Sealing Brochure

Transcription

Sealing Brochure

Zylinderkopfdichtungen
Sealing systems
Advanced
Advanced
Sealing
MLS-Technology
Technology –– Leistungsfähigkeit
Trends, concepts, and
in jeder
materials
Lage
Contents
3
Sealing Products – VICTOR REINZ
4
Systematic quality
5
Development services
10
Sealing system trends
11
Other things you should know
12
Survey of materials and concepts
16
Beaded metal gaskets with
24
Beaded metal gaskets with
elastomer coating
fiber-reinforced elastomer coating
26
Beaded metal gaskets
30
Metal/rubber gaskets
36
High-temperature gaskets
38
Fiber composite gaskets
46
Molded rubber gaskets
48
Special solutions
52
Future concepts
54
Product range
55
The DANA network
Treat it rough, make it tough:
While your customer enjoys a fast drive, our
gaskets endure a grueling test. It’s good to know
they’re made by VICTOR REINZ.
Better ideas. Manufactured by VICTOR REINZ.
ALWAYS A STEP AHEAD
For more than 50 years, VICTOR REINZ
has been an established name among
the world’s top automobile manufacturers. Reliable, top-quality products
and on-time delivery are as much a
part of VICTOR REINZ as our innovative
design and systems competence.
At VICTOR REINZ, good ideas continue
to evolve and our gaskets continue to
improve. This spirit of innovation enables us to consistently find new ways
to upgrade the performance of our
gaskets – and, in turn, your engine.
We will continue to meet the demands
of engine builders now and in the future.
Beyond our competitors
In order to meet the sealing demands
placed by modern engines, you need to
be an expert in your trade. By continually improving our products, we frequently discover solutions that determine future market developments and
provide a perfect balance between performance and economy. We call this
“Advanced Sealing Technology”.
However, we don’t stop there. We utilize the most advanced equipment, the
most rigorous testing standards, finite
element analysis, simulations, and extensive expertise to provide products
that truly stand out in the marketplace.
Equally important, every employee at
VICTOR REINZ is truly committed to
serving our customers.
Sealing Products – VICTOR REINZ:
A global presence
In 2003, Dana Corporation consolidated
and reorganized its five gasket, shielding
system, and cylinder head cover module
facilities into a central, clearly defined
group: Sealing Products – VICTOR REINZ.
As a world leader in gasket production,
Dana now provides worldwide service
and support from 19 locations in Europe,
North America, South America, and Japan
through subsidiaries and affiliates. You’ll
find us in every important automotive
manufacturing hub providing the most
innovative system solutions in the world.
Performance defined:
VICTOR REINZ
¬ Recognized for providing the world’s
most innovative gasket solutions
¬ Top-quality products and high
process reliability
¬ Total systems competence
¬ Worldwide access to consulting, development, production, logistics, and
servicing at the highest level through
the DANA Sealing Products network
When you choose VICTOR REINZ, you
decide for intelligent sealing concepts –
plus the highest level of consulting, development, production, logistics, and
service competence.
¬3
Always faster, always better –
from initial concept to series production
STREAMLINED PRODUCTION CYCLES
Every business strives to perform faster
and better, but this is especially critical
in the rapidly changing automotive world.
Smart response
If required, we can deliver installationready gaskets directly to your assembly line – based solely on the engine's
design data. Our design system is compatible with your in-house CAD system,
whether it’s CATIA, ProEngineer, IDEAS,
or Unigraphics.
Time and again, our customers are
surprised by the short lead times at
VICTOR REINZ. We do this by employing all necessary experts in-house,
from development to series production.
As a result, handling times are greatly
reduced. In addition, we can perform
all the important validation tests on-site
with our own equipment.
Smart combinations
Ingenious matching of conventional development tools to each other can result
in significant time savings.
One example: At VICTOR REINZ we not
only test and simulate entire sealing
systems with computers – we also use
modern prototyping procedures to build
functional models at a very early stage.
When testing the specific sealing functions, these prototypes supply extremely valuable data. This enables us to
determine in advance whether a gasket’s performance is maximized, so that
individual functions don’t require optimization later.
Nonetheless: Even something good
can be improved
Since approximately 70 percent of an
automobile’s components come from
external suppliers, the quality of a vehicle depends greatly on the quality of
the supplied products. Because quality
cannot be improved later, we understand
that intelligent product design, exact
planning, and compatible engineering
from the start will ensure quality assurance in product development and
manufacturing.
ISO/TS 16949: Our quality standards include DIN EN ISO 9001,
VDA 6.1 and EAQF 94 as well as specific customer requirements from GM, DaimlerChrysler, and all German auto makers.
DIN EN ISO
14001
Steinbeis-Initiative «Customers
evaluate
suppliers»
Partners with the best
VICTOR REINZ’s expertise has been
valued by the European automotive
industry for decades. From the MCC
Smart to the Maybach V12 engine and
the high-tech gaskets for Formula One
racing, VICTOR REINZ supplies complete gasket systems that are unmatched for quality and performance.
Our aim: To be partners with the best.
Which is why our reference list reads
like a »Who’s who« of European auto
makers. For details, see our reference
list at www.reinz.com.
DANA Leadership Award
Nissan: NX 96,
Next 21 Recogni- Volvo Cars Award
of Excellence
tion Award
Spirit of
Innovation
Systematic quality: The high standard of our quality management system is reflected by the many honors bestowed upon us by our customers. The environment also benefits from our work,
as evidenced by a growing number of environmental compatibility certificates.
¬4
»Design that's right the first time«
STEPS TO OPTIMUM PRODUCT DESIGN
Transforming vision into reality
Our project teams consist of application
engineers who work with developers,
designers, manufacturing and quality
experts, logistics specialists, and buyers
to find the best solution.
In this way, the expertise of each participant is taken into account from the
beginning. This close collaboration exemplifies the value we place on our relationship with our customers.
Assessment of
requirements
Logistics
Design & construction
Manufacturing
»Built-in«
understanding
Series production
release
Calculation
Flexible and fast – the optimized development process at
VICTOR REINZ. This enables us to avoid errors during every
phase of product development. The viability of our processes is borne out when the first prototype goes into series
production practically unchanged. At VICTOR REINZ, repeat
trial-and-error prototyping is a thing of the past. Today,
clear and direct communication with the customer along
with computer-aided analysis reduces testing time and ensures that our designs are correct from the start.
Testing
Prototyping
¬5
Responsibility from beginning to end
PROACTIVE DEVELOPMENT PARTNERSHIP YOU CAN TRUST
We look forward to being your partner throughout the design
and production process, and welcome open dialogue at any
time – whether it’s contract development or purposeful, objective product consultation. The scope of VICTOR REINZ expertise covers all aspects from development to logistics.
Here are a few examples:
Assessment of
requirements
Assessment of
requirements:
The earlier the better
Every gasket involves many specific
functions, so it pays to consult with us
early. Frequently, the object is not only
to provide sealing from different media,
but also to minimize component deformation. If all functional requirements
are considered from the beginning, complications and loss of time are greatly
reduced during subsequent project
stages.
This attention to detail begins right
away, during your first consultation
with our application and development
engineers. Design procedures are
straightforward. We require just a few
parameters: Operating temperature,
internal pressure, dynamic behavior,
number of fixing screws, plus a few
details on the materials used for the
surrounding components, their surface
finish, and their geometry.
That's it – our engineers determine
the rest.
¬6
Design & construction:
Built to fit
Calculation
Design & construction
While vehicles are not built around the
gaskets, they are still critical components. Attention to product design combined with high-quality materials is the
best foundation for functional, reliable,
high-quality gaskets.
Thinking ahead is part of going the extra
mile for customer at VICTOR REINZ.
During the gasket’s design phase, we
simulate the automated assembly sequence in the production line or during
servicing, and also consider the packaging aspects. Even recycling issues
and clean separation of the materials
used is factored in.
Interfaces:
“Built-in” understanding
Finite Elements Analysis
(FEA): Working smarter
from the start
Ever more often, increasingly complex
designs are required for metal gaskets.
Whether in the exhaust train, in turbochargers, or special gaskets for highpressure diesel fuel pumps – suitable
sealing is ensured by half beads, full
beads, and the patented Wave-Stopper®.
Not an easy task. If requested by the
customer, we conduct FEA calculations
of the entire sealing system, i.e. the
gasket and the components to be sealed.
The advantage: During FEA calculations early in the design phase, all relevant functional parts and critical areas
of the entire sealing system are examined in detail to ensure optimum gasket development in the shortest time.
Moreover, FEA calculations supply valuable details on component stiffness,
distortion, and pressure distribution.
Prototyping
Take metal gaskets, for example: We
use close-to-production tooling from the
start. After the sheets have been coated
on series production plant, and the gasket contour has been cut with lasers,
even the most complex beads can be
stamped with our embossing tools. Of
course, all these tools are produced on
our premises quickly and cost-effectively. Your advantage: Prototypes are of the
same quality as the later series gaskets
– with few deviations. Modern CNC-controlled measurement equipment ensures
optimum quality monitoring.
Subsequently, all relevant data are recorded in a technical document.
Tougher than
practical use
Testing
»Built-in«
understanding
Sealing systems from VICTOR REINZ
not only fit the vehicles for which they
are designed; they also fit the 3D computer-design worlds of our customers.
We speak the same language as your
designers and supply geometrical data
of the required cylinder head cover in
the specified data format, using the
fastest available online data transmission methods.
Prototyping: Equal to
the final product
VICTOR REINZ development engineers
think and work in conjunction with our
customers' development departments.
This leads to the high efficiency that
gives our customers a leading edge,
and permits our products to be adapted quickly to changing conditions.
Along with the latest engine testing
methods, we conduct extensive testing
in our chemical and physical laboratories whenever necessary. As a customer, you have the choice of numerous
testing and simulation possibilities,
allowing you to determine the testing
scope and budget. This ensures that you
receive optimum value during the testing phase.
Scientific methods instead of chance: The application of FEA
An entirely new level of quality for prototypes – made
makes many empirical approaches superfluous during the
possible by VICTOR REINZ with close-to-production
design of a sealing system.
tooling.
¬7
In addition, through Dana Sealing Products and its four development centers
in Neu-Ulm, North America, Japan, and
Brazil, we have worldwide access to 27
engine test stands and associated laboratories for analysis and static/dynamic
pre-testing.
All activities are coordinated by the
Competence Center R & D in Neu-Ulm,
to ensure your testing benefits from the
most advanced technology »Made in
Europe«.
Laboratory tests (excerpt)
¬ RPM 1) 510-3D: The setting behaviour (creep resistance) of a gasket is
determined as a function of surface
pressure and temperature. The resulting (derivable) loss of bolt load is
decisive for the sealing behaviour.
¬ RPM 1) 511-S: The distribution of
surface pressure on the surrounding
components is determined by means
of a computer-controlled hydraulic
test stand. With metal gaskets, for
example, a test program with repeated loading/unloading cycles is used
to determine the bead characteristics, which are then compared with
the calculated FEA values from the
simulation.
¬ RPM 1) 528: By means of resonance
pulsers and simulators, various operating conditions (temperature, pressure, dynamics) are simulated, and
conclusions are drawn about the gasket's durability.
¬ RPM 1) 535: Determines a gasket's
sealing potential, depending on the
component's surface roughness, its
flatness, and the bolt force. Seal
tightness is tested with nitrogen or
with liquid media such as engine oil
or antifreeze.
¬ RPM 1) 550: By means of a pressuresensitive film (Fuji film), the distribution of surface pressure over the
gasket is determined, scanned, and
evaluated electronically.
Of course, we conduct any additional
laboratory tests requested by the customer. These range from investigating
the media resistance of the material
used, through porosity, roughness, and
evenness tests of the sealed components, up to special examinations of
residual particles, e.g. if gaskets for
dust-sensitive components such as
high-pressure injection pumps are to
be packaged under cleanroom conditions.
Test set-up to determine
the sealing potential
according to RPM 1) 535.
From icy cold to burning
hot – thermal shock test
causes engine and gaskets to age several years
within hours.
Documentation
For detailed communication: All test
results are summarized and explained
in a comprehensive test report. This
simplifies and speeds up subsequent
fine-tuning with your engine designers
and builders.
RPM 1) = REINZ-Prüf-Methode (REINZ Test Method): Numerous laboratory test procedures are described in corresponding RPMs,
and represent testing methods that are widely accepted in the industry.
Hot creep [%]
15
10
5
¬8
[°C]
Determination of surface pressure distribution with RPM 1) 550.
Beaded metal gasket with
elastomer coating
ture
mpera
Test te
Fiber composite gasket
300
250
200
150
100
50
Material 1
Material 2
75
50
30
0
10
2
/mm ]
essure [N
Surface pr
Hot-creep behaviour of different elastomer-coated gaskets according to RPM 1) 510-3D.
Quality assurance:
Beyond the standards
Series production
release
Intelligent quality management for rational zero-error production ensures
manufacturing reliability and efficiency
– we call it Systematic Quality. During
the testing phase, we simulate the manufacturing process by using close-toseries tooling. This enables us to test
gaskets close to their final state without delay, complete with a detailed test
report and quality certificates for all
the materials used, as required for sample approval.
Subsequently, we can immediately begin pre-series and series production.
VICTOR REINZ has already been certified in accordance with the latest (2002)
issue of ISO/TS 16949, which is accepted by all automobile manufacturers –
worldwide. Moreover, our Environmental
Management System complies with
DIN EN ISO 14001 for the use of environmentally compatible technologies.
Obviously, these standards and official
certificates have high practical significance, but equally important is our
internal approach to ensuring product
quality and environmental awareness.
Concentrated performance – our entire development
knowledge is focused on high-end products.
Rest assured that our employees are
truly committed to maintaining the
strong relationships and high level of
confidence we’ve developed over the
years with our customers – it’s something that can’t be measured, but which
we continually provide.
Manufacturing: Efficient
and cost-effective
Manufacturing
Flexible, fast, and cost-effective manufacturing is made possible at VICTOR
REINZ by utilizing the most modern
manufacturing technologies in our production lines and cells. The gasket's
final properties are influenced decisively and specifically by the individual
processing stages and their sequence.
In this way, our head gaskets provide
optimum customer value: Excellent manufacturing that leads to top quality and
maximum functionality and durability.
Logistics
Logistics and packaging:
Custom-designed for
your line
VICTOR REINZ delivers your gaskets
packed and ready for installation directly to your assembly line, thus simplifying your logistics. We also design packaging to maximize economic, ecological, and logistic aspects. To ensure that
Highly automated production lines minimize time and cost.
»just-in-sequence« really means quality up to the assembly line, we employ
logistic tracking systems such as DLL,
CMMS3, and eCAP.
All of our technical efforts and the best
product quality would be in vain, if the
last link in the chain is not just as perfect as all the preceding ones. That’s
why every day at VICTOR REINZ, we
strive to turn satisfied customers into
delighted customers.
Welcome to VICTOR REINZ.
Put us to the test!
¬ Responsibility from beginning to
end from a single source
¬ State-of-the-art development and
prototyping tools
¬ Worldwide access to services
¬ Coordination through the Competence Center R & D in Neu-Ulm
¬ Systematic quality assurance –
from production at VICTOR REINZ
up the customer's assembly line
Worldwide product availability: Wherever your facility
is located, you'll find us close by.
¬9
Sealing systems for the entire power train –
everything else is secondary
ABOUT TRENDS
Trends apply for almost everything.
For automobiles just as for the components used to build them – and for
gaskets, of course. Hereby, the trend
is clearly toward pure metal and coated metal gaskets. Apart from the functionality, durability, and maintenance
freedom of these gaskets, another major
reason for this trend is the suitability
for automated assembly, i.e. simple
handling with robots and automatic
manipulators. Naturally, this doesn't
mean that VICTOR REINZ does not offer
fiber composite as an alternative.
Because they remain to be essential
for many applications.
Make sure its VICTOR REINZ
VICTOR REINZ recognizes these demands at an early stage, and responds
to trends with new products. Regardless of the equipment that needs a
gasket – we always have more than
one good solution in stock.
Why you should play it safe
A growing number of automotive manufacturers are placing their trust in
VICTOR REINZ sealing systems. In
addition to meeting all of the above
demands, our gasket materials and
sealing concepts are so reliable that
they perform their tasks throughout
the vehicle’s lifespan. We help you
build better automobiles.
More engine output, higher packing densities, tougher environmental legislation. Sealing systems from VICTOR REINZ
ensure better performance. Regardless of the working conditions.
Survey of materials and concepts
PLEASE TURN THE PAGE
¬ 10
Essential features of
sealing systems
¬ Advanced sealing technology with
special core, coating, and design
elements
¬ Handling high temperatures,
aggressive media, and high component dynamics
¬ Sealing concepts for modern
engines, e.g. new materials such
as magnesium alloys, or compact
construction with extremely narrow sealing contours
¬ Coverage of widely different application areas in the entire power
train – from engine and transmission to the final drive train up to
the complete exhaust gas system
¬ Demand-oriented and cost-optimized technologies
Other things you should know
DEMANDS PLACED ON SEALING SYSTEMS
Correct material selection and optimum
design are decisive criteria for the
functionality and durability of gaskets
and seals.
Depending on application area and ambient conditions, different requirements
are placed on the selected material and
the design.
¬
¬
¬
¬
¬
¬
¬
Temperature resistance
Media resistance
Corrosion resistance
Recovery behavior
Setting behavior
Easy installation
Recyclability
Ensuring a high surface texture quality
is an important basic requirement for a
functioning sealing system.
With critical surface texture qualities, we
recommend a leakage test using volume
flow measuring equipment.
Gasket selection
With VICTOR REINZ, selection of a suitable sealing concept is really simple.
We require just a few parameters:
Surface texture of the
surrounding components
One important basic requirement for
optimum sealing is the surface texture
of the components to be sealed. Surface
texture is determined according to DIN
EN ISO 4287 and DIN EN ISO 4288 using
the profile method to generate an envelope profile from which the following
values are defined:
Primary profile
¬ Application area
¬ Ambient conditions
¬ Temperature range (peak temperature, continuous temperature)
¬ Conformability
¬ Internal pressure stress
¬ Dynamics
The following pages show all the
relevant information.
Pt
Waviness profile Wt
Max. roughness Rmax
¬
¬
¬
¬
Primary profile Pt
Waviness profile Wt
Roughness RZ
Maximum roughness Rmax
Exemplary envelope
profile to describe the
Z1
Roughness Rz
Z2
Z3
Z4
Z5
RZ = (Z1 + Z2 + Z3 + Z4 + Z5) / 5 section roughness Rz
surface texture of a
flange.
¬ 11
Innovation included: Survey of materials and concepts
THREE STEPS TO FIND THE OPTIMUM SEALING SYSTEM
Find your optimum sealing system in three steps. Start by getting an overall impression
of our comprehensive sealing product range. All the relevant information on application areas and ambient conditions are given on this page.
Step
1
Select your application area
Quick survey: Selection
of the ideal material and
Select your specific application area: From A for airbag housing to W for water pump. The range of VICTOR REINZ gasket
materials and sealing concepts is equally diversified as the
application possibilities in modern engines. The ideal solution
for every application. Typical for VICTOR REINZ.
Step
2
the best sealing concept
is dictated by the specific application area.
1
Check the ambient conditions
Fine tuning: The ambient
conditions are decisive
for optimum perfor-
Select the operating temperature range (accordingly shorter
peak temperature and lower continuous temperature), conformability (depending on component distortion and roughness), and the permissible internal pressure – just a few
marginal conditions are enough to limit the possible choices.
Step
3
mance of the correct
gasket material and
sealing concept.
Check the details
Detailed information on
material construction,
specific properties, gen-
Detailed information on material construction, specific properties, general application areas, as well as typical application
examples and present trends are given on the following pages.
The reference table is helpful.
eral application areas, as
well as typical application
examples and present
trends are given on the
following pages. The reference table is helpful.
Our application experts look forward to your phone call.
Any more questions?
Our application experts will help you quickly, efficiently, and
competently. We will be pleased to discuss your special application. Simply give us a call.
+ 49 (0) 731-70 46-0
1)
Normally, gaskets are designed with beads (half of full beads)
2)
based on stainless steel or galvanized carbon steel
3)
based on fiber composite gaskets
4)
based on RETALL® FPM plus, RETALL® F51 with non-stick coating
5)
based on metal gaskets with elastomer coating with fiber-reinforced
elastomer coating
6)
based on RETALL® HRS, RETALL® HTS
7)
based on metal gaskets with elastomer coating, with fiber-reinforced
elastomer coating or plain metal gaskets
8)
¬ 12
2
based on carbon steel or aluminium
3
Beaded metal gaskets with elastomer coating
PROGRESSION® CS
PROGRESSION® CS
plus
PROGRESSION® CA
SLS (1 x 0.38 mm)
SLS (1 x 0.38 mm)
SLS (1 x 0.35 mm)
SLS (1 x 0.35 mm)
SLS (1 x 0.35 mm)
Application area (excerpt)
1)
RETALL® FPM plus
Beaded metal gasket with fiber-reinforced
elastomer coating 1)
RETALL® F51
RETALL® F52
MatriCS®
MatriCS® plus
SLS (1 x 0.25 mm)
X8)
SLS (1 x 0.5 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.5 mm)
Airbag housing
Automatic manual transmission (AMT)
Automatic transmission
Camshaft adjuster
Catalytic converter
Charge air damper
Compressor
SLS (1 x 0.35 mm)
SLS (1 x 0.38 mm)
SLS (1 x 0.25 mm)
SLS (1 x 0.35 mm)
SLS (1 x 0.35 mm)
SLS (1 x 0.35 mm)
SLS (1 x 0.35 mm)
SLS (1 x 0.25 mm)
SLS (1 x 0.35 mm)
SLS (1 x 0.35 mm)
SLS (1 x 0.35 mm)
SLS (1 x 0.35 mm)
SLS (1 x 0.25 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.5 mm)
Door lock
EGR mixing chamber
EGR valves
Electronic connector
Exhaust manifold
Exhaust pipe
Fuel pump
SLS (1 x 0.38 mm)
Gearbox cover
SLS (1 x 0.38 mm)
High-pressure diesel pump cover
High-pressure diesel pump flange
Hydraulic pump
SLS (1 x 0.38 mm)
SLS (1 x 0.38 mm)
SLS (1 x 0.35 mm)
SLS (1 x 0.35 mm)
SLS (1 x 0.35 mm)
Intake duct
Intake manifold (4-duct)
SLS (1 x 0.38 mm)
SLS (1 x 0.38 mm)
SLS (1 x 0.35 mm)
SLS (1 x 0.35 mm)
SLS (1 x 0.35 mm)
SLS (1 x 0.25 mm)
Oil cooler
Oil filter bracket
Oil pan
Oil pump
Oval flange
SLS
SLS
SLS
SLS
SLS
SLS (1 x 0.35 mm)
SLS (1 x 0.35 mm)
SLS (1 x 0.25 mm)
SLS
SLS
SLS
SLS
Retarder
SLS (1 x 0.38 mm)
Soot filter
Steering servo pump
SLS (1 x 0.38 mm)
SLS (1 x 0.35 mm)
Throttle flap
Timing cover
Turbocharger
SLS (1 x 0.38 mm)
SLS (1 x 0.38 mm)
SLS (1 x 0.35 mm)
Universal drive shaft
SLS (1 x 0.38 mm)
SLS (1 x 0.35 mm)
Vacuum pump
Valve cover
Water pump
SLS (1 x 0.38 mm)
(1
(1
(1
(1
x
x
x
x
0.38
0.38
0.38
0.38
mm)
mm)
mm)
mm)
SLS (1 x 0.38 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.35 mm)
SLS (1 x 0.5 mm)
(1
(1
(1
(1
(1
x
x
x
x
x
0.35
0.35
0.35
0.35
0.35
mm)
mm)
mm)
mm)
mm)
SLS (1 x 0.35 mm)
SLS (1 x 0.35 mm)
SLS (1 x 0.2 mm)
SLS (1 x 0.23 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.25 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.25 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.25 mm)
SLS (1 x 0.25 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.25 mm)
X8)
SLS (1 x 0.5 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.35 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.35 mm)
SLS (1 x 0.5 mm)
SLS (1 x 0.35 mm)
SLS (1 x 0.5 mm)
1)
SLS (1 x 0.5 mm)
SLS (1 x 0.5 mm)
Beaded metal gasket with fiber-reinforced
elastomer coating 1)
PROGRESSION® CS
PROGRESSION® CS
plus
PROGRESSION® CA
RETALL® FPM plus
RETALL® F51
RETALL® F52
MatriCS®
MatriCS® plus
240
- 40 up to + 200
++
240
- 40 up to + 200
++
130
- 40 up to + 120
++
300
- 40 up to + 280
++
280
- 30 up to + 240
++
280
- 30 up to + 240
++
300
- 40 up to + 220
+
300
- 40 up to + 220
++
+
0
++
++
0
-
++
++
++
++
++
++
+
+
++
++
16
16
18
20
22
22
24
24
Ambient conditions
Temperature range
Peak temperature (short-term) [°C]
Continuous temperature [°C]
Conformability (depending on
roughness and distortion)
Permissible internal pressure
Dynamics
Details on page
RETALL® HRS
1)
RETALL® HTS
thermo-glide®
FPM 70
2)
ACM 50 und ACM 60
High-temperature
gaskets
HTV 50
Xtreme® plus
Fiber compo
AFM® 30
AFM® 31
AFM® 32/2
1.0 mm
1.5 mm
X
X
DLS (2 x 0.25 mm)
X
X
0.3 mm
0.5 mm
DLS (2 x 0.3 mm)
0.5 mm
1.0 mm
with inner bead
0.75 mm
0.3 mm
0.5 mm
SLS (1 x 0.2 mm)
SLS (1 x 0.25 mm)
DLS (2 x 0.2 mm)
DLS (2 x 0.25 mm)
MLS (3 x 0.2 mm)
MLS (4 x 0.2 mm)
DLS (2 x 0.25 mm)
DLS (2 x 0.3 mm)
MLS (3 x 0.25 mm)
MLS (3 x 0.3 mm)
DLS (2 x 0.25 mm)
DLS (2 x 0.3 mm)
X
Substrate Retall® HRS
with inner bead
or 1.4828
DLS (2 x 0.2 mm)
DLS (2 x 0.25 mm)
MLS (3 x 0.2 mm)
MLS (4 x 0.2 mm)
Substrate Retall® HRS
oder 1.4828
DLS (2 x 0.2 mm)
DLS (2 x 0.25 mm)
with inner bead
X
0.5 mm
1.5 mm
SLS (1 x 0.2 mm)
0.5 mm
1.5 mm
0.5 mm
X
X
X
X
X
1.0 mm
1.5 mm
1.5 mm
1.0 mm
1.0 mm
1.5 mm
SLS (1 x 0.2 mm)
X
X
MLS (3 x 0,2 mm)
X
X
1.5 mm
Substrate Retall® 1.4828
SLS (1 x 0.3 mm)
DLS (2 x 0.3 mm)
SLS (1 x 0.3 mm)
DLS (2 x 0.3 mm)
MLS (3 x 0.25 mm)
1.5 mm
with inner bead
X
X
1.0 mm
1)
2)
High-temperature
gaskets
Fiber compo
RETALL® HRS
RETALL® HTS
thermo-glide®
FPM 70
ACM 50 und ACM 60
HTV 50
Xtreme® plus
AFM® 30
AFM® 31
AFM® 32/2
700
650
-
950
950
0
1000
+
250
- 25 up to + 230
++
160
- 40 up to + 150
++
250
- 40 up to + 200
++
950
950
+
400
250
+
300
250
++
300
250
++
+
++
+
+
+
++
+
+
+
+
+
+
+
0
++
++
+
+
+
+
26
26
28
30
32
34
36
38
40
42
site gaskets
Screen printed SH
Molded rubber
gaskets
3)
Screen printed QE
3)
Screen printed SF
3)
ACM 50 and ACM 60
Special solutions
Firmly bonded sealing Firmly bonded sealing
compounds DX 4)
compounds F52 5)
Wave-Stopper®
6)
Fixing/
clamping claw
7)
Application area (excerpt)
Airbag housing
X
X
X
Automatic manual transmission (AMT)
Automatic transmission
X
Camshaft adjuster
Catalytic converter
Charge air damper
Compressor
X
X
Door lock
X
EGR mixing chamber
EGR valves
Electronic connector
Exhaust manifold
X
X
X
X
Exhaust pipe
X
Fuel pump
Gearbox cover
X
X
X
X
X
X
X
X
X
X
X
X
High-pressure diesel pump cover
High-pressure diesel pump flange
Hydraulic pump
X
Intake duct
Intake manifold (4-duct)
X
X
X
X
X
Oil cooler
Oil filter bracket
Oil pan
Oil pump
Oval flange
Retarder
X
Soot filter
Steering servo pump
X
X
X
X
Throttle flap
Timing cover
Turbocharger
X
X
X
X
X
Universal drive shaft
Vacuum pump
Valve cover
Water pump
X
X
X
site gaskets
Screen printed SH
Molded rubber
gaskets
3)
Screen printed QE
3)
Screen printed SF
3)
ACM 50 and ACM 60
Special solutions
Firmly bonded sealing Firmly bonded sealing
compounds DX 4)
compounds F52 5)
Wave-Stopper®
6)
Fixing/
clamping claw
7)
Ambient conditions
150
- 30 up to + 90
++
220
- 50 up to + 180
++
150
- 10 up to + 130
++
160
- 40 up to + 150
++
120
110
++
250
- 24 up to + 230
++
++
++
+
0
++
++
0
+
-
0
44
44
44
46
48
48
Temperature range
Peak temperature (short-term) [°C]
Continuous temperature [°C]
Conformability (depending on
roughness and distortion)
Permissible internal pressure
Dynamics
50
51
Details on page
PROGRESSION® CS AND PROGRESSION® CS PLUS – STANDARD SOLUTION FOR AN ATTRACTIVE PRICE
Material
PROGRESSION® CS and PROGRESSION®
CS plus are metal gaskets with an elastomer coating on both sides. Moreover,
both sides of the gasket material have
a non-stick surface.
PROGRESSION® CS has a core of 0.25 mm
thick steel sheet, coated on both sides
with a 65 µm layer of nitrile rubber
(NBR). PROGRESSION® CS plus differs
in that its core is of 0.2 mm thick stainless spring steel (material 1.4310) with
a 75 µm layer of NBR on both sides.
CS plus gaskets are always beaded.
Therefore, these gasket materials provide perfect solutions e.g. for intake
manifolds and areas subjected to high
mechanical and/or thermal loads, as
well as particularly narrow sealing faces
with low surface pressures. Other typical applications are oil pans, transmission flanges, housings, and pumps.
Properties
Apart from excellent conformability to
uneven sealing surfaces, PROGRESSION®
CS and PROGRESSION® CS plus ensure
outstanding sealing against liquids and
gases. Both gasket materials are resistant against oils, fuels, antifreeze, refrigerants, and biologically degradable
lubricants.
PROGRESSION® CS plus exhibits much
higher elasticity and recovery than
PROGRESSION® CS, and even better
mechanical strength and corrosion resistance.
Application example
For stable systems with low bolt forces
and low thermal expansion, PROGRESSION® CS offers an attractive price/performance ratio, e.g. as a flange gasket
on the engine intake side.
PROGRESSION® CS plus is intended
primarily for systems with high dynamic
loading and high alternating pressures
up to 120 bar, e.g. in the power steering pump.
Application areas
PROGRESSION® CS is the standard solution for static applications with medium bead loads, whilst PROGRESSION®
CS plus is intended for highly dynamic
applications with high bead loads. Both
materials are suitable for working temperatures up to 200 °C.
Trend
CS plus are the answer to increasing
pressures and dynamics in modern,
high-performance engines. Both gasket
materials offer numerous possibilities
for integration, and have sufficient reserves for future sealing concepts.
Non-stick coating
Full-surface NBR coating
Bonding agent
Core material carbon steel or
stainless spring steel
(type 1.4310)
Half bead
Full bead
Constructional layers of PROGRESSION® CS and PROGRESSION® CS plus.
¬ 16
Design versions with half and full beads.
PROGRESSION® CS
PROGRESSION® CS plus
Technical data
1)
PROGRESSION® CS
Core
Carbon steel
Core thickness
0.25 mm
0.2 mm
Thickness of NBR coating (each side)
65 µm
75 µm
~ 2.15 kg/m2
~ 2.15 kg/m2
> 45 N/mm2
> 45 N/mm2
<7%
<7%
< 10 %
< 10 %
- in water / antifreeze (50:50); 5 h, 100 °C
<5%
<5%
Thickness increase
240 °C
240 °C
Peak temperature (short-term)
-40 up to +200 °C
-40 up to +200 °C
Continuous temperature
75 N/mm2
75 N/mm2
PROGRESSION® CS
Gaskets according to drawing, dimensions provided, or other agreements
Max. width 500 mm
Max. width 500 mm
Nominal thickness
0.38 mm
±0.04 mm
0.38 mm
±0.04 mm
Construction
1.4310
Weight per unit of surface area
Creep resistance
to DIN 52913
16 h, 300 °C
Swelling
to ASTM F146
- in oil IRM 903; 5 h, 150 °C
Thickness increase
in ASTM Fuel B; 5 h, RT
Thickness increase
Surface pressure (max. at 200 °C)
Dimensions and forms of delivery
Tolerances
1)
The above technical data are valid for the material "as delivered",
without any additional treatment.
Integral clips ensure simple (overhead) installation.
High quality thanks to clean-cut edges.
Beads (half beads) provide higher line pressures.
¬ 17
PROGRESSION ® CA – LIGHTWEIGHT WITH A BRIGHT FUTURE
Application areas
PROGRESSION® CA is the preferred gasket material for all lightweight components, and temperatures up to 120 ºC.
Its special advantages become apparent
when used with Al and Mg flanges, as
there is no corrosion.
Material
PROGRESSION® CA is a metal (aluminium) gasket material, with an elastomer
coating on both sides. Moreover, both
sides of the material have a non-stick
surface. PROGRESSION® CA has a core
of 0.20 mm thick aluminium sheet
(Al/Mg alloy), coated on both sides with
a 75 µm layer of nitrile rubber (NBR).
Normally, PROGRESSION® CA is beaded.
Properties
PROGRESSION® CA has outstanding specific properties: Low weight, high thermal conductivity, excellent corrosion resistance. Particularly when used to seal
aluminium components, the identical
thermal expansion coefficient is of decisive importance.
Due to its unique combination of aluminium, elastomer, and beads, PROGRESSION® CA offers all the features
required for good conformability to
uneven surfaces, high sealing integrity
with liquids and gases, high elasticity of
the installed gasket (recovery), plus
good media resistance.
Application example
The high performance potential of PROGRESSION® CA is not only due to the
materials used. Especially because of
low surface pressures and occasional
high values of surface roughness, this
gasket material is used e.g. in charge
air dampers and other mechanical compressors.
Trend
The trend toward lightweight construction
will increase. Engines and individual components of aluminium or magnesium are
determining factors in automotive engineering. PROGRESSION® CA effectively
supports this development. Also in future.
Non-stick coating
Full-surface NBR coating
Bonding agent
without bead
Al/Mg alloy core
Half bead
Fullbead
®
Constructional
layers of
CA.
Guaredisch ndeunfeg
sitPROGRESSION
dolor sit ament.
¬ 18
Design versions
without
andament.
with half or full bead.
Guaredisch
ndeunfeg
sit bead,
dolor sit
PROGRESSION® CA
Technical data
1)
PROGRESSION® CA
Construction
Core
Al/Mg alloy
Core thickness
0.20 mm
75 µm
~ 0.70 kg/m2
Creep resistance
to DIN 52913
16 h, 300 °C
Swelling
> 47 N/mm2
to ASTM F146
- in oil IRM 903; 5 h, 150 °C
Thickness increase
<5%
- in ASTM Fuel B; 5 h, RT
Thickness increase
< 10 %
- in water/antifreeze (50:50); 5 h, 100 °C
Thickness increase
<5%
130 °C
-40 up to +120 °C
75 N/mm2
PROGRESSION® CA
max. width
Max.
Breite 500
500 mm
mm
Nominal thickness
0.35 mm
0,35
±0.04
0,04 mm
Tolerances
1)
High
sealingndeunfeg
potential sit
with
lightweight
construction.
Guaredisch
dolor
sit ament.
Guaredisch ndeunfeg sit dolor sit ament.
Guaredisch ndeunfeg sit dolor sit ament.
¬ 19
RETALL ® FPM PLUS – TEMPERATURE & MEDIA UNDER CONTROL
Application areas
RETALL® FPM plus is used for sealed
joints that place high demands on mechanical and thermal loading. These
include EGR, intake manifold, engine
ancillaries, and valves.
Material
RETALL® FPM plus consists of a sheet
steel core that is coated on both sides
with a high-quality elastomer. Moreover, both sides of the gasket material
have a non-stick surface. RETALL® FPM
plus has a core of stainless spring steel
(type 1.4310), and a thin elastomer
coating of fluorine rubber (FPM). The
gaskets are always beaded.
Properties
The special coating of RETALL® FPM plus
is a guaranteed combination of high
temperature resistance up to 280 °C,
and excellent media resistance. Other
features are outstanding conformability
to uneven surfaces, very high sealing
integrity with liquids and gases, high
elasticity of the installed gasket (recovery), plus mechanical strength. All of
these sealing properties are due to the
combination of an elastomer-coated
metal core and beads.
Application example
Thanks to its high temperature resistance, RETALL® FPM plus is the preferred
material for valve gaskets in exhaust
gas recirculation (EGR) systems. The
gaskets are fitted with clamping claws,
e.g. for clipping them to oval flanges.
Screw retainers greatly simplify overhead installation.
Trend
The demand for environmentally compatible engines with optimized emission values leads to increasingly high
operating temperatures for EGR systems. RETALL® FPM plus is a gasket
material that has been designed specifically for the demands placed by
EGR systems.
Non-stick coating
Full-surface FPM coating
Bonding agent
Core of stainless spring steel
(type 1.43010)
Half bead
Full bead
Constructional layers of RETALL® FPM plus.
¬ 20
Design versions with half and full beads.
RETALL® FPM plus
Technical data
1)
RETALL® FPM plus
Construction
Core
1.4310
Core thickness
0.20 mm
25 µm
~ 1.65 kg/m2
Creep resistance
to DIN 52913
16 h, 300 °C
Swelling
> 45 N/mm2
to ASTM F146
- in oil IRM 903; 5 h, 150 °C
Thickness increase
<5%
Thickness increase
<5%
Thickness increase
<5%
300 °C
-40 up to +280 °C
100 N/mm2
RETALL® FPM plus
Max. width 500 mm
Nominal thickness
0.25 mm
±0.02 mm
Tolerances
1)
Fixing clip for easier installation.
Quality pays off – temperature and media-resistant coatings.
¬ 21
RETALL ® F51 AND RETALL ® F52 – OPTIMUM SEALING WITH PARTIAL COATING
used e.g. in high-pressure fuel pumps,
where peak pressures in excess of
2400 bar are possible, whilst RETALL®
F52 is used e.g. in the control modules
for automatic transmissions.
Material
RETALL® F51 and RETALL® F52 are metal gasket materials, which have been
partially coated with fluorine rubber
(FPM) using the screen-printing process.
RETALL® F51 has a core of corrosionproof stainless steel (type 1.4310), whilst
with RETALL® F52 it is made of carbon
steel or aluminium.
RETALL® F51 gaskets are always beaded.
Properties
The partial coating of RETALL® F51 guarantees extremely low setting behaviour,
e.g. in the vicinity of the head bolts, and
reliable clamping conditions. RETALL®
F51 has good conformability, high elasticity, very good sealing integrity with
liquids and gases, plus outstanding
thermal resistance up to 240 °C continuous temperature.
RETALL® F52 also has good conformability, excellent creep resistance, is resistant to automatic transmission fluids
(ATF), and temperature resistant up to
240 °C.
Thanks to possible coating thicknesses
up to 500 µm, component distortions
can be optimally compensated.
Application areas
RETALL® F51 and RETALL® F52 offer
all the features required for demanding
special solutions. In combination with
special bead designs, RETALL® F51 is
Application example
The combination of pulsating internal
pressures, low bolt clamping forces,
and wide bolt spacing is a challenge
for every gasket. Thanks to the pronounced plastic-elastic behavior of the
partial coating, RETALL® F52 is the ideal
sealing concept for automatic transmission control modules, as it provides
optimum compensation of component
distortions.
Trend
When it comes to contamination from
particles or dust, high demands are
placed on precision components such
as high-pressure fuel pumps. VICTOR
REINZ was the first gasket manufacturer to introduce automatic cleaning &
packaging processes for gaskets, thus
meeting customer demands in terms
of cleanliness.
Non-stick coating
Partial FPM coating
Bonding agent
Core of stainless spring steel
(type 1.43010), of carbon
steel, or aluminium
Half bead
Full bead
Constructional layers of RETALL® F51 and RETALL® F52.
¬ 22
Design versions of RETALL® F51 with half and full beads.
Technical data
1)
RETALL® F52
Carbon steel
1.4310
Aluminium
Core thickness
0.20 mm
0.80 up to 1.8 mm
5 up to 40 µm
60 up to 500 µm
Density of FPM coating
~ 1.90 g/cm3
~ 1.90 g/cm3
70 Shore A
70 Shore A
~ 1.55 kg/m2
~ 1.55 kg/m2
- in oil ATF
resistant
resistant
- in oil IRM 903; (replaces oil No. 3) 5 h, 150 °C
resistant
resistant
resistant
-
280 ˚C
280 ˚C
-30 up to +240 ˚C
-30 up to +240 ˚C
RETALL® F51
RETALL® F52
0.20 mm
acc. to EN 10258-10259
0.80 up to 1.8 mm
acc. to EN 10258-10259
RETALL® F51
RETALL® F52
RETALL® F51
Construction
Core
Hardness
to DIN 53505
Swelling
to ASTM F146
Nominal thickness
Tolerances
1)
Increased safety through highly precise positioning of the coatings (RETALL® F51).
With RETALL® F52, high coating thicknesses provide optimal compensation of
component distortions.
¬ 23
Beaded metal gaskets with fiber-reinforced elastomer coating
MATRICS ® AND MATRICS ® PLUS – PERFECT CONFORMABILITY
Material
Matrix Coated Steel – MatriCS® for short
– is the unique combination of a sheet
steel core and a fiber-reinforced elastomer coating. MatriCS® has a carbon
steel core, whilst MatriCS® plus uses
stainless steel. A coating of fiber-reinforced, temperature-resistant elastomer
is rolled onto both sides of the sheet
core. Hereby, a primer layer ensures a
perfect and durable rubber-metal bond,
and a non-stick gasket surface guarantees optimum disassembly properties.
MatriCS® consists of a 0.25 mm thick
steel sheet, coated on both sides with
a 0.125 mm layer of high-quality, fiberreinforced nitrile rubber (NBR).
MatriCS® plus differs from MatriCS® in
that the core material is 0.2 mm stainless spring steel (type 1.4310) with a
slightly thicker elastomer coating of
0.15 mm.
Properties
MatriCS® and MatriCS® plus combine
mechanical strength and outstanding
creep resistance with high compressibility and excellent recovery. MatriCS®
and MatriCS® plus stand for high temperature and media resistance, in
particular with regard to mineral and
synthetic oils, fuels, antifreeze, and refrigerants.
With its stainless steel core, MatriCS®
plus offers additional advantages. The
gasket is corrosion-proof, has an even
longer service life, and due to its even
better recoverability, it features optimized dynamic behavior.
Application areas
MatriCS® and MatriCS® plus are designed to withstand high mechanical
and thermal loads. Therefore, these
gasket materials provide universal
sealing solutions for engines, engine
ancillaries, and for drivetrains.
MatriCS® is the standard answer for
rough sealing surfaces, whilst MatriCS®
plus sets new standards in the damping of component dynamics. Typical
applications for MatriCS® are intake
manifolds, oil pans, EGR systems, and
gearbox covers; for MatriCS® plus they
include timing chain covers, oil pans,
and water pumps.
Application example
The strengths of MatriCS® and MatriCS®
plus come to bear especially with flexurally weak components that exhibit
low sealing pressures and poor pressure
distribution. With gearbox covers, for
example, beaded gaskets provide highly reliable and durable sealing even
with low bolt forces and rough sealing
faces.
Trend
Lightweight construction and downsizing concepts require increasingly wide
bolt spacing and higher temperatures.
MatriCS® and MatriCS® plus boost the
performance potential of elastomercoated metal gaskets by means of
significantly improved conformability,
and low setting at high temperatures.
Non-stick coating
Full-surface reinforced NBR coating
Bonding agent
Without bead
Core material carbon steel or
Half bead
Full bead
Constructional layers of MatriCS® and MatriCS® plus.
¬ 24
Design versions without bead, and with half or full bead.
Technical data
1)
MatriCS
®
MatriCS® plus
Construction
Core
Carbon steel
Core thickness
0.25 mm
125 µm
~ 2.20 kg/m
1.4310
Creep resistance
150 µm
~ 1.80 kg/m2
2
to DIN 52913
16 h, 300 °C
> 45 N/mm2
> 45 N/mm2
4 up to 10 %
4 up to 10 %
< 40 %
< 40 %
<5%
<5%
<5%
<5%
Thickness increase
<5%
<5%
300 °C
300 °C
-40 up to +220 °C
-40 up to +220 °C
100 N/mm2
100 N/mm2
MatriCS®
MatriCS® plus
Max. width 500 mm
Max. width 500 mm
Nominal thickness
0.5 mm
±0.05 mm
0.5 mm
±0.05 mm
Zusammenpressung und Rückfederung
to ASTM F36J
Zusammenpressung
Rückfederung
Swelling
MatriCS®
MatriCS® plus
0.20 mm
to ASTM F146
- in oil IRM 903; 5 h, 150 °C
Thickness increase
Thickness increase
Tolerances
1)
Reliable joint between core and coating thanks to bonding agent.
Beads (full beads) provide higher line pressures.
¬ 25
Beaded metal gaskets – now up to 1100 °C
RETALL ® HRS AND RETALL ® HTS – LESS CAN BE MORE
results are obtained at working temperatures up to 650 ºC, and up to 950 ºC
with RETALL® HTS.
Material
RETALL® HRS and RETALL® HTS are
purely metal gasket materials with one
or more layers, made of stainless spring
steel or stainless high-temperature
steel. With multilayer versions, the individual layers are spot-welded and,
depending on the application, they are
beaded.
Application areas
The application areas of RETALL® HRS
and RETALL® HTS depend on the specific requirements. RETALL® HRS is the
best choice for working temperatures
up to 650 ºC and high demands on
elasticity, whilst RETALL® HTS is ideal
for working temperatures up to 950 ºC
but with lower demands on recovery.
Both material types are used mainly
for exhaust manifolds, turbochargers,
EGR flanges, diesel particle filters, and
catalytic converters.
Especially for series production, RETALL®
HRS and RETALL® HTS are the standard
solution for exhaust system applications.
Properties
RETALL® HRS and RETALL® HTS exhibit
high temperature resistance and high
durability. With RETALL® HRS, the best
Application example
RETALL® HRS is preferably used for
two-layer exhaust manifold gaskets.
Special designs with beads and stop-
pers ensure good recovery, as required
by high component dynamics as well
as occasional extreme thermal expansion. Stoppers relieve the beads so that
they are not fully compressed, and the
defined working range is maintained.
The stopper serves as a pre-sealing
element and reduces the dynamics at
the component surfaces.
For applications on and around the turbocharger, the strengths of RETALL®
HTS play a decisive role. The material's
high temperature resistance sets new
standards in this area.
Trend
High dynamics and temperature stresses with increasing exhaust gas back
pressures – these requirement specifications for modern turbocharged engines are met by gaskets made with
RETALL® HRS and RETALL® HTS.
Tip!
For applications with extreme operating conditions, the new RETALL®
HRTS with a high-temperature steel
core can be used. This gasket material withstands temperatures up to
1100 °C, whilst exhibiting good recovery behaviour.
Sheet steel type 1.4310 or 1.4828
Constructional layers of RETALL® HRS and RETALL® 1.4828.
¬ 26
Single-layer (SLS), two-layer (DLS), and multi-layer (MLS) design versions.
Technical data
1)
RETALL® HRS
RETALL® HTS
1.4310 acc. to EN 10088-2
1.4828 acc. to EN 10059
RETALL® HRS
RETALL® HTS
Nominal thickness
0.2 mm, 0.25 mm, 0.3 mm
0.2 mm up to 0.6 mm
Tolerances
other thicknesses on request
acc. to EN 10258/10259
other thicknesses on request
acc. to EN 10258/10259
Material no.
RETALL® HRS
RETALL® HTS
1)
Beads (full beads) provide higher line pressures.
Integral screw retainer.
¬ 27
THERMO-GLIDE ® – PERFECTLY TIGHT IN SPITE OF HIGH DYNAMICS AND TEMPERATURES
Application areas
thermo-glide® is particularly suitable
for sealed joints that must provide good
micro-sealing under high dynamic and
thermal loading. Main application areas
are for components subjected to different thermal expansion rates: e.g. exhaust manifold gaskets, turbocharger
gaskets, highly stressed gaskets for
EGR systems, and other gaskets in the
exhaust train.
Material
thermo-glide® is a powder-coated layer
of lubricating lacquer for metal gaskets. The combination of high-temperature-resistant resins and special organic lubricant materials is used to
increase the potential of RETALL® HRS
and RETALL® HTS.
Normally, thermo-glide® is applied to
the gasket surface that is exposed to
the hotter and/or rougher side of the
sealed joint.
Properties
The high-temperature-resistant thermoglide® coating reduces friction and
improves the gasket's conformability
to micro-roughnesses. This ensures
considerably better sealing integrity.
thermo-glide® resists temperatures up
to 1000 °C.
Thanks to the simultaneous use of several wear and friction-reducing lubricants, thermo-glide® exhibits optimal
slip characteristics in a wide temperature range. It provides lasting protection
from surface damage due to cold welding, as the frictional wear of the gasket
and component surfaces under thermal
and dynamic loading is significantly
reduced.
Application example
Modern exhaust manifold gaskets between cylinder head and manifold must
provide perfect sealing in spite of high
temperature variations and frictional
movement. Even during cold tests,
thermo-glide® has very low leakage
values, and in its role as a problemsolving layer, it prevents damage to the
beads caused by frictional movement.
Trend
Increasingly tough emission regulations
place new demands on the sealing integrity of the entire exhaust train. Already today, special bead technology in
combination with thermo-glide® ensures
the compliance with future emission
legislation involving reduced leakage
rates for lower exhaust gas emissions.
Optional cover layer
Full-surface, high-temperatureresistant slip coating
Blank stainless steel core
Constructional layers of thermo-glide®.
¬ 28
Technical data
1)
thermo-glide®
Construction
Thickness of thermo-glide® coating (each side)
30 µm
Component roughness Rz
< 20 µm
Max. operating temperature
1000 ºC
thermo-glide®
Base material: plain gaskets with stainless steel core
thermo-glide®
Nominal thickness
0.20 mm up to 3.00 mm
acc. to DIN 28091-1
Tolerances
1)
Multi-layer design for high component dynamics.
Maximum sealing with minimum friction.
¬ 29
FPM 70 – INCLUDING FLEXIBLE MEDIA AND TEMPERATURE RESISTANCE
Material
FPM 70 consists of a metal core with
molded-on FPM elastomer profiles. The
core is made of stainless steel (e.g.
type 1.4303) or galvanized carbon steel.
Media-resistant fluorine rubber with a
hardness of 70 Shore A is used as
elastomer.
Hereby, the fluorine rubber can be surface molded, edge molded, or backbone
molded. The elastomer elements are
always used with controlled compression, whereby travel limiting is ensured
e.g. by means of a groove in the component.
Properties
Regarding media resistance, FPM 70 is
an outstanding combination providing
resistance to fuels, water/antifreeze,
and lubricating oil. The gasket material
is designed for a wide temperature
range from -24 °C up to +230 °C.
Other positive features are low setting
and bolt load loss (also in case of wide
bolt spacing), low clamping force requirements for high sealing potential,
plus high elasticity and durability.
Application areas
FPM 70 is particularly suitable for simultaneous sealing of different media
from each other, e.g. in oil filter cooling modules. Other application areas
are sealed joints in the intake duct,
the throttle flap, or in transmissions.
Application example
The edge-molded version of FPM 70
permits the oil and water channels in
oil filter cooling modules to be sealed
in a simple manner. For applications
previously requiring the use of different elastomer materials, FPM 70 is
today's answer. Hereby, the fluorine
rubber molded onto the metal core
adapts to component distortions without overpressing.
Trend
Gaskets with a large surface also need
to be manufactured cost-effectively in
small quantities. Alternatives to onepiece gaskets are inserts of FPM 70
around coolant or oil channels, which
are laser-welded onto the gasket.
Stainless steel or
galvanized carbon steel
Edge-molded FPM
Surface Molded
Edge Molded
Backbone Molded
Constructional layers of FPM 70.
¬ 30
Surface molded, edge molded, and backbone molded elastomer profiles.
Technical data
1)
FPM 70
Construction
Core of stainless steel or galvanized carbon steel
X
Surface-molded elastomer
X
Edge-molded elastomer
X
Backbone-molded elastomer
X
Hardness
to DIN 53505
Compression set
to DIN 53517
16 h, 150 °C
< 40 %
to DIN 53545
up to < -24 ºC
250 ºC
230 ºC
FPM 70
Low-temperature value
70 Shore A
Media resistance
Oil
+
Fuels
+
Water/antifreeze agent (50:50)
+
FPM 70
Molded-on metal/rubber gaskets according to drawing,
dimensions provided, or other agreements
1)
max. size
800 mm x 500 mm
Utmost functionality thanks to high processing quality.
¬ 31
ACM 50 AND ACM 60 – THE COST-EFFECTIVE STANDARD SOLUTION
Material
ACM 50 and ACM 60 consist of a metal
core with molded-on ACM elastomer
profiles. The core is made of stainless
steel (e.g. type 1.4303) or galvanized
carbon steel. Acrylic rubbers with a
hardness of 50 Shore A or 60 Shore A
are used as elastomer.
Hereby, the acrylic rubber can be surface molded, edge molded, or backbone
molded. The elastomer elements are
always used as force shunts, whereby
travel limiting is ensured e.g. by means
of a groove in the component.
Properties
ACM 50 and ACM 60 are characterized
by very good resistance against oil in a
wide temperature range between -30 °C
and +150 °C. Other positive features
are low setting and bolt load loss (also
in case of wide bolt spacing), low clamping force requirements for high sealing
potential, plus high elasticity and durability.
Application areas
ACM 50 and ACM 60 provide a high
sealing potential at low clamping forces.
Similarly, setting tendency and bolt
load loss are low, even with wide bolt
spacing. As a result, this gasket material is preferred for flexurally weak components with low surface pressures,
e.g. for oil pans and valve cover modules.
Application example
The metal/rubber material ACM 50 is
used for backbone-molded gaskets on
valve covers. Ensuring top quality: To
position the core sheet precisely during
the production process, it is held by
means of special locating pins. Apart
from perfect sealing, the subject of NVH
(noise, vibration, harshness) also plays
a decisive role.
ACM 50 – a solution that's not only tight,
but also quiet.
Trend
ACM 50 and ACM 60 provide cost-effective standard solutions not only for
all classical applications, but also customized solutions for modern engine
design. In short – an excellent tip.
Moreover, ACM 50 and ACM 60 are
finding increasing use in applications
with very high demands on durability,
and for components with distortion problems.
Stainless steel or
galvanized carbon steel
Edge-molded ACM
Surface Molded
Edge Molded
Backbone Molded
Constructional layers of ACM 50 and ACM 60.
Surface molded, edge molded, and backbone molded elastomer profiles.
¬ 32
Technical data
1)
ACM 50/60
Construction
X
X
X
X
Hardness
to DIN 53505
Compression set
to DIN 53517
16 h, 150 °C
50/60 Shore A
< 20 %
to DIN 53545
< -30 ºC
160 ºC
150 ºC
Oil
+
Fuels
0
-
ACM 50 and ACM 60
Media resistance
ACM 50/60
1)
max. size
800 mm x 500 mm
Integral screw retainer.
¬ 33
HTV 50 – THE SIMPLE SOLUTION FOR SPECIAL PURPOSES
Material
HTV 50 consists of a metal core with
molded-on silicone elastomer profiles.
The core is made of stainless steel
(e.g. type 1.4303) or galvanized carbon
steel. Silicone rubber with a hardness
of 50 Shore A is used as elastomer.
HTV stands for High Temperature Vulcanization.
The silicone rubber is edge-molded to
the metal core. Hereby, the moldings
are always used as force shunts, whereby travel limiting is ensured e.g. by
means of a groove in the component.
Properties
Due to its outstanding flow properties,
HTV 50 is very simple to apply and
process, so that retro-vulcanization is
not necessary. Its temperature resistance lies in the range between -40 °C
and +200 °C. Other positive features
are low setting and bolt load loss (also
in case of wide bolt spacing), low clamping force requirements for high sealing
potential, plus high elasticity and durability. The material is conditionally oilresistant.
Application areas
HTV 50 is the ideal solution for all standard applications. In particular for sealing tasks involving covers and electrical
connectors.
Stainless steel
or galvanized carbon steel
Edge-molded silicone
Construction of edge-molded HTV 50.
¬ 34
Application example
With engines designed using magnesium, corrosive electrochemical potentials arise along the bare punched edges
at the outer contours of the gasket's
individual metal layers.
In combination with a special insulating
coating, a circumferential sealing lip of
HTV 50 is molded along the outer punched edges to provide effective corrosion
protection.
Trend
Simple processing without retro-vulcanization is a cost-effective sealing solution for special cases. HTV 50 is the
individual gasket material for special
requirements.
Technical data
1)
HTV 50
Construction
X
X
Hardness
to DIN 53505
Compression set
to DIN 53517
16 h, 150 °C
50 Shore A
< 30 %
to DIN 53545
< -40 ºC
220 ºC
200 ºC
0
Fuels
-
-
HTV 50
1)
max. size
800 mm x 500 mm
¬ 35
HTV 50
Oil
Media resistance
High-temperature gaskets
XTREME ® PLUS – WHEN EXTREME TEMPERATURES REPRESENT AN ABSOLUTE CHALLENGE
Material
Xtreme® plus consists of a tanged steel
core, onto which a fiber-reinforced mica
layer is rolled from both sides. The core
material is a 0.20 mm thick stainless
steel (type 1.4828) sheet that has been
tanged. Apart from expanded mica,
the coating material contains temperature resistant fibers as well as a small
amount of high-grade elastomers as
binder. Due to the special properties of
the mica material, which prevents the
gasket from burning-in or baking to
the sealing surface, a non-stick coating is not necessary.
The material is available in overall thicknesses of 1.2 mm and 1.6 mm.
Properties
Xtreme® plus withstands high temperatures up to 950 °C, and provides a
high sealing potential over the entire
temperature range. Due to its high compressibility and elasticity, this gasket
material is extremely conformable,
compensates component deformations
in an optimal manner, and exhibits constant material properties also under
changing operating conditions.
Further advantages are high creep resistance, i.e. a low setting tendency,
good media resistance, high gas tightness, and good thermal insulation with
a low coefficient of thermal conductance.
Under extreme mechanical loads, the
optional internal bead permits higher
internal pressures and provides better
cross-sectional sealing.
Wider beads reduce the gasket's setting
behaviour. If required, a one-sided bead
up to the gasket's outer contour increases mechanical strength and improves the gliding properties through
special measures.
Application areas
Xtreme® plus was developed especially
for high-temperature applications, and
therefore provides optimum solutions
for all tasks in the exhaust area. It is
particularly suitable for turbocharger
gaskets, but also for installation between
cylinder head and exhaust manifold, in
the downstream flanges of exhaust
trains, and for components in EGR systems.
Application example
The preferred use of Xtreme® plus is
for turbocharger gaskets. Here, Xtreme®
plus compensates component movements caused by large temperature
variations very well. For special solutions, the gaskets usually have metal
beaded edges.
Trend
Tighter emission regulations have a
decisive influence of engine development, whilst engines are becoming
more compact and have higher outputs.
This leads to higher exhaust gas temperatures and simultaneously higher
combustion pressures. In summary,
the engine has fewer opportunities for
cooling down. The high-temperature
gasket material Xtreme® plus is ideally
suited to meet these demands.
High-temperature coating
Expanded mica
Tanged metal core
Stainless steel type 1.4828
without beaded edge
with simple edge beading
with extended edge beading
Constructional layers of Xtreme® plus.
¬ 36
Design versions without bead, with simple and with extended edge beading.
Technical data
1) 2)
Xtreme® plus
Construction
Core
Stainless steel 1.4828
Core thickness
Creep resistance; 16 h, 300 °C
0.20 mm and 0.30 mm
to DIN 52913
Nominal thickness 1.2 mm
~ 42 N/mm2
Nominal thickness 1.6 mm
~ 38 N/mm2
Compressibility and recovery
to ASTM F36 J
Compressibility
5 % up to 15 %
Recovery
Swelling
> 40 %
to ASTM F146
- in oil IRM 903; 5 h, 150 °C
Thickness increase
<5%
Weight increase
< 15 %
Thickness increase
<5%
Weight increase
< 10 %
Thickness increase
< 10 %
Weight increase
< 18 %
950 °C
75 N/mm2
Xtreme® plus
Xtreme® plus
Nominal thickness
Tolerances
1.2 mm and 1.6 mm
±0.01 mm
2)
For critical applications, an inner bead is advantageous.
1)
Optional inner bead permits higher internal pressures and provides better cross-sectional sealing.
¬ 37
Fiber composite gaskets
AFM ® 30 – MEDIUM-HARD STANDARD SOLUTION FOR DEMANDING OPERATING CONDITIONS
thermal resistance. AFM® 30 is suitable
for short-term peak temperatures up to
400 ºC, and continuous temperatures
up to 250 ºC.
Both sides of AFM® 30 are coated with
a high-friction layer as standard, which
facilitates dismantling and makes additional surface treatment unnecessary
in most cases.
Material
AFM® 30 is a composite gasket material based on synthetic fibers. This asbestos-free gasket material contains aramid
fibers and other temperature-resistant
asbestos substitutes that have been processed together with high-grade elastomers under increased pressure and
elevated temperature.
Properties
AFM® 30 is a standard quality that meets
high operational demands. This composite gasket material provides reliable
sealing against gases, oils, fuels, and
antifreeze agents; moreover, it exhibits
good conformability, high tensile and
shear strength, as well as mechanical/
High-friction layer
on both sides
Synthetic fibers,
elastomers, filling media.
Constructional layers of AFM® 30.
¬ 38
Application areas
AFM® 30 is used primarily for sealing
transmission, hydraulic, refrigerant, and
engine oils, as well as fuels. Other uses
for AFM® 30 are found in oil pans, oil
filter housings, water pumps, and air
compressors.
Application example
The good conformability and low setting
tendency of AFM® 30 is particularly useful when sealing automatic transmissions. Moreover, the material exhibits a
high coefficient of friction for torque
transfer.
Technical data
1) 2)
AFM® 30
Tensile strength (cross grain)
to ASTM F 152
Creep resistance
to DIN 52913
16 h, 300 °C
> 12 N/mm2
~ 36 N/mm2
to ASTM F 36 J
Compressibility
7 % up to 15 %
Recovery
> 50 %
Gas permeability with nitrogen
to DIN 3535, Part 6 FA
Swelling
~ 0.5 cm3/min
to ASTM F146
Thickness increase
< 10 %
Weight increase
< 10 %
Thickness increase
< 10 %
Weight increase
< 10 %
Thickness increase
<5%
Weight increase
< 10 %
250 ˚C
Max. operating pressure
100 bar
AFM® 30
Tolerances
1)
2)
0.30 mm up to 5.00 mm
acc. to DIN 28091-1
AFM® 30
Nominal thickness
Max. operating temperature and max. pressure may not occur
simultaneously.
Screen-printing for improved sealing effect and higher internal pressure loads.
¬ 39
AFM ® 31 – STANDARD COMPOSITE SOLUTIONS WITH HIGH SEALING POTENTIAL
able for short-term peak temperatures
up to 300 ºC, and continuous temperatures up to 250 ºC.
Material
AFM® 31 is a composite gasket material based on synthetic fibers. This asbestos-free gasket material contains aramid
fibers and other temperature-resistant
asbestos substitutes. AFM® 31 is manufactured together with high-grade elastomers under increased pressure and
elevated temperature.
Both sides of AFM® 31 are coated with
in most cases.
Application areas
AFM® 31 is used mainly for sealing joints
between components that are easily
deformed, and have relatively low clamping pressures, such as oval flanges, oil
pans, and gearbox covers.
Properties
Furthermore, AFM® 31 is a very conformable gasket material that is highly
compressible and flexible. Worth noting
is the very good sealing effect against
gases and liquids, such as oils, fuels,
and antifreeze agents – also with low
bolt clamping forces. AFM® 31 is suit-
Application example
Frequently, the sealing surfaces of oil
pans are flexurally weak, so that high
clamping pressures are not possible. The
composite material AFM® 31 achieves
optimum sealing results with wider bolt
spacings combined with low clamping
pressure.
High-friction layer
on both sides
Synthetic fibers,
elastomers,
and filling media
Constructional layers of AFM® 31.
¬ 40
Technical data
1) 2)
AFM® 31
to ASTM F 152
Creep resistance
to DIN 52913
16 h, 175 °C
> 8 N/mm2
~ 24 N/mm2
to ASTM F 36 J
Compressibility
14 % up to 23 %
Recovery
> 50 %
Swelling
~ 0.1 cm3/min
to ASTM F146
Thickness increase
< 10 %
Weight increase
< 20 %
Thickness increase
< 15 %
Weight increase
< 20 %
Thickness increase
<5%
Weight increase
< 15 %
250 ˚C
80 bar
AFM® 31
Nominal thickness
Tolerances
2)
simultaneously.
AFM® 31
1)
0.30 mm up to 2.00 mm
acc. to DIN 28091-1
High quality thanks to clean-cut edges.
¬ 41
AFM ® 32/2 – STANDARD SOLUTION FOR APPLICATIONS WITH HIGH MECHANICAL LOADS
Both sides of AFM® 32/2 are coated with
in most cases.
Material
AFM® 32/2 is a composite gasket material based on synthetic fibers. This
asbestos-free gasket material contains
aramid fibers and other temperatureresistant asbestos substitutes that have
been processed together with high-grade
elastomers under increased pressure
and elevated temperature.
Properties
AFM® 32/2 has very high mechanicalthermal stability and tensile strength.
The material is highly conformable, and
is especially suitable for sealing oils
and other liquid media. AFM® 32/2 is
suitable for short-term peak temperatures up to 400 ºC, and continuous
temperatures up to 250 ºC.
High-friction layer
on both sides
Synthetic fibers,
elastomers,
and filling media
Constructional layers of AFM® 32/2.
¬ 42
Application areas
AFM® 32/2 is frequently used to seal
joints subjected to high mechanical
loads. Typical application areas are
intake manifolds, compressor flanges,
and components that must withstand
severe vibration, such as the chassis.
Application example
As an optimum solution for applications
involving high mechanical loads, AFM®
32/2 is also the classical material used
for door lock pads. Hereby, the material is used as an underlay (sometimes
with an adhesive layer) to provide scratch
protection. In these applications, the
high-strength material also absorbs
vibrations and provides corrosion protection.
Technical data
1) 2)
AFM® 32/2
to ASTM F 152
Creep resistance
to DIN 52913
16 h, 175 °C
> 15 N/mm2
~ 36 N/mm2
to ASTM F 36 J
Compressibility
7 % up to 12 %
Recovery
> 50 %
Swelling
~ 1.0 cm3/min
to ASTM F146
Thickness increase
<8%
Weight increase
< 12 %
Thickness increase
<7%
Weight increase
< 10 %
Thickness increase
<5%
Weight increase
< 15 %
250 ˚C
150 bar
AFM® 32/2
Nominal thickness
Tolerances
1)
simultaneously.
AFM® 32/2
2)
0.30 mm up to 3.00 mm
acc. to DIN 28091-1
Adhesive layer on one side serves as an assembly aid.
¬ 43
SCREEN-PRINTED GASKETS SH, QE, AND SF – INDIVIDUAL TUNING FOR FLAT GASKETS
Material
Screen-printed gaskets are manufactured by applying polymer compound
beads onto a substrate material, and
subsequent vulcanization of the compact or foamed elastic sealing beads.
Depending on the application and the
substrate material, special bonding
lacquers are used, which also act as
corrosion inhibitors with carbon steel
substrates.
The substrate material can be metal or
composite, i.e. carbon steel, stainless
steel, or aluminium, as well as AFM® –
our asbestos-free composite material
based on synthetic fibers.
Also depending on the application, the
beads have different specifications.
Properties
Screen-printed gaskets achieve significantly better micro and macro-adaptation, and therefore improve the sealing
effect and internal pressure resistance
of flat gaskets. The printed beads can
be applied on one or both sides of the
gasket.
SH-type material exhibits good resistance to mineral oils and greases, has
high mechanical strength, and therefore
permits high line pressures.
QE is resistant to a wide range of media,
is temperature resistant and non-aging.
Moreover, the sealing bead is highly conformable and only requires low clamping pressure to obtain good sealing
results.
Due to the foaming process, SF-type
material is extremely conformable, and
has a medium temperature resistance.
Application areas
Screen-printed gaskets are always used
when conventional gaskets are unable
to provide adequate sealing results.
Even the standard design with constant
SH screen-printing
QE screen-printing
SF screen-printing
Constructional layers of SH, QE, and SF screen-printed gaskets.
¬ 44
sealing/supporting bead heights and
widths ensures good sealing integrity,
especially with flexurally weak components and/or low clamping pressures.
By varying the bead geometry, it is possible to control the surface pressure
precisely, e.g. for joints between different pressures or media.
For timing covers, oil pans, or hydraulic
pumps, screen-printed gaskets enable
practically every bead shape to be implemented without complex tooling.
Application example
Due to uneven pressure distribution as
well as the partially low clamping pressure, flexurally weak components place
high demands on flat gaskets. Elastic
polymer sealing beads can solve these
tasks optimally, for example on timing
covers.
Trend
Innovative engine concepts depend on
gaskets that are matched to the specific
application. Screen-printed gaskets
permit special solutions to be realized
quickly and unconventionally. Due to
the line pressure effect, high-integrity
surface and cross-sectional sealing is
achieved. Consequently, the component
stiffness or clamping pressure required
for a good seal can be lower than with
simple flat gaskets.
Technical data
1)
SH screen-printing
QE screen-printing
SF screen-printing
Construction
Metal substrate
Carbon steel
Carbon steel
Stainless steel,
Stainless steel,
aluminium
Composite substrate
aluminium
AFM® 30
AFM® 30
AFM® 30
AFM® 31
AFM® 31
AFM® 31
AFM 32/2
AFM 32/2
AFM® 32/2
Bead height
0.05 mm up to 0.25 mm
0.05 mm up to 0.25 mm
0.1 mm up to 0.8 mm
Polymer type
Polyurethane
Silicone
Epoxy
®
®
(slightly foamed)
Color
blue
gray
red-brown
-30 up to +90 ºC
-50 up to +180 ºC
-10 up to +130 ºC
SH screen-printing
QE screen-printing
SF screen-printing
Gaskets
SH screen-printing
QE screen-printing
SF screen-printing
1)
with sealing bead according to a drawing
Screen-printing for improved sealing effect and higher internal pressure loads.
Highly precise positioning thanks to perfected manufacturing processes.
¬ 45
ACM 50 AND ACM 60 – MAXIMUM SEALING POTENTIAL WITH MINIMUM CLAMPING FORCE
Material
ACM 50 and ACM 60 are molded rubber
gaskets using acrylic rubber. The elastomer elements are always used as force
shunts, whereby travel limiting is ensured e.g. by means of a groove in the
component or with threaded buffers.
Profile geometries matched precisely
to the application are the guarantee for
optimum functionality. ACM 50 and
ACM 60 have different hardness grades.
The hardness of ACM 50 is 50 Shore A,
whilst that of ACM 60 is 60 Shore A.
Properties
ACM 50 and ACM 60 provide a high
sealing potential at low clamping forces.
Similarly, setting tendency and bolt load
loss are low, even with wide bolt spacing. The cost-effective standard solution
is suitable for a wide temperature range
between -30 °C and +150 °C, and has
very good resistance against oil.
Equally convincing are the elasticity and
durability of ACM 50 and ACM 60.
Application areas
The properties of ACM 50 and ACM 60
are perfect for reliable sealing of flexurally weak components, as these
cases only permit limited clamping
forces.
ACM 50 and ACM 60 are used mainly
for valve cover gaskets, but also for oil
pans and timing covers.
H 100 profile
B profile
Double B profile
Design versions with B, Double B, and H 100 profiles.
¬ 46
Application example
Especially with valve cover gaskets, reliable sealing must be ensured in spite
of wide bolt spacing or unfavorable
creep behavior in the case of plastic
valve covers. In combination with the
special 'H' profile, ACM 50 and ACM 60
achieve an optimum overall performance. Due to its high recovery rate,
a wide working range, and a defined
buckling characteristic, the profile is
pushed up automatically to ensure a
tight seal.
Trend
Also in future, flexurally weak plastic
components will play an important role
in modern lightweight engines. ACM
50 and ACM 60 provide good standard
solutions that can also be used for plastic components with a tendency to
creep. Similarly, this gasket material is
finding increasing use for housing covers made of aluminium or magnesium.
Technical data
1)
ACM 50/60
Hardness
to DIN 53505
Compression set
to DIN 53517
< 20 %
16 h, 150 °C
50/60 Shore A
to DIN 53545
< -30 ºC
160 ºC
150 ºC
Media resistance
Oil
+
Fuels
0
-
ACM 50/60
Gaskets
ACM 50 and ACM 60
1)
according to drawing
Complex designs thanks to perfected manufacturing technology.
¬ 47
Special solutions
FIRMLY BONDED SEALING COMPOUNDS DX AND F52 – RELIABLE SEALING IN CRITICAL SITUATIONS
Application areas
When applied in the form of a bead, DX
is used to seal highly uneven and rough
surfaces. F52 is used in situations involving high component dynamics and/or
elevated temperatures, and requiring
chemical resistance.
Material
Critical sealing conditions arise in cases
of component deformation, high surface
roughness, and in separation areas.
These difficulties can be solved by applying highly plastic sealing compounds
to the gaskets. During installation, the
compound is compressed, thus ensuring a reliable seal also in critical situations.
For this purpose, either the firmly bonded and cured DX compound based on
polyurethane (PU) or the foamed fluorine
rubber (FPM) F52 compound are used.
Properties
The sealing compounds DX and F52
are temperature resistant up to 120 °C
and 240 °C respectively, and resistant
to various media such as engine oil
and coolants. Both compounds have
good bonding properties.
Due to their outstanding flow characteristics, the compounds extrude into
the smallest cavities, surface roughnesses, and gaps without causing a
partial reduction of the gasket's
mounting surface pressure.
DX
F52
Design versions of firmly bonded sealing compounds DX and F52.
¬ 48
Application example
The firmly bonded sealing compound DX
is used typically for the joints of vacuum pumps, whilst F52 is used e.g. in
critical sealing conditions with oil pans.
Trend
Complex engine designs increasingly
require gaskets with additional seals.
The aim is to eliminate the need to
apply the additional seal during installation, and to deliver the gasket complete with compound as a »modular
solution« instead.
Technical data
1)
DX
F52
PROGRESSION®-Series,
PROGRESSION®-Series,
MatriCS® (plus)
RETALL®-Series
Construction
Metal substrate
MatriCS® (plus)
Composite substrate
AFM® 30
AFM® 31
AFM® 32/2
Bead height
1.1 mm
up to 0.6 mm (foamed)
Polymer type
Oligomers
FPM
Polyurethane compound
Color
transparent
blue
up to 120 ºC
-30 up to +240 ºC
DX
F52
Gaskets
Firmly bonded
sealing compounds
DX/ F52
1)
with sealing bead according to a drawing
Highly precise positioning thanks to perfected manufacturing processes.
¬ 49
WAVE-STOPPER ® – PUTTING PRESSURE ON THE LINE
pressure image can be created in the
critical areas. Due to the great degree
of design freedom, the Wave-Stopper®
is able to adapt perfectly to changing
component stiffness. This permits pressure peaks to be equalized, and the
pressures on adjacent components are
distributed evenly. Typical application
areas are exhaust manifold, exhaust
pipe, and turbocharger.
Material
Normally, the Waver-Stopper® consists
of several concentric individual waves.
The wave characteristics are influenced
by various design criteria, and the core
sheet thickness. By means of partially
terminated waves, the gasket can be
individually adapted to the component
stiffness and contour.
Properties
The Wave-Stopper® exhibits pronounced
plastic/elastic behavior, which can be
matched precisely to the gasket's working environment. Moreover, the wave
height profiles can be varied, thus permitting a topographic adaptation.
Consequently, the available bolt clamping forces are utilized to better effect,
and component distortions are reduced.
Application example
Wave-Stopper® achieves excellent results in turbochargers with thermal distortion of the sealed joints. Together
with additional beads, the plastic/elastic behaviour ensures adequate sealing
pressure levels under all operating conditions, and thus provides optimum
sealing.
Application areas
The Wave-Stopper® is used primarily
in combination with gaskets that must
achieve high line pressures due to yielding components or because of high temperature stresses. Thanks to the individual adaptability, a highly uniform
Trend
Not only the design of MLS cylinder head
gaskets has been affected decisively
by the Wave-Stopper®. The Wave-Stopper® is a cost-effective alternative for
complex and critical applications in the
exhaust train.
Design versions. Topographic adaptation using the plastic/elastic characteristics of
the Wave-Stopper®.
¬ 50
CLIPS, CLAWS, AND FASTENERS – FAST, SIMPLE, AND SECURE
Material
Various types are available, such as the
REINZ fixing claw, the REINZ dome, or
other special versions of clips and fasteners.
Basically, all the different types and versions can be used with all beaded metal
gaskets – with and without elastomer
coating.
Properties
Clips and fasteners serve to hold flat
gaskets securely in place. This is always
necessary if the gasket is preassembled
by a systems supplier, or if it must be
prevented from falling during installation
on the assembly line.
Application areas
Clips, claws, and fasteners are used in
countless applications – from A for airbag housing to W for water pump. In
short: Whenever the loss of gaskets from
preassembled engine components must
be prevented, or their installation on the
assembly line is to be simplified.
Application example
Positioning and securing. Occasionally,
combinations of different types of clips,
claws, and fasteners are used, for example in complex oil filter cooler modules. During installation, the gasket must
be positioned precisely (dome), before
it can be secured overhead (clip or claw)
to prevent it falling.
Trend
Faster, simpler, and safer are today's
key words. Detailed solutions using innovative fasteners are extremely useful
during efforts to simplify installation or
assembly, thereby reducing overall costs.
Clip
¬ 51
Fixing/
clamping claw
Design versions using a clip or dome.
Wave-Stopper®
Dome
A vision for the future
HELPING CREATE FUTURE
ENGINE CONCEPTS
TWO EXAMPLES OF THE
AUTOMOTIVE FUTURE
By constantly evaluating market and
technology trends, VICTOR REINZ is
helping make visions become reality.
In fact, many of today’s engine standards are based on innovative solutions from VICTOR REINZ. So it's no
wonder that VICTOR REINZ has developed a strong reputation for ongoing,
outstanding product innovations in the
automotive industry.
SENSORICS ®
The amount of vehicle electronics continues to increase. Measurement and
control will play an essential role in
modern engines. For example, integrated sensors enable fuel consumption
and emissions to be reduced significantly. However, this also involves new demands on sealing technology for modern
engine designs. In future, sensors in
the head gasket will measure temperature and pressure directly in the combustion chamber, to supply data about
the combustion process to the engine
management system. Electronic components inside the engine control fuel
injection, the ignition, and/or the valves,
which means that the electric signals
must be fed to the outside via the gasket.
Solutions for the automotive future come
from VICTOR REINZ. The active cylinder
head gasket SensoriCS® for pressure
and temperature measurement, and the
Window Gasket for the feedthrough of
electronic signals are just two outstanding examples of VICTOR REINZ innovation.
With VICTOR REINZ, automotive visions come true.
In the future, a cylinder head gasket
will no longer be simply a sealing element – it will be an intelligent component in the overall engine system. In
fact, at VICTOR REINZ the future is
now: SensoriCS® – the intelligent MLS
head gasket with integrated pressure
and temperature sensors – helps provide an intelligent engine management
and cooling system.
Pressure measurement Δp
To further reduce emissions and improve
fuel consumption in future IC engines,
measuring the combustion pressures is
a must. This measurement will permit
the engine management system to influence the combustion process far more
precisely. Through active control factors
including injection time and quantity, as
well as EGR ratio, the engine operates
only in the optimum map area, so that
emissions and fuel consumption are reduced. What's more, this system enables
the engine's combustion parameters to
be adapted effectively and flexibly to
different fuel qualities.
Component temperature
Normal coolant flow
Component temperature with
SensoriCS® (reduced coolant flow)
Component temperature close
to cylinders with SensoriCS®
Coolant temperature at
conventional location
Engine output
140
120
100
80
60
40
0
1
2
3
4
5
6
7
8
9
10
20
0
144
145
Time
[min]
Zeit [min]
¬ 52
146
147
148
149
150
151
152
180
160
140
120
100
80
60
40
20
0
153
Time [min]
High temperature gradient for fast attainment of the ideal operating temperatures of engine
Stays tight. And in touch with the future: SensoriCS®. Fast temperature signals to the engine
and catalytic converter.
management system.
Temperature [°C]
160
140
120
100
80
60
40
20
0
Engine output [kW]
Temperature
[°C]
Temperatur
[°C]
Temperature measurement ΔT
Also here, temperature sensors supply
data to the engine management system,
directly from inside the engine – permit-
ting the coolant flow to be controlled
for optimum exploitation of the generated heat. Exact, requirement-dependent
heat management of the coolant circuit
enable the engine and catalytic converter to reach their ideal operating temperatures much faster. Similar application possibilities are also possible in the
areas of optimized combustion and onboard diagnostics. These technological
advances will provide higher engine
efficiency while simultaneously reducing
harmful emissions, lowering fuel consumption, and lengthening the service
life of critical components.
WINDOW GASKET
The VICTOR REINZ Window Gasket allows the simple feedthrough of electronic signals without additional holes, e.g.
in the engine block, and the risk of leakage channels. This unique concept
permits the installation of one or more
cable harnesses as well as the use of
variable plug-in connections, such as
power leads for solenoids, switches,
fuel injection, or sensors. Moreover,
through the use of thermoplastics for
the substrate in combination with hightemperature resistant elastomers for
the sealing elements, the design exhibits excellent performance. Typical
application areas for this new technology are valve cover seals, oil pan gas-
kets, gearbox gaskets, and similar sealing functions. The Window Gasket avoids
potential leakage paths due to conventional installation methods, reduces
component complexity, is easy to install,
and ensures simple disassembly and
reassembly, for example during repair
operations.
WHAT WILL THE
FUTURE BE LIKE?
Naturally, we cannot predict the future
of the automobile. But we do have clear
conceptions about the future of gaskets
and sealing technology. Because the
future already exists in our development
departments. You can learn more about
these exciting developments by requesting more information; simply give us a
call and we will send an information
package to you.
Our contributions
toward the future of the
automotive industry:
¬ Systematic evaluation of market
and technology trends
¬ Continuous adaptation of current
technologies to changing conditions
in order to meet the developmental trends of modern combustion
engines
¬ Development of intelligent product
innovations (active SensoriCS® head
gasket for measuring pressure and
temperature differences, Window
Gasket for feedthrough of electronic
signals)
¬ Contribution toward weight reduction in engine designs through new
materials
¬ Contribution toward emission reduction through distortion-optimized solutions
Publication: Cylinder Head Gaskets for the New AI/Mg
Composite Construction, MTZ Issue 12/2004
Publication: Enhanced Functionality for Cylinder Head
Gaskets. Advanced Development of the Wave-Stopper®,
MTZ Issue 10/2003
Publication: Cylinder Head Gasket with Integrated Temperature Sensors. Detecting Component Temperatures in
the Heart of the Engine, MTZ Issue 12/2002
„Facts made by VICTOR REINZ.“
Publication: New Technology for Multi-Layer Steel
Cylinder Head Gasket, MTZ Issue 10/2001
SensoriCS® – reduced harmful emissions, lower fuel consumption, and longer service
Window Gasket – the future for gaskets with electronic
life of critical engine components.
signal feedthrough.
¬ 53
The VICTOR REINZ product range
EXCELLENT IN ALL AREAS
When it comes to the powertrain, we
feel completely at home. So it's no wonder that our specialties are not limited
to sealing technology for modern engines. The name VICTOR REINZ stands
for innovative sealing systems – from
engine and transmission to the entire
drive train and the exhaust gas system
– including high-tech shielding and valve
cover systems.
Innovative technologies for the powertrain come from VICTOR REINZ.
The entire world
of gasket technology
»Thanks to VICTOR REINZ, we are using innovations that are just being invented elsewhere.«
¬ 54
¬ Multi-layer steel (MLS) cylinder
head gaskets
¬ Metal gaskets
¬ Coated metal gaskets
¬ High-temperature gaskets
(Xtreme®, thermo-glide®)
¬ Metal/elastomer gaskets
¬ Composite gaskets (AFM®)
¬ Screen-printed gaskets
¬ Molded rubber gaskets
¬ Sensor gaskets for temperature
and pressure measurement
(SensoriCS®)
¬ Gaskets with signal feedthrough
(Window Gasket)
¬ Shielding systems for thermal
and acoustic insulation
¬ Multi-functional valve cover
systems with efficient removal
of oil mist
¬ Customized solutions for
commercial vehicle applications
¬ Special solutions
VICTOR REINZ in the Dana network
SYNERGY AND TECHNOLOGY
TRANSFER BENEFITS OUR
CUSTOMERS
As part of the Dana Corporation, VICTOR
REINZ has the resources to provide the
best solutions worldwide – including
ideas, service, and products in automotive manufacturing hubs located in
points around the globe.
All our facilities are networked in order
to maximize our knowledge and efficiencies to serve you better.
AUTOMOTIVE ORIENTATION IN
THE XXL FORMAT
As one of the largest independent automotive suppliers, the Dana Corporation
is represented on every continent. Alone
3,900 specialists within Dana Sealing
Products, who are part of the 45,000
Dana employees worldwide, develop and
manufacture innovative sealing systems
for the international automotive industry on four continents. We also serve
emerging markets providing worldwide
access to Dana’s expertise.
Our experts in every division of the Dana
Corporation, together with our customers,
develop the most advanced innovations
based on true company synergy. This
multi-discipline approach allows us to
see the big picture, supplying state-ofthe-art components, modules, systems,
and complete assemblies matched to
the needs of the global automotive
market.
As a result of this company synergy, we
at VICTOR REINZ have become even
faster, more innovative, and more competitive than ever before. Our purchasing, development, and sales advantages
are passed on directly to our customers.
And that's not all.
TRENDSETTING CELLS –
TECHNOLOGICAL MILESTONE
The Dana Corporation is committed to
promoting mobility, today and into the
future. At our facility in Neu-Ulm, VICTOR
REINZ is already engaged in the production of series-ready components for fuel
cells. We are on the threshold of a technology that will no longer be hampered
by emissions challenges in regard to today’s combustion engines. Companies
who play a leading role in these technologies have a bright future.
For these developments and anything
else the future holds in store, you can
be confident that with VICTOR REINZ,
you’ll always benefit from the most advanced developments inspired by the
close cooperation of our experts worldwide.
Today. Tomorrow. And as long as there
are automobiles.
Solution for the future: Series-ready bluepack® fuel cell
stack »Made in Neu-Ulm«.
¬ 55
Printed in Germany 03/06 · 39-00197-01
REINZ-Dichtungs-GmbH
Reinzstrasse 3-7
89233 Neu-Ulm
Germany
Phone +49 (0) 731-70 46-0
Fax +49 (0) 731-71 90 89
www.reinz.com

Sealing Brochure

Transcription

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