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0907
Lorenz & Company
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Specialty gaskets:
Metaloseal®—metal-elastomer—elastomer.
Extremely versatile, extremely robust.
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ElringKlinger—present in automoti ve m
Canada Leamington | USA Livonia · Branchburg | Mexico Toluca | Brazil Piracicaba | Germany Dettingen/Erms · Langenzenn · Runk
Spain Reus | Italy Mazzo di Rho | South Africa Johannesburg | People’s Republic of Chi
Cylinder head gaskets
Specialty gaskets
Housing modules
Topographic housing
components
4 | At a glance
Metaloseal® specialty gaskets
6 | The sealing system without compromises
7 | Systems expertise
8 | Metaloseal® exhaust gaskets
12 | Metaloseal® for oil, coolant, and fuel systems
Metal-elastomer and elastomer specialty gaskets
14 | Maximum performance—safe and reliable
16 | Examples of uses
2
20 | Materials expertise
Shielding systems
Transmission
applications
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moti ve markets throughout the world.
nzenn · Runkel · Bietigheim-Bissingen · Heidenheim /Brenz · Idstein · Rottenburg/Neckar | Great Britain Redcar · Gateshead
public of China Changchun | South Korea Changwon | Japan Tokyo | India Ranjangaon
mission
ations
Bipolar plates
for fuel cells
Original
Elring spare parts
PTFE components
Engine measuring
and testing services
Experience mobility—Drive the future:
The ElringKlinger group of companies.
ElringKlinger—innovative development partner and series supplier to the
international automotive industry and other industries. We think ahead
and take on responsibility. For more sustainability and environmental
compatibility. Today and tomorrow.
Our trendsetting technologies and sophisticated product solutions contribute to further reduce fuel consumption and emissions, and enable the
use of alternative fuels and the development of new drive technologies.
With comprehensive engineering and production expertise, we allow more
freedom of design for engines, transmissions, exhaust systems, and auxiliary aggregates. Together with our customers, we successfully promote
new technologies. To this end, we have around 3,400 employees working
at 21 locations throughout the world.
3
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At a glance:
Specialty gaskets for engine, transmission, and exhaust system.
Reliable from -40°C to +1100°C.
4
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Modern sealing systems accomplish a great deal: They guarantee a reliable
sealing of various media (oil, coolant, fuels, fuel gases) both from the outside as well as in relation to each other. Furthermore, they act as power
transmission elements between engine components while performing significant additional functions.
With Metaloseal® specialty gaskets as well as metal-elastomer and elastomer specialty gaskets, ElringKlinger provides suitable product solutions
for a variety of sealing tasks in the engine, transmission, exhaust system,
and auxiliary aggregates, e.g., compressors and pumps. Materials and
design are matched optimally to the specific requirements.
5
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Metaloseal® specialty gaskets.
The sealing system without compromises.
Elastomer-coated Metaloseal®
gasket for the engine/pressure
oil, and compressed air systems.
Metaloseal® multi-layer gasket
for exhaust systems.
Partially coated Metaloseal®
Transmission cover gasket
with partial coating.
gasket for exhaust recirculation
systems.
A highly efficient sealing system based on elastomer-coated and uncoated
metal carrier materials. The functional principle: line sealing by means of
a bead.
One of its greatest advantages is the ability to combine different metals
with various types of elastomer depending on the application location. The
additionally coined beads can be used to optimally match the properties
of the carrier material to the sealing system. The beads reduce the sealing pressure to a line compression. This helps achieve higher sealing
pressures at constant bolt force, or vice versa a lower bolt force is used
at constant sealing pressures.
The variety of combinations between metallic carrier materials and elastomer materials can cover almost all application locations in engine, transmission, exhaust system, and auxiliary aggregates.
Furthermore, Metaloseal® gaskets can perform additional functions. Thus,
for example, oil baffles or sensors can be
Coating
integrated for even more efficient engine
management.
Full bead
Metal carrier
Metaloseal® sealing systems
6
can be matched exactly to the
respective requirement profile
due to the variable combination
of the parameters of metal
carriers, coating, and bead.
Met
the
SCR
exh
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Systems expertise.
Welcome to the future.
FEM analysis of a distortion
system (engine components,
gasket, bolts).
Metaloseal® gaskets and
thermal shielding part for
SCR injection systems for
exhaust aftertreatment.
Metal/soft material
gasket for automatic
transmissions.
Metal gasket with partial
elastomer coating for automatic
transmissions.
FEM analyses and state-of-the-art testing and simulation techniques help
us ensure the readiness of our Metaloseal® sealing systems for series production as early as in the prototype phase. Engineering in close cooperation with our customers. Fast, reliable, and economical.
Testing fatigue strength of
the beads on a servohydraulic
system.
For us, systems expertise also means working consistently on new materials, technologies, designs, and applications. For innovative product solutions. For the sealing tasks of tomorrow.
Dynamic hot gas test bench
Dynamic hot gas testing of exhaust system components under realistic
conditions.
Test bench components
Reverse bending test bench
Biaxial test bench
horizontal and vertical axis
Max. force amplitude
15 kN
Max. half-wave amplitude
150 mm
Hot gas burner
Number of burners
Gas temperatures
Max. counter pressure
Volume flow rate
Dynamic hot gas test bench.
2
250 – 1100°C
1 bar
300 – 750 kg/h
Sealing force [N/mm]
300
200
Thermal change test by using
transmission control plates.
100
Elasticity behavior of
Metaloseal® gaskets in
the sealing gap.
7
0
0
100
200
300
400
500
Sealing gap [μm]
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Metaloseal® exhaust gaskets. For maximum
thermo-mechanical stress. Reliable up to 1100°C.
Two-layer exhaust gasket to
absorb sliding movements
between cylinder head and
exhaust manifold.
Three-layer exhaust gasket.
Exhaust pipe connecting
concept with integrated
gasket.
Car manufacturers and automotive suppliers are confronted with new and
complex challenges in the form of the increasingly strict emission limit
values worldwide. The resulting downsizing programs and exhaust
aftertreatment systems set partly new and demanding general conditions,
especially for sealing technology. Thus, high requirements are placed
especially on the leak tightness of exhaust systems. In the Metaloseal®
technology, the use of heat-resistant carrier materials and coatings has
optimized the sealing function and also provided the basis for reliably
mastering critical boundary conditions.
Metaloseal® exhaust gaskets by ElringKlinger reliably meet the requirements of both modern and future exhaust systems. They effectively perform sealing and durability functions under the most difficult operating
conditions. For maximum reliability.
8
Metal-profile gaskets
(high-temperature alloy)
for turbochargers.
Mu
for
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Multi-layer exhaust gasket
for V-bond flanges
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Gasket with hightemperature coating for
catalytic converters.
Seite 9
Gasket for hot gas
application made of metalmica composite material.
Check valve for exhaust gas
recirculation (higher exhaust
gas recirculation rates with
reduced space requirement).
Sealing and shielding
module in fuel injection
for the regeneration
of particulate filter in
commercial vehicles.
Advantages at a glance
Compared with conventional composite gaskets, the Metaloseal® system is
characterized by the following decisive advantages:
• Use of materials having maximum resistance to thermo-mechanical
stresses
• Good adaptability to heavily deformed sealing surfaces
• Long-term durability
• Variable design (absorption of sliding movements of head/manifold)
• Reliable engineering based on defined material properties
• Heat-resistant coatings ensure the best sealing and frictional behavior
Highly elastic sealing element
for hot gas applications.
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Multifunctional Metaloseal® exhaust gaskets
Innovative and versatile—exhaust gaskets with advanced tasks:
• Additional elements for easier and reliable installation
• Customized gaskets with pre-assembly elements suitable for modular
integration
• Integration of the coolant passage
• Integration of the check valve
Combined solution:
exhaust gasket plus heat
shield.
• Combination with heat shield
• Sealing plus shielding for exhaust aftertreatment systems
(AdBlue® injection and SCR catalyst)
ADBlue® module—a contribution to reduce emissions
As a competent development partner, ElringKlinger is also involved in this
module solution for SCR injection systems for exhaust aftertreatment: with
Metaloseal® gaskets as well as a multi-layer Elrotherm® heat shield. In addition, we take on the complete assembly.
AdBlue®-based SCR systems are considered to be a key technology for complying with the stricter emissions standards for passenger cars and commercial vehicles. The urea-water solution AdBlue® enables the conversion of
poisonous nitrogen oxides into the exhaust to water vapor and elemental
nitrogen.
The module performs the following
functions: sealing in relation to
the urea-water solution (AdBlue®),
air gap insulation, cooling of valve
tips in the area of the injection, as
well as thermal shielding of connections.
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Carrier materials
Coatings
Temperature range
150°C to 250°C
Cold-rolled strip
FPM (based)
Corrosion resistance
Spring steel
FRM (based)/NBR (based)
Coolant resistance
Corrosion-resistant steel
EGR system
Cylinder head/manifold
Temperature up to 350°C
Spring steel
Dynamic load
Spring steel
Friction wear
Spring steel
Resin-stabilized NBR
Solid lubricant in synthetic resin matrix
Exhaust aftertreatment systems (AdBlue® injection and SCR catalyst)
Temperature range
150°C to 750°C
Spring steel
Thermal isolation
HT-resistant steel
FPM (based)
Solid lubricant in synthetic resin matrix
Heat-resistant coating
Exhaust pipe, turbocharger, precatalytic converter, etc.
Temperature up to 1100°C.
Optimized micro sealing,
dynamic load
HT-resistant steel,
HT-resistant alloy (Ni-based),
mica
High-temperature resistant coating
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No compromises. Metaloseal® sealing system
for oil, coolant, and fuel systems.
Metaloseal® gasket with
oil channels for a camshaft
phaser.
Water pump gasket for
gasoline engines.
Oil module gasket with
coolant passage.
Elastomer-coated beaded metal gaskets have proven to be a reliable and
cost-effective sealing concept. With impressive advantages: Elastomer and
metallic materials as well as the bead design can be combined flexibly,
thus enabling a tailor-made gasket design oriented precisely to the respective application.
Each functional component fulfills specific requirements. And this clear
assignment of sealing tasks constitutes the special strengths of the
Metaloseal® sealing system:
• Adaptation to major component deformations by means of beads
(macro sealing)
• Adaptation to component roughness by means of elastomer coating
(micro sealing)
Gasket with flexible tongues
for easier installation of
component, gasket, and
bolts.
• High chemical resistance by means of special elastomer formulas
• Cross-sectional leak tightness by means of thin elastomer layers
• High rigidity provided by metal carriers
Further advantages
• Dependable long-term performance
• Additional partial elastomer coatings seal components with graded
surfaces.
• Reliable engineering based on defined material properties
• High dimensional stability
• Fully recyclable
Gasket with integrated oil
baffle, made of pre-coated
Metaloseal® base material,
deep-drawn.
12
Compressor gasket in
pneumatic systems of
commercial and railway
vehicles.
Sea
pum
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Seal for a vacuum fuel
pump.
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Gasket for power shift
transmission.
Seite 13
Modular mounting of an
intake gasket.
Metaloseal® gasket with additional
elastomer sealing contour for
pressure oil sealing.
Multifunctional Metaloseal® gaskets
Metaloseal® can do more. In addition to performing sealing tasks, Metaloseal®
also enables the implementation of numerous additional functions:
• Oil baffle integrated into the gasket
• Gasket with channeling function
• Gasket with elements for pre-assembly and easier
Coating
installation
• Check valve integrated into the gasket
Advantages
• Fewer components
• Less work required for assembly
Metal carrier
• Optimized functionality
• Weight reduction
The Metaloseal® sealing system can be
adapted to exactly meet the individual
requirement profile by using a variable
combination of metal carriers, coating,
and bead parameters.
• Lower cost
Material combinations
Metal carrier
Coating
Bead form
Aluminum
Half bead
Static sealing
Cold-rolled strip
Static sealing
Spring steel
Dynamic sealing
NBR
Resistant to oil, coolant, and fuel,
temperature range of operation: -40 to +160°C
NBR with enhanced friction coefficient
Resistant to oil, coolant, and fuel, torque transmission,
temperature range of operation: -40 to +160°C
FPM
Especially high chemical resistance,
temperature range of operation: -40 to +210°C
PUR and silicone
Resistant to oil, coolant, and fuel,
high temperature resistance
Half bead
2-line sealing
Full bead
3-line sealing
Topographical bead geometry
For large distances between bolts and flanges with a high
degree of deformation
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Metal-elastomer and elastomer specialty gaskets.
Maximum performance—safe and reliable.
State-of-the-art engine technology calls for innovative sealing systems.
Components and build-on parts are increasingly made of plastic for reasons related to weight and functionality. The result: reduced component
stiffness and the associated increased deformations, which occur during
distortion and must be compensated for by the sealing system.
Metal-elastomer and elastomer specialty gaskets by ElringKlinger provide
reliability and functionality even under extreme conditions. Tried and
tested a million times over. Both sealing systems—with and without metal
carriers—have been adapted precisely to the sealing tasks, in addition to
being optimized in terms of functionality and costs. The elastomer materials used are developed and produced by ElringKlinger. This also ensures
the highest quality possible.
Performance
• Reliable sealing, even at low sealing pressures
• Compensation of large component tolerances
Metal-elastomer
chain case gasket.
• Three-dimensional shaping
• Reduced bolt force and fewer bolts
• Acoustic isolation of components
Engineering service
ElringKlinger determines the best possible elastomer gasket design for
each application with respect to material, profile geometry, and design of
the sealing system.
Elastomer specialty gaskets
for intake manifold and spark
plug sealing
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Metal-elastomer specialty gaskets
The sealing system consists of a metal carrier with molded-on elastomer
profiles—for maximum functionality and service life in the sealing of components subject to high stresses. It is especially suitable for use in loadcarrying joints. Modern injection molding technology also makes it possible
to bond different materials on a carrier (metal/plastic) in order to use the
ideal material for each medium to be sealed.
Two-component technology:
EPDM for water, ACM for oil.
For example
• Oil pump gasket
• Heat exchanger gasket
• Timing case gasket
• Thermostat housing gasket
Metal carrier
AEM elastomer
for oil sealing
Timing case gasket.
Bolt
Component
Design of a metal-elastomer specialty gasket.
Metal-elastomer gasket for
crankcase. This gasket consists
of different metal segments
connected by means of the
elastomer sealing lip.
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Elastomer specialty gaskets
Ideal for basically all sealing joints on the engine. With specifically
matched profile geometries, for maximum functionality at lowest sealing
pressures. In load-carrying joints, elastomer gaskets must be fitted in the
ancillary frictional connection, e.g., by using grooves on the part, or metal
limiters under the bolts.
ElringKlinger develops
Oil pan gasket for
commercial vehicles.
• the elastomer profile corresponding to the engine components
• the elastomer material corresponding to the requirements related to
automotive fluids and temperature
Exemplary. For many applications.
Oil pan gaskets
• Available for engine and transmission applications
• Noise-isolated and rigidly bolted designs possible
• Useable in combination with different oil pan materials (aluminum,
stamped steel, and plastic)
• Various systems can be configured, thus enabling optimum adaptation
Oil pan gasket for oil pans
made of aluminum and steel,
bolted in a noise-isolated
fashion. Metal carrier with
overmolded elastomer.
Oil pan gasket for oil pans
made of aluminum and steel,
rigidly bolted. Metal carrier
with edge molded elastomers.
16
to the respective installation environment
The sealing systems used for plastic oil pans are similar to those used in
plastic cam cover gaskets.
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Isolating element
Gasket
F/N
F/N
4000
4000
3000
3000
2000
2000
1000
1000
Working point
0
2
4
5 4 3 2 1 0
Compression/mm
Force-deformation curves of the isolating system. The combination of finite element
calculations, laboratory simulations, and material development enables customized,
noise-isolated sealing systems.
Requirements
Solutions
Isolation of structureborne noise
Elastic mounting of the component between
elastomer gasket and isolating element
Reliable
screw system
Component combination of bolt and sleeve
Sealing
Elastomer materials optimized in terms of price
and performance, and a gasket design with
optimum functionality
Pre-assembled system The isolating system is fixed to the component
in a loss-proof fashion
Assembly
The bolt is mounted adjustably in the sleeve.
The module is mounted on the engine as a
single, complete unit. A centering tip on the
bolt facilitates automatic assembly.
Service
The isolating system can be replaced easily and
cost-effectively
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• Universal applications in plastic, aluminum, and stamped steel
cam covers
• Sealing system and isolating system from one source—optimally
adapted to each other
• Materials adapted precisely to the respective application for
maximum reliability
Cam cover gasket with
elastomer-overmolded steel
carrier for cam covers made
of aluminum, magnesium,
and steel.
Elastomer gasket for
three-dimensional
flange geometry and
isolating system.
Non-noise-isolated
• Economical sealing solution for cam covers made of plastics,
aluminum, magnesium, and steel
• Variety of systems enabling optimum adaptation to the installation
space in each case
• Integration of additional component functions
Cam cover gasket with
integrated cable duct.
19
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Intake manifold gaskets
• Available for gasoline and diesel engines
• Noise-isolated and hard-mounted versions possible
• Various designs depending on the material of the intake and the
installation environment
Intake gasket with molded-on
carrier sealing lip.
• The heat-resistant and fluid-resistant properties of the materials
enable their uncompromisingly reliable use at usually high exhaust
gas recirculation rates and also in combination with intake fuel
injection systems
Cam cover gaskets
Noise-isolated
Engine noise can be reduced effectively by the elastic isolation of reso-
Noise-isolated intake
manifold gasket.
nant bodies, such as cam covers, intake manifolds, and oil pans. In doing
so, the conflicting requirements and characteristics of the components
must be combined in the isolating system: the increased damping effect
of an isolating element and the increased sealing force of the elastomer
gasket. The quiet solution by ElringKlinger: noise-isolated sealing systems.
Precisely designed right down to the last detail.
Hard-mounted intake
manifold gasket.
Sleeve
(load-carrying element)
Rubber
grommet
Housing component/
resonant body
Gasket retention
feature
Elastomer
gasket
Bolt
Elastomer
gasket
Elastomer intake gasket.
Elastomer gasket and isolating system.
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Materials expertise. Elastomers of the finest quality.
Engineering service
ElringKlinger determines the best possible gasket design for each application with respect to material, profile geometry/design of the sealing
system.
n
7
Minimum sealing pressure
Maximum compression
Identification of dynamic
elastomer characteristics.
FEM calculation of an elastomer profile.
Identification of thermodynamic characteristics
Elastomers must provide a reliable sealing performance for a wide range of
engine operating conditions. At an operating temperature of -40°C and at
150°C alike, regardless of the extent of the dynamic sealing gap movements.
Material tests
Sealing force [N]
350
300
250
200
150
100
50
0
0,01
0,1
1
10
100
1000
10000
100000
Test duration [hours]
In order to guarantee the sealing performance of ElringKlinger materials
throughout the service life of the components, tests have been established
that make it possible to predict the sealing behavior of our components
depending on their lifetime, temperature, and the dynamics of the seal20
ing system. These results are also processed further in our FEM analyses.
(1.0 N/mm2)
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Elastomer materials
As elastomer materials for sealing systems, ElringKlinger exclusively uses
in-house developments, which are optimized to special customer requirements. Specialization in high-performance materials emphasizes the systems expertise in sealing systems for engine and transmission applications.
Overview of elastomer materials
Elastomer selection based on oil and temperature resistance.
Abbreviation (ISO 1629)
FPM
MVQ
MFQ
ACM
AEM
EPDM
ECO
HNBR
Fluorocarbon
rubber
Silicone
rubber
Fluorocarbon
silicone
rubber
Polyacrylate
rubber
Ethylene
polyacrylate
rubber
Ethylene
propylene
diene
rubber
Epichlor
hydrin
rubber
Hydrated
nitril
rubber
Fuel
+
-
-
-
-
-
+
o
Coolant
+
o
o
-
-
+
-
o
Oil
+
o
+
+
+
-
+
+
Thermal application
ranges
-40 to
+230°C
-70 to
+200°C
-70 to
+180°C
-40 to
+160°C
-40 to
+160°C
-50 to
+150°C
-40 to
+120°C
-30 to
+150°C
Product examples
CHG
intake
area
CHG
special
applications
CHG
special
applications
Oil pan,
cam
cover
Oil pan,
cam
cover
Water
pump
Special
applications
in the
fuel
system
Special
applications
Chemical term
Range of applications
+ well suitable / 0 suitable / - unsuitable / CHG = cylinder head gasket
Temperature resistance
MVQ
LSR
Better
cold flexibility
FKM
FMVQ
EPDM
Better
resistance
to fuels/oils
ACM/AEM
HNBR
Temperature
resistance
Temperature
resistance
CSM
AU
NBR
NR
CR
SBR
Oil resistance
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The information contained in this brochure is the result of technological analyses. They may be subject to changes depending on the design of the system. We reserve the
right to make technical changes and improvements. The information is not binding and does not represent warranted characteristics. Any claims for compensation based
on this information shall not be recognized. We accept no liability for printing errors.
ElringKlinger AG | Max-Eyth-Strasse 2 | 72581 Dettingen/Erms | Germany
Tel. +49 (0)71 23/724-0 | Fax +49 (0)71 23/724-90 06 | info@elringklinger.de | www.elringklinger.de
0907
Lorenz & Company
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