In the Metaloseal®

technology, the use of heat-resistant carrier materials and coatings has

optimized the sealing function and also provided the basis for reliably

mastering critical boundary conditions.

Metaloseal® exhaust gaskets by ElringKlinger reliably meet the require-

ments of both modern and future exhaust systems. They effectively per-

form sealing and durability functions under the most difficult operating

conditions. For maximum reliability.

Metaloseal® exhaust gaskets. For maximum thermo-mechanical stress. Reliable up to 1100°C.

Two-layer exhaust gasket to

absorb sliding movements

between cylinder head and

exhaust manifold.

Mu

for

Exhaust pipe connecting

concept with integrated

gasket.

Metal-profile gaskets

(high-temperature alloy)

for turbochargers.

Three-layer exhaust gasket.


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Gasket with high-

temperature coating for

catalytic converters.

Gasket for hot gas

application made of metal-

mica composite material.

Multi-layer exhaust gasket

for V-bond flanges

Check valve for exhaust gas

recirculation (higher exhaust

gas recirculation rates with

reduced space requirement).

Sealing and shielding

module in fuel injection

for the regeneration

of particulate filter in

commercial vehicles.

Advantages at a glance

Compared with conventional composite gaskets, the Metaloseal® system is

characterized by the following decisive advantages:

• Use of materials having maximum resistance to thermo-mechanical

stresses

• Good adaptability to heavily deformed sealing surfaces

• Long-term durability

• Variable design (absorption of sliding movements of head/manifold)

• Reliable engineering based on defined material properties

• Heat-resistant coatings ensure the best sealing and frictional behavior

Highly elastic sealing element

for hot gas applications.


Multifunctional Metaloseal® exhaust gaskets

Innovative and versatile—exhaust gaskets with advanced tasks:

• Additional elements for easier and reliable installation

• Customized gaskets with pre-assembly elements suitable for modular

integration

• Integration of the coolant passage

• Integration of the check valve

• Combination with heat shield

• Sealing plus shielding for exhaust aftertreatment systems

(AdBlue® injection and SCR catalyst)

ADBlue® module—a contribution to reduce emissions

As a competent development partner, ElringKlinger is also involved in this

module solution for SCR injection systems for exhaust aftertreatment: with

Metaloseal® gaskets as well as a multi-layer Elrotherm® heat shield. In addi-

tion, we take on the complete assembly.

AdBlue®-based SCR systems are considered to be a key technology for com-

plying with the stricter emissions standards for passenger cars and com-

mercial vehicles. The urea-water solution AdBlue® enables the conversion of

poisonous nitrogen oxides into the exhaust to water vapor and elemental

nitrogen.

The module performs the following

functions: sealing in relation to

the urea-water solution (AdBlue®),

air gap insulation, cooling of valve

tips in the area of the injection, as

well as thermal shielding of con-

nections.

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Combined solution:

exhaust gasket plus heat

shield.


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EGR system

Temperature range Cold-rolled strip FPM (based)

150°C to 250°C

Corrosion resistance Spring steel FRM (based)/NBR (based)

Coolant resistance Corrosion-resistant steel

Cylinder head/manifold

Temperature up to 350°C Spring steel Resin-stabilized NBR

Dynamic load Spring steel

Friction wear Spring steel Solid lubricant in synthetic resin matrix

Exhaust aftertreatment systems (AdBlue® injection and SCR catalyst)

Temperature range Spring steel FPM (based)

150°C to 750°C

Thermal isolation HT-resistant steel Solid lubricant in synthetic resin matrix

Heat-resistant coating

Exhaust pipe, turbocharger, precatalytic converter, etc.

Temperature up to 1100°C. HT-resistant steel, High-temperature resistant coating

Optimized micro sealing, HT-resistant alloy (Ni-based),

dynamic load mica

Sealing area/requirements Carrier materials Coatings


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No compromises. Metaloseal® sealing system for oil, coolant, and fuel systems.

Elastomer-coated beaded metal gaskets have proven to be a reliable and

cost-effective sealing concept. With impressive advantages: Elastomer and

metallic materials as well as the bead design can be combined flexibly,

thus enabling a tailor-made gasket design oriented precisely to the respec-

tive application.

Each functional component fulfills specific requirements. And this clear

assignment of sealing tasks constitutes the special strengths of the

Metaloseal® sealing system:

• Adaptation to major component deformations by means of beads

(macro sealing)

• Adaptation to component roughness by means of elastomer coating

(micro sealing)

• High chemical resistance by means of special elastomer formulas

• Cross-sectional leak tightness by means of thin elastomer layers

• High rigidity provided by metal carriers

Further advantages

• Dependable long-term performance

• Additional partial elastomer coatings seal components with graded

surfaces.

• Reliable engineering based on defined material properties

• High dimensional stability

• Fully recyclable

Compressor gasket in

pneumatic systems of

commercial and railway

vehicles.

Water pump gasket for

gasoline engines.

Metaloseal® gasket with

oil channels for a camshaft

phaser.

Oil module gasket with

coolant passage.

Sea

pum

Gasket with flexible tongues

for easier installation of

component, gasket, and

bolts.

Gasket with integrated oil

baffle, made of pre-coated

Metaloseal® base material,

deep-drawn.


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Multifunctional Metaloseal® gaskets

Metaloseal® can do more. In addition to performing sealing tasks, Metaloseal®

also enables the implementation of numerous additional functions:

• Oil baffle integrated into the gasket

• Gasket with channeling function

• Gasket with elements for pre-assembly and easier

installation

• Check valve integrated into the gasket

Advantages

• Fewer components

• Less work required for assembly

• Optimized functionality

• Weight reduction

• Lower cost

Material combinations

Seal for a vacuum fuel

pump.

Gasket for power shift

transmission.

Modular mounting of an

intake gasket.

Metaloseal® gasket with additional

elastomer sealing contour for

pressure oil sealing.

Metal carrier Aluminum Static sealing

Cold-rolled strip Static sealing

Spring steel Dynamic sealing

Coating NBR Resistant to oil, coolant, and fuel,temperature range of operation: -40 to +160°C

NBR with enhanced friction coefficient Resistant to oil, coolant, and fuel, torque transmission, temperature range of operation: -40 to +160°C

FPM Especially high chemical resistance,temperature range of operation: -40 to +210°C

PUR and silicone Resistant to oil, coolant, and fuel,high temperature resistance

Bead form Half bead 2-line sealing

Full bead 3-line sealing

Topographical bead geometry For large distances between bolts and flanges with a high degree of deformation

The Metaloseal® sealing system can be

adapted to exactly meet the individual

requirement profile by using a variable

combination of metal carriers, coating,

and bead parameters.

Half beadMetal carrier

Coating


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State-of-the-art engine technology calls for innovative sealing systems.

Components and build-on parts are increasingly made of plastic for rea-

sons related to weight and functionality. The result: reduced component

stiffness and the associated increased deformations, which occur during

distortion and must be compensated for by the sealing system.

Metal-elastomer and elastomer specialty gaskets by ElringKlinger provide

reliability and functionality even under extreme conditions. Tried and

tested a million times over. Both sealing systems—with and without metal

carriers—have been adapted precisely to the sealing tasks, in addition to

being optimized in terms of functionality and costs. The elastomer mate-

rials used are developed and produced by ElringKlinger. This also ensures

the highest quality possible.

Performance

• Reliable sealing, even at low sealing pressures

• Compensation of large component tolerances

• Three-dimensional shaping

• Reduced bolt force and fewer bolts

• Acoustic isolation of components

Engineering service

ElringKlinger determines the best possible elastomer gasket design for

each application with respect to material, profile geometry, and design of

the sealing system.

Metal-elastomer and elastomer specialty gaskets. Maximum performance—safe and reliable.

Metal-elastomer

chain case gasket.

Elastomer specialty gaskets

for intake manifold and spark

plug sealing


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Timing case gasket.

Two-component technology:

EPDM for water, ACM for oil.

Metal-elastomer gasket for

crankcase. This gasket consists

of different metal segments

connected by means of the

elastomer sealing lip.

Metal-elastomer specialty gaskets

The sealing system consists of a metal carrier with molded-on elastomer

profiles—for maximum functionality and service life in the sealing of com-

ponents subject to high stresses. It is especially suitable for use in load-

carrying joints. Modern injection molding technology also makes it possible

to bond different materials on a carrier (metal/plastic) in order to use the

ideal material for each medium to be sealed.

For example

• Oil pump gasket

• Heat exchanger gasket

• Timing case gasket

• Thermostat housing gasket

Metal carrier AEM elastomerfor oil sealing

Bolt Component

Design of a metal-elastomer specialty gasket.


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Elastomer specialty gaskets

Ideal for basically all sealing joints on the engine. With specifically

matched profile geometries, for maximum functionality at lowest sealing

pressures. In load-carrying joints, elastomer gaskets must be fitted in the

ancillary frictional connection, e.g., by using grooves on the part, or metal

limiters under the bolts.

ElringKlinger develops

• the elastomer profile corresponding to the engine components

• the elastomer material corresponding to the requirements related to

automotive fluids and temperature

Oil pan gaskets

• Available for engine and transmission applications

• Noise-isolated and rigidly bolted designs possible

• Useable in combination with different oil pan materials (aluminum,

stamped steel, and plastic)

• Various systems can be configured, thus enabling optimum adaptation

to the respective installation environment

The sealing systems used for plastic oil pans are similar to those used in

plastic cam cover gaskets.

Oil pan gasket for

commercial vehicles.

Exemplary. For many applications.

Oil pan gasket for oil pans

made of aluminum and steel,

bolted in a noise-isolated

fashion. Metal carrier with

overmolded elastomer.

Oil pan gasket for oil pans

made of aluminum and steel,

rigidly bolted. Metal carrier

with edge molded elastomers.


Requirements Solutions

Isolation of structure- Elastic mounting of the component between borne noise elastomer gasket and isolating element

Reliable Component combination of bolt and sleevescrew system

Sealing Elastomer materials optimized in terms of priceand performance, and a gasket design with optimum functionality

Pre-assembled system The isolating system is fixed to the componentin a loss-proof fashion

Assembly The bolt is mounted adjustably in the sleeve. The module is mounted on the engine as a single, complete unit. A centering tip on the bolt facilitates automatic assembly.

Service The isolating system can be replaced easily and cost-effectively

0123450 2 4

1000

Compression/mm

1000

2000 2000

3000 3000

4000 4000

Working point

F/N F/N

Force-deformation curves of the isolating system. The combination of finite element

calculations, laboratory simulations, and material development enables customized,

noise-isolated sealing systems.

Isolating element Gasket

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• Universal applications in plastic, aluminum, and stamped steel

cam covers

• Sealing system and isolating system from one source—optimally

adapted to each other

• Materials adapted precisely to the respective application for

maximum reliability

Non-noise-isolated

• Economical sealing solution for cam covers made of plastics,

aluminum, magnesium, and steel

• Variety of systems enabling optimum adaptation to the installation

space in each case

• Integration of additional component functions

Elastomer gasket for

three-dimensional

flange geometry and

isolating system.

Cam cover gasket with

integrated cable duct.

Cam cover gasket with

elastomer-overmolded steel

carrier for cam covers made

of aluminum, magnesium,

and steel.


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Intake manifold gaskets

• Available for gasoline and diesel engines

• Noise-isolated and hard-mounted versions possible

• Various designs depending on the material of the intake and the

installation environment

• The heat-resistant and fluid-resistant properties of the materials

enable their uncompromisingly reliable use at usually high exhaust

gas recirculation rates and also in combination with intake fuel

injection systems

Cam cover gaskets

Noise-isolated

Engine noise can be reduced effectively by the elastic isolation of reso-

nant bodies, such as cam covers, intake manifolds, and oil pans. In doing

so, the conflicting requirements and characteristics of the components

must be combined in the isolating system: the increased damping effect

of an isolating element and the increased sealing force of the elastomer

gasket. The quiet solution by ElringKlinger: noise-isolated sealing systems.

Precisely designed right down to the last detail.

Intake gasket with molded-on

carrier sealing lip.

Elastomer intake gasket.

Noise-isolated intake

manifold gasket.

Hard-mounted intake

manifold gasket.

Elastomer gasket and isolating system.

Sleeve(load-carrying element)

Rubbergrommet

Elastomergasket

Bolt

Gasket retentionfeature

Elastomergasket

Housing component/resonant body


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Materials expertise. Elastomers of the finest quality.

Engineering service

ElringKlinger determines the best possible gasket design for each appli-

cation with respect to material, profile geometry/design of the sealing

system.

Identification of thermodynamic characteristics

Elastomers must provide a reliable sealing performance for a wide range of

engine operating conditions. At an operating temperature of -40°C and at

150°C alike, regardless of the extent of the dynamic sealing gap move-

ments.

Material tests

In order to guarantee the sealing performance of ElringKlinger materials

throughout the service life of the components, tests have been established

that make it possible to predict the sealing behavior of our components

depending on their lifetime, temperature, and the dynamics of the seal-

ing system. These results are also processed further in our FEM analyses.

Identification of dynamic

elastomer characteristics.

Test duration [hours]

0

50

100

150

200

250

300

350

Sealing force [N]

0,10,01 1 10 100 1000 10000 100000

Minimum sealing pressure

(1.0 N/mm2)

Maximum compression

FEM calculation of an elastomer profile.

7

n


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Elastomer materials

As elastomer materials for sealing systems, ElringKlinger exclusively uses

in-house developments, which are optimized to special customer require-

ments. Specialization in high-performance materials emphasizes the sys-

tems expertise in sealing systems for engine and transmission applications.

Overview of elastomer materials

Elastomer selection based on oil and temperature resistance.

+ well suitable / 0 suitable / - unsuitable / CHG = cylinder head gasket

Abbreviation (ISO 1629) FPM MVQ MFQ ACM AEM EPDM ECO HNBR

Chemical term Fluoro- Silicone Fluoro- Poly- Ethylene Ethylene Epichlor Hydratedcarbon rubber carbon acrylate poly- propylene hydrin nitrilrubber silicone rubber acrylate diene rubber rubber

rubber rubber rubber

Range of applications

Fuel + - - - - - + o

Coolant + o o - - + - o

Oil + o + + + - + +

Thermal application -40 to -70 to -70 to -40 to -40 to -50 to -40 to -30 toranges +230°C +200°C +180°C +160°C +160°C +150°C +120°C +150°C

Product examples CHG CHG CHG Oil pan, Oil pan, Water Special Specialintake special special cam cam pump appli- appli-area appli- appli- cover cover cations cations

cations cations in the fuel

system

EPDM

MVQLSR

FMVQ

FKM

NR

SBR

CSM

CR

NBR

ACM/AEMHNBR

AU

Better resistance to fuels/oils

Temperatureresistance

Temperatureresistance

Oil resistance

Temperature resistanceBetter cold flexibility


The information contained in this brochure is the result of technological analyses. They may be subject to changes depending on the design of the system. We reserve theright to make technical changes and improvements. The information is not binding and does not represent warranted characteristics. Any claims for compensation basedon this information shall not be recognized. We accept no liability for printing errors. 0

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ElringKlinger AG | Max-Eyth-Strasse 2 | 72581 Dettingen/Erms | Germany

Tel. +49 (0)71 23/724-0 | Fax +49 (0)71 23/724-90 06 | [email protected] | www.elringklinger.de

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Documents

Specialty gaskets: Metaloseal —metal-elastomer—elastomer. · Temperature up to 350°C Spring steel Resin-stabilized NBR ... (macro sealing) • Adaptation to component roughness