Metal gaskets deal with these extreme conditions that would ruin rubber or fiber gaskets in seconds. Metal gaskets are used in sealing solutions in industries where failure is more than just a costly inconvenience; it could be catastrophic. Understanding metal gasket applications and how they seal and where they are used will help you make informed decisions about equipment maintenance. This article will provide an overview of everything you need to know about metal gaskets, from the basic function to applications in major industries.
What are Metal Gaskets?
Metal gaskets are sealing devices composed of different metals. Metal gasket applications seal two surfaces together under extreme conditions. By deforming slightly under compression, metal gaskets cover the microscopic irregularities in flange surfaces and can prevent leakage of either liquids or gases.
They are available in various types, including these:
- Flat gaskets
- Ring joint gaskets
- Spiral wound gaskets
- Kammprofile gaskets
- Metal jacketed gaskets
- Corrugated gaskets
The type of metal used in a gasket will generally depend on the operating environment and the seal’s specification for the application. Different metal gasket applications require different materials.
Applications of Metal Gaskets
Let’s take a look at metal gasket applications across various industries:
Automotive Industry
The use of metal gaskets in automotive engineering exists because the engine creates conditions nearly impossible to seal.
- Fuel detonates thousands of times per minute, causing temperatures high enough to melt aluminum and pressures that would explode any other component
- The cylinder head gasket resides where these detonations occur, separating different pressures and temperatures, while a rubber gasket would fail within seconds
- Turbochargers spin at greater than 100,000 RPM while compressing the air, which creates tremendous heat on top of what is already present from exhaust temperatures
Metal gaskets simply compress enough to fill microscopic gaps yet remain rigid enough to contain the forces trying to tear everything apart.
Oil and Gas Industry
Metal gaskets are used in the oil and gas industry because failure means catastrophes are possible:
- Wellheads at drilling sites can handle pressures exceeding 15,000 psi, or over approximately 500 times the pressure in your car tires.
- Ring joint gaskets created from super tough metals like Inconel wedge into grooved flanges to form seals that actually get tighter under increased pressure.
- Pipelines of hundreds or thousands of miles long require no failure at every place where they connect in order to avoid environmental devastation.
Aerospace Industry
Here are the metal gasket applications in the aerospace industry:
- Jet engine turbine sections operate at a temperature where most materials are vaporized. They require the use of exotic alloys that maintain strength while glowing red-hot.
- Fuel systems must produce reliable seals from a stationary desert runway at 120°F or at cruising altitude down to minus 60°F.
- Hydraulic systems that fly flight surfaces generate constant pressure cycling, often over 3,000 psi, where metal gaskets are used
Petrochemical Industry
Chemical facilities handle materials that would dissolve rubber gaskets like acid dissolving tissue paper. Metal gasket applications in a chemical facility include everything from high concentrations of sulfuric acid to caustic solutions, and at high temperatures. Kammprofile gaskets and metal jacket gaskets are able to provide durable metal outer surfaces against the chemicals being used.
Power Generation Industry
Power plants operate continuously, typically with steam turbines exposed to higher than 1000°F and about 3500 psi of pressure. Metal gasket applications provide the necessary lifespan because if something goes wrong, the generation capacity is taken offline.
Advantages of Metal Gaskets
Here are the advantages of metal gaskets:
High Temperature Resistance
Temperature can degrade most sealing materials long before mechanical loads become problematic. Rubber gaskets typically start failing by around 400 °F. Fiber-based gaskets usually can tolerate a bit more temperature, but still fail at temperatures of 600-800°F. Metal gaskets operate in a different zone altogether:
- In many applications, a stainless steel gasket can maintain its sealing capabilities at up to 1500 °F
- Specialized high-temperature alloys like Inconel can operate at temperatures of over 2000 °F
- The metal not only survives exposure to this high temperature but continues to function in a thermal cycling condition
Chemical And Corrosion Resistance
Applications in chemical processing exist because metals can resist these aggressive attack mechanisms. Stainless steel is typically resistant to a majority of common industrial chemicals. Metals will form a passive oxide layer that protects the base material from further attacks. This property will increase the service life utilization from a few months to years.
Durability
Metal gaskets can withstand mechanical abuse that would destroy softer materials. Pressure cycling, vibration, and thermal expansion produce forces that work to loosen gasket seals over time. Metal construction can also resist mechanical fatigue. The gaskets retain their compression and seal over thousands of cycles. Durability directly translates to reduced maintenance costs and longer service intervals.
Structural Strength
High-pressure metal gasket applications require gaskets that won’t blow out under stress. Metal has the structural strength to contain much of that pressure, whereas you would have to squeeze the softer material right through the gaps between the flanges. In all, it is critical in metal gasket applications that deal with pressure spikes.
TMNetch: Custom Metal Gasket
Locating a manufacturer who grasps the exacting tolerances of metal gasket applications is crucial to the success of your project. TMNetch utilizes photochemical etching technology for precision-produced custom metal gaskets:
- Works in stainless steel, brass, copper, and specialized alloys in matters of thickness from .01 mm to 3.0 mm, covering most standard gasket applications.
- ISO 9001: 2015 certified facility with automated production systems that can deliver working prototypes from your design files within days.
- Burr free edges with consistently tight tolerances with no tooling costs.
Visit TMNetch to see how they may align with your own project.
FAQs Related To Metal Gasket Applications
How do metal gaskets work?
Under pressure from bolts, metal gaskets deform slightly to fill minute differences in the surfaces of the flanges. They create a more reliable metal-to-metal seal even under extreme conditions.
What is the difference between a metal gasket and a rubber seal?
Metal gaskets can tolerate extreme temperatures, pressures, and aggressive chemicals that can destroy rubber seals in minutes. Rubber works well in moderate conditions, but stops working under extremes of heat.
What is the best material for a gasket?
The best material for a gasket depends on the prevailing conditions in the application. Most industrial applications can rely on stainless steel. Inconel gaskets can withstand extreme temperatures and corrosion.
Are metal gaskets one-time use?
Most metal gaskets are designed to be single-use. The compression of the gasket will create a permanent deformation, making it impossible to reuse.
Conclusion
Metal gaskets are the standard in industrial sealing applications where failure is not an option. Whether we’re talking about your car’s engine or the power plant that provides electricity to your home, these products operate quietly in conditions that would destroy conventional sealing materials. Knowing where and why metal gaskets work effectively is valuable in making educated decisions. Investing in metal gaskets will save time and money through reduced downtime, enhanced operator safety, and longer replacement intervals.
