Document Yjw90d2o9bkGEwZnNw80zGBn8

I GM PRESENTATION - May 21, 1986 GASKET MATERIALS - Jim Ulrich -T V--^' / ' Suoc HI A. INTRODUCTION Good morning! I'm Jim Ulrich, Materials Technical Service Engineer, and I'd like to tell you about the different types of matac-Mls used for gaskets, with particular emphasis on our non asbestos line. We will go over the different uses to which gaskets are put, and see what some of the best materials are to use for various types of sealing conditions, i'll also show you some examples of coatings that are used to enhance the properties of the gaskets to which they are applied. We can also talk about some of the tests that we run on gasket materials. Later on, we'll take a tour of our Engineering facilities, and you can see where new materials are fabricated and how they are tested. Snot *2 B. NEED FOR NON-ASBESTOS MATERIALS The health hazards associated with asbestos fibers have become well-known. Asbestos is a carcinogen, a cancer-causing agent. Air-borne particles can enter the lungs and cause serious problems many years after initial exposure. Accordingly, governmental institutions have passed legislation severely limiting the concentration of asbestos fibers that can be present in the air in a workplace. Asbestos-containing gasket materials are not in themselves hazardous to use. Many of them have the asbestos DANA-0336.030 VPD-143-0000040 z fibers encapsulated with elastomeric or other binders. But when operations are performed on these materials such as cutting or abrading, no amount or type of binder can totally prevent fibrous particles from entering the air and possibly being respired into the lungs. ' . VICTOR is well on the way to having available a complete line of non-asbestos containing gasket materials that have the same good physical properties and do the same job of engine sealing as asbestos-containing products. Advantages of asbestos include high heat resistance, crush resistance, good dimensional stability, and relatively low cost. The goal in selecting non-asbestos materials to perform the same jobs as asbestos is to optimize these properties, emphasizing particular characteristics for materials of various intended uses. It is our goal to be completely out of the use of asbestos by the end of 1987, having completed the conversion of all asbestoscontaining gaskets to non-asbestos versions by that date. All Aftermarket soft gaskets are now made of non-asbestos materials, and the changeover of steel-reinforced composite materials is proceeding. The conversion of OE parts is also underway, and will continue until complete. VPD-143-0000041 3 SUD #3 C. HIGH TEMPERATURE MATERIALS One group of gasket materials requiring a particular set of characteristics are those used in high-temperature applications such as for manifold gaskets and other exhaust system components. These must contain fibrous or other particulate matter which is capable of withstanding severe heat, and a minimal amount of organic binder -,-ponent which helps hold the composition together prior to installation and which may eventually burn off during use. We have given the name CORAMIC to a family of materials of this type. These are all reinforced with perforated steel core, and can be used to replace our old CORBESTOS grades of asbestoscontaining materials. A diverse group of facings are available for CORAMICS. A non-asbestos beater treated paper has been developed containing an asphalt binder as a replacement for the asphaltic beater treated asbestos used in our CORBESTOS products. Applying this facing to both sides of perforated steel core, we have CORAMIC 29, and on one side of core it is CORAMIC 129. This material can be used for flat gaskets or shaped to make coiled exhaust pipe flange gaskets. CKT. Another facing material which we utilize to some extent contains vermiculite. Vermiculite will withstand temperatures up to 2200 F, making this facing exceptionally good in contact against exhaust gases. A disadvantage is that vermiculite sheet has poor VPD-143-0000042 water resistance, although against fuels and oils it is satis factory. Our vermiculite sheet on two surfaces of perforated steel core is designated CORAMIC 439, and a single-layer version is CORAMIC 199. L)ITS A replacement is now in use across the board for white asbestos millboard with cement binder. The non-asbestos material is designated MINERAL BOARD, and consists largely of inorganic fibers and fillers including clays and cement, with a small amount of organic matter to give it some strength and body. This was one of the most important areas to be changed from asbestos to non asbestos usage, because of the limited degree with which the fibers are bound, and the ease with which particles can enter the atmosphere. The MINERAL BOARD replacement is used as the center layer between overlapped metal outer layers of many types of gaskets and cdmponents and has excellent heat resistance. It can also be used as the center layer between two outer layers of perforated steel in a construction called CORAMIC 299. We also put it on the outside of the core, where with two MINERAL BOARD facings we have CORAMIC 219, and with one layer CORAMIC 119. For thin gasket constructions, we use a non-asbestos paper with organic binder. This is used as a filler in layer-type constructions, as well as in combinations with perforated steel core. The version with two paper faces is CORAMIC 269, and with a single non-asbestos paper face CORAMIC 169. This material is use ful at higher temperatures and in non-water contact applications. x VPD-143-0000043 S' Two material versions from our VICTOCOR family of composites are also finding considerable usage in high temperature applications. These have a graphite sheet facing, which due to its broad range of temperature resistance is suitable in a lot of different areas. Our VICTOCOR 189, with a standard graphite facing, and VICTOCOR 389 using a special formulation which retards oxidation, both are used in contac1- with high-temperature gases encountered in exhaust sealing systems. Slioc D. COMPOSITE MATERIALS FOR CYLINDER HEAD & INTAKE MANIFOLD GASKETS A second major class of gasket materials to consider is the broad group of composite materials useful for sealing cylinder heads, intake manifolds, and many other related applications, where heat is not generally as extreme as in the exhaust system. VICTOCOR is a name established about 25 years ago, and has come to be applied to many facing-on-perforated-core constructions, most having an elastomeric binder. When the facing is chemically bonded to a flat layer of reinforcing steel, the name SOLICOR is used. Let's look at some of these materials. I have already mentioned two VICTOCOR grades with graphite facing that we emphasize for high heat applications. A third version is VICTOCOR 199, somewhat denser than the 189 mentioned previously, <SJc7. which is functioning well as a cylinder head gasket. The flexible graphite sheet facing is all graphite, and contains no binders or VPD-143-0000044 fillers. It is a unique product which will seal a wide variety of liquids and gases over an extremely large temperature range, -400 to 1500 F. It is suitable against many corrosive substances, and is very conformable for excellent sealing characteristics with low relaxation. The high lubricity of graphite helps to maintain sealing during movement of the mating surfaces due to thermal or mechanical stresses. The unique structure of graphite sheet enables the dissipation of heat in a lateral direction, while at the same time it exhibits low thermal conductivity through the thickness of the sheet. We also make gaskets with an aluminum foil layer laminated to one or both sides of the graphite facing, VICTOCOR 189A and 189B. The inclusion of an aluminum foil outer layer promotes heat transfer through the gasket and is useful in such applications as throttle body injection gaskets, to maintain temperature and keep the system from freezing due to evaporation as fuel passes through the nozzles. There are several grades of non-asbestos VICTOCOR which start with a facing called VICTOPAC 989. This is a beater addition sheet . .. made by the papermaking process, containing synthetic fibers, MftTT /\hPl fillers, and a low amount of nitrile rubber binder. Applying this facing to a perforated steel core and densifying by means of calender rolls, gives us a basic product termed VICTOCOR 159B. Engine tests on this composition have shown equal or better performance to the equivalent asbestos-containing materials. We VPD-143-0000045 7 can also enhance the properties of this composition where necessary, by saturating the fluid sealing areas of a fabricated gasket with a resinous solution. The result is VICTOCOR 889, ideally suited for automotive bimetallic engines, or VICTOCOR 859 which utilizes a silicone impregnation and is functioning well in marine applications. Saturated gaskets of these types give good initial sealing and low torque loss. The area around the combustion o^ ir.93, which is protected by a steel flange, does not get saturated, thus keeping only a minimal amount of organic matter in this area, resulting in good combustion sealing. Another kind of VICTOCOR uses a compressed non-asbestos sheet facing with elastomeric binder on a perforated core, and we call this VICTOCOR 479. This high grade material has outstanding 6> XT. resistance to all engine fluids and gases, and is typically used for cylinder'head gaskets in heavy duty applications. The SOLICOR concept is also useful for reinforced gasket con structions. In this case, we apply fibrous facing materials to a solid steel core without perforations, by means of an adhesive CM.T. bond. The unperforated core contributes to a strong, uniform, and dimensionally stable material throughout the gasket, with good radial strength. The firm chemical bond assures complete adhesion of the facing to the core throughout the life of the gasket and provides outstanding sealing characteristics. VPD-143-0000046 8 Other types of gaskets in our line in the broad, general hard gasket category are beaded steel gaskets with a resinous coating. minor side gaskets with molded silicone rubber on steel, and heavy steel plate gaskets with molded inserts 3 6XTS $LIO #s E. SOFT PACKING MATERIALS A third brc: ' class of gasket materials are known as soft packings or soft gasket materials. These are generally used in less severe applications than those discussed previously. They are principally fibrous or particulate in nature, with elastomeric or other organic binder, and are basically.single layers of flexible composition, with no steel or other reinforcement. They must be strong enough to hold together on their own, in the given application, and have good sealability under the particular set of conditions. They have many uses such as in sealing water pumps, transmissions, oil pans, and valve covers. In the compressed sheet category, we have four grades of material that we make ourselves at our Robinson plant by the calendersheeter process. VICTOPACS 9, 19, 69, and 79 have different types of rubber binder to impart differing degrees of oil and fuel resistance, including one-grade which intentionally is compounded for high oil swell, to promote sealing on rough or irregular surfaces. These are the densest types of soft gasket materials. VPD-143-0000047 Next are the beater addition sheets, made by a papermaking process, utilizing some strong, high-temperature synthetic fibers and nitrile latex binder, for which we offer three grades of differing densities, VICTOPACS 229, 239, and 259. These materials have excellent torque retention, crush resistance, and AJrtS. sealability. They are replacing asbestos in many applications. Materials w'.-'-jh have always been non-asbestos include those in our VICTOLEX line. These are cellulose sheets with latex binder, with various degrees of conformability, that are useful at lower ' temperatures, those under 300 F. VICTORITB B is a fiber material saturated with a glue-glycerin solution, which withstands oil, gasoline, and grease. CORK continues to be a gasketing material of major importance. Used in th form of cork-rubber sheeting, it has many uses in a lightly loaded applications such as valve cover gaskets. We have a cork material version with a polymeric binder and steel reinforcing center layer, which we call TUFF-CORK. This combina tion is soft and conformable for good sealing, yet strong and easily handled due to the rigidity imparted by the steel core. It also has excellent dimensional stability with freedom from shrinkage or extrusion, resulting in extended shelf life and perfect part fit during assembly. It also offers better torque retention than standard cork products without reinforcement. VPD-143-0000048 10 Slid* 6> F. GASKET COATINGS Several types of coatings can be applied to all or a portion of gaskets to enhance the sealing properties in difficult areas, or to prevent the gasket from adhering to the mating surfaces upon disassembly of the engine. VICTOR 597 and 999 are antistick 6-Kt. 4ifr.coatings used on hard and soft gaskets respectively. VICTOR 948 is a red Teflon-based coating useful for both the antistick characteristic and to promote sealability; we also have clear and black versions. One of our newest coating developments is SEALCOTE 966, a clear silicone compound which aids initial cold sealability. 4*7S The term VICTOCOTE is used to describe a- family of coatings used in selective areas of gaskets as an aid to sealing, by allowing for increased unit loading in these regions. These are applied by a screen printing process to solid areas of required size and shape, or in the form of beads around openings or in other portions of the gasket. These include VICTOCOTE 930. a conformable Neoprene latex; VICTOCOTE 950, a silicone elastomer IV 54 for good heat resistance; and VICTOCOTE 960, a nitrile-epoxy QCQ- compound with good strength and fluid resistance. SLID* *7 G. TESTING OF GASKET MATERIALS A number of tests are run on gasket materials to determine their value or to compare one to another. VICTOR is an active member of VPD-143-0000049 the ASTM Gasket Committee, a group of representatives from throughout industry and government -- including producers of gasket materials and gaskets as well as the ultimate users. By strict consensus procedures, agreement is reached on test methods for evaluating gasket materials, so that all are doing things the same way, and specifications issued by one company have some meaning to the suppliers as well as the customers of that company. There are a number of proprietary tests which VICTOR has developed to enable evaluation of materials in areas not yet addressed by the ASTM Committee. ASTM tests on gasket materials include: Compressibility and recovery Tensile strength Fluid resistance Sealability Creep relaxation Flexibility Dimensional stability Thermal conductivity Ignition loss Adhesion to mating surfaces ` Unique VICTOR-developed tests include: Heat aging Crush-extrusion resistance Additional forms of sealability testing VPD-143-0000050 12 Load-deformation testing on a continuous loading device Flange embedment deformation testing Antifreeze resistance testing We will show you how some of these tests are run when you visit our Engineering laboratories in a little while. Do you have -ry questions on gasket materials? Next, Jerry Belter will talk about the Design of Gaskets. * * * * * * it it it It 860513GMPRESEN V?D. 143. 00QSl GASKET MATERIALS Jim Ulrich A. INTRODUCTION B. NEED FOR NON-ASBESTOS MATERIALS C. HIGH TEMPERATURE MATERIALS D. COMPOSITE MATERIALS FOR CYLINDER HEAD AND INTAKE MANIFOLD GASKETS E. SOFT PACKING MATERIALS F. GASKET COATINGS G. - TESTING OF GASKET MATERIALS JAU #1 VPD-143-0000052 NEED FOR NON-ASBESTOS MATERIALS 1. HEALTH HAZARDS OF ASBESTOS 2. GOVERNMENT LEGISLATION 3. DANGERS IN HANDLING GASKET MATERIALS ' 5. CHARACTERISTICS OF ASBESTOS VS. NON-ASBESTOS MATERIALS 6. VICTOR CONVERSION TO NON-ASBESTOS JAU #2 VPD-] 43.0000053 HIGH TEMPERATURE MATERIALS 1. GENERAL CHARACTERISTICS OF CORAMIC MATERIALS 2. NON-ASBESTOS BEATER TREATED FACING 3. VERMICULITE SHEET 4. MINERAL BOARD 5. NON-ASBESTOS PAPER WITH ORGANIC BINDER 6. GRAPHITE-FACED VICTOCOR MATERIALS JAU #3 VPD-143-0000054 COMPOSITE MATERIALS FOR CYLINDER HEAD AND INTAKE MANIFOLD GASKETS GENERAL CHARACTERISTICS - VICTOCOR AND SOLICOR VICTOCOR 199 WITH GRAPHITE FACING GRAPHITE SHEET WITH ALUMINUM FOIL LAYER VICTOPAC 989 NON-ASBESTOS FACING VICTOCOR 159B VICTOCOR 889 AND 859 IMPREGNATED GASKETS VICTOCOR 479 SOLICOR MISCELLANEOUS OTHER HARD GASKETS * JAU #4 VPD-143-0000055 SOFT PACKING MATERIALS GENERAL CHARACTERISTICS OF SOFT PACKINGS NON-ASBESTOS COMPRESSED SHEET NON-ASBESTOS BEATER ADDITION SHEETS VICTOLEX VICTORITF CORK-RUBBER TUFF-CORK JAU #5 VPD-143-0000056 GASKET COATINGS 1. PURPOSE OF COATINGS 2. ANTISTICK COATINGS 3. SEAIiCOTE 4. VICTOCOTE JAU #6 VPD-143-0000057 TESTING OF GASKET MATERIALS 1. ASTM GASKET COMMITTEE . 2. ASTM TESTS - COMPRESSIBILITY AND RECOVERY TENSILE STRENGTH FLUID RESISTANCE SEALABILITY RELAXATION FLEXIBILITY DIMENSIONAL STABILITY THERMAL CONDUCTIVITY IGNITION LOSS ADHESION 3. VICTOR-DEVELOPED TESTS - HEAT AGING CRUSH-EXTRUSION RESISTANCE ADDITIONAL FORMS OF SEALABILITY TESTING LOAD-DEFORMATION FLANGE EMBEDMENT ANTIFREEZE RESISTANCE J.U.over05-86 JAU #7 VPD-143-0000058