Busak+Shamban No. 2, 2006

in thegrooveThe world of seals and service

Manufacturing Spotlight

The china connectionTrelleborg inaugurates new plant in Shanghai

Orkot® bearings on the largest hydropower project ever built

Mobile Hydraulics

Better by designZurcon® U-Cup RU9 outperforms its rivals

Harnessing the energy of the Yangtze

All Industries

Hydro Power

contentscontents

Aerospace

MobileHydraulics

Hydro Power

ManufacturingSpotlight

Extras

Motor Sport

Automotive

Hydraulics

News 3

Turcon® M30 extends seal life against harder mating surfaces 6New material gives exceptional sealing integrity in aerospace primary flight controls and utility actuation systems

Better by design 8Zurcon® U-Cup RU9 proves to outperform its standard rivals

Taking pole position! 12For over 40 years Wills Rings® have helped beat the competition on race tracks worldwide

Harnessing the energy of the Yangtze 14Orkot® bearings are fitted on Alstom hydro generators used on the largest hydropower project ever built

Smog busters 20Busak+Shamban meets the challenge of sealing EGR valves in diesel engines

Are your O-Rings at risk of attack? 22Ozone-resistant NBR materials help prevent O-Rings cracking when stored in an elongated state

The China connection 24Trelleborg inaugurates new plant in Shanghai

Nice & easy does it – Request for Quotation online! 26Check out the Busak+Shamban electronic online catalog

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GlobalSpec.com is a leading vertical search engine. Itserves the engineering, manufacturing and relatedscientific and technical market segments. More than3,000,000 registered users from all across the globeaccess the site. It is quickly becoming ‘the place’where the engineering community gathers andconducts business.

There are three main features of theGlobalSpec.com site:

SpecSearch Database - providing sophisticatedsearching capabilities, the site analyzes over21,000 digitalized catalogs, including those fromBusak+Shamban, and returns suggestions forrequested products

Engineering Web - indexes hundreds of millions ofpages of engineering content from open websites aswell as proprietary content publishers

E-Newsletters - provides product area informationon demand

Since it was founded 10 years ago, GlobalSpec hasstrived to provide innovative information servicesthat support the job tasks of the engineering andrelated professional communities.

A search engine by engineers forengineers

GlobalSpec.com

WEB WATCH

Booz Allen Hamilton’s annual research report SmartSpenders - Global Innovation puts Trelleborg among theless than 100 companies globally that get the best returnson investments in research and development (R&D). Thestudy includes the 1,000 companies that reported the mostspending on R&D around the world in 2004.The report points out the 94 companies that are high-leverage innovators outperforming their industries, andTrelleborg is one of ten European companies on the “smartspender” list.

“These companies have a well-developed strategy for R&Dthat is aligned with their business and competitiveconditions,” comments Booz Allen Nordic’s chairman of theboard Torbjörn Kihlstedt.

The study uses seven performance screens, such as salesgrowth, gross margin percentage and total shareholdersreturns — from 2000 to 2005 — as the basis for the analysis.Other international giants on the list include Toyota,Apple, Google, Caterpillar and Christian Dior.

Trelleborg is a really smart spenderin innovation globally, says recentstudy

Research Efficient

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Spotlight on our Logistics CenterAmericas (LCA) facility in FortWayne

Busak+Shamban opened our second Logistics Center inFort Wayne in the United States in early 2005. Part ofthe site of 24,000 square feet (2,230 square meters) inIndiana, it has grown to include the company’swarehousing, handling systems and centralizedpurchasing functions.

The center stocks thousands of stock keeping units(SKUs) and uses the latest warehouse managementtechnology, incorporating bar coding and RF scanning.This assists its productivity and in accurately fulfillingcustomer orders. It also provides value-added serviceslike product kitting and certification.

“The logistics center was an important step in ourstrategic plan to aggressively grow market share in theAmericas,” said Tim Call ison, President ofBusak+Shamban Americas. “By accurately forecastingthe needs of our customers and stocking the rightproducts, we are slashing order lead times from weeksto days. This gives Busak+Shamban a competitiveadvantage when serving existing accounts as well as inattracting new business.”

On the move in America

On 6 November 2006 Trelleborg SealingSolutions Broomfield, USA received theircertificate for achievement of the OHSAS18001 standard for their Health & Safetymanagement system.

Trelleborg Sealing Solutions Helsingør,Denmark and Busak+Shamban LogisticsCenter in Stuttgart, Germany have beenaudited and found to be compliant to therequirements of ISO/TS 16949:2002.

Company awards!

Shipments from LCAhave doubled in 2006,and now 35 percent ofall end-customershipments come fromLCA. Volume is expectedto double again in 2007.

You are welcome

When in Fort Wayne, why notvisit the Busak+Shamban facility

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Busak+Shamban - in the groove - All Industries, No. 2, 2006© Busak+Shamban, 2006. All rights reserved® All trademarks are the property of Busak+Shambanand Trelleborg AB.

Editorial Office:Busak+Shamban Deutschland GmbHHandwerkstraße 5-7, 70565 Stuttgart, Germany Email: groove@busakshamban.com Web: www.busakshamban.com

Editorial team:Heather Castleman, Donna Guinivan, Whitney Killip,Wendy Sack, Robert Zahiri

Responsible under German Press Law: Robert ZahiriGraphic Arts: dialogart, Stuttgart, GermanyPrinting: W. Kohlhammer, Stuttgart, Germany

Disclaimer: The information in this magazine isintended to be for general reference purposes onlyand is not intended to be a specific recommendationfor any individual application. The application limitsfor pressure, temperature, speed and media givenare maximum values determined in laboratoryconditions. In application, due to the interaction ofoperating parameters, maximum values may not beachieved. It is vital therefore, that customers satisfythemselves as to the suitability of product andmaterial for each of their individual applications. Any reliance on information is therefore at the user’sown risk. While every effort is made to ensure theaccuracy of information contained herewith,Busak+Shamban cannot warrant the accuracy orcompleteness of information. For exceptional operating conditions, please contactyour Busak+Shamban representative.

Tim Sprunger was recently namedBusak+Shamban Global AutomotiveSegment Director. Tim joins us fromLear Corporation where he wasresponsible for Japanese jointventure operations, working both inthe United States and Japan. Prior tothis, he held numerous senior salesand operational roles at Visteon,where he spent a significant periodof time based in Japan managingVisteon’s global sales to Toyota.

“This senior appointment supportsthe commitment made byBusak+Shamban to significantlygrow our presence in key segmentsin the automotive industry,” saidTim Call ison, President ofBusak+Shamban Americas. “Timwill draw on his extensiveknowledge and experience tostrengthen and grow our marketposition in the automotive industry.He will also work closely with ourexisting automotive teams in theAmericas, Europe and Asia Pacific.”

Busak+Shamban Sweden had asuccessful exhibition at ElmiaSubcontractor in Jönköping from14 - 17 November 2006. An annualevent it is considered to be themost important venue in NorthernEurope for the subcontractingindustry.

Last week some 1,200 exhibitorsfrom more than 30 differentcountries and over 15,000visitors met in Jönköping. Wepresented our product range withspecial focus on our chemicalprocessing capabil it ies andZurcon® polyurethane basedproduct range.

Busak+Shamban Sweden at ElmiaSubcontractor

Exhibiting around the world

Global Automotive Segment Director NamedTim grew up in Japanand is fluent in theJapanese language, animportant skill, as wecontinue to develop ourbusiness in Asia Pacific.

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Aerospace

Newly engineered Turcon® M30 from Busak+Shamban optimizes sealperformance, giving exceptionalintegrity in aerospace primary flightcontrols and utility actuation systems.

To meet environmental requirements there isa trend for replacement of chrome-platedcomponents with tungsten carbide coatedones. This has dramatically reduced the use ofhazardous chemicals, but the harder, densersurface makes sealing more challenging.

Turcon® M30 gives excellentperformance

The inherent porosity of chrome-platedmating surfaces makes them able to storelubricant. This and their malleability prolongsseal life. Tungsten carbide, however, isextremely hard and can reduce seal life. Sealswith better friction and wear characteristicshave been found to improve sealingperformance.

Turcon® M30 extends seal life against harder mating surfaces

7

Chrome - Is it hazardous ?New regulations set forth by the US EnvironmentalProtection Agency (EPA) and Occupational Safetyand Health Agency (OSHA) require the reduction inthe use of chrome in aerospace applications. The EPA now lists chromium as one of the 17 mosttoxic chemicals while OSHA has identified it as acarcinogen.

Turcon® M30 is a high pressure, non-abrasivePTFE-based compound specifically developedfor aerospace applications in the materiallaboratories of Trelleborg Sealing Solutions. Itsformulation offers enhanced frictioncharacteristics along with superior wearresistance and improved leakage control. Thismakes seals manufactured in this compoundwell suited for fitment against tungstencarbide-coated mating surfaces.

Tests prove the effectiveness of Turcon® M30

The effectiveness of Turcon® M30 againsttungsten carbide mating surfaces has beenproven in controlled tests. The Turcon®

M30 material surpassed a target leakagerate of one drop per 1,000 cycles.

In fact, leakage was recorded at only onedrop per 30,000 cycles. In other research athigh pressures of 5000 psi and velocity of 9m/min (30 ft/min) over 5 million cycles, itdemonstrated better wear rates than theother compounds. While in anotherdevelopment program, a VL seal wascombined with an excluder, both inTurcon® M30. Leakage measured at 5000psi was zero, insufficient to form a drop.

www.busakshamban.com

For copies of Aerospaceliterature visit theDownload Area on

Mobile Hydraulics

8

Better by

design

The Zurcon® U-Cup RU9 may have a similar profile to an ordinary U-Cup, but it has proven to outperform itsstandard rivals.

Busak+Shamban has used advanced sealingdesign to engineer the Zurcon® U-Cup RU9,and in tests it has proved to have superiorperformance to standard U-Cups. Thisinnovative seal, which is manufactured from aproprietary material and includes patentedtechnology, is able to give longer service life inrod seal applications.

Exceptional hydraulic sealing

When system pressure is high, the contactsurface between the Zurcon® U-Cup RU9 andthe piston rod increases. The seal deforms soits entire friction generating inside surface is incontact with the piston rod. This improves thepressure distribution on the rod. The resultingtribological benefits (the effect of friction,lubrication and wear of interacting surfaces)enhance the friction characteristics of the seal.

The patented microstructure of the Zurcon®

U-Cup RU9 combines sliding surfaces in theseal with back-pumping channels. In back-pumping technology, on the forward stroke ofthe shaft an oil lubricating film is distributedunder the seal. On the return stroke the oil isback-pumped into the system, preventingleakage. This extends seal life by reducingdynamic friction and breakaway force, evenafter pro-longed periods of rest.

The Zurcon® U-Cup RU9 is manufactured fromproprietary polyurethane material speciallyengineered by Busak+Shamban for theproduction of sealing elements. This gives highwear resistance, low compression set, has awide operating temperature range and almostuniversal media compatibility.

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• Trimmed sealing lip• Tight interference fit• Excellent static sealing effect

• Expansion-free space toreduce friction at the dynamic contact surface

• Expansion-free space for increased extrusion resistance

• Trimmed sealing lip• High dynamic and static

sealing effect

• Slide segment for increasedback-pumping ability

• Reduced friction• Low heat generation

Unique features giveoutstanding sealingcharacteristics

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This graph illustratesthe low frictioncharacteristics of theZurcon® U-Cup RU9

The Zurcon® U-Cup RU9 was testedalongside standard U-Cups against allthe main operating criteria for U-Cups:leakage, friction forces, level oflubricating oil and extrusion. The lastthree were measured over a range ofpressures. In all of these tests and at allpressures the Zurcon® U-Cup RU9performed significantly better thanstandard U-Cups.

In mobile and stationary hydraulicapplications, rod seals are exposed to highpressure and friction for extendedperiods. To achieve a long service life,seals must be wear and extrusion resistant,compatible with aggressive media, have

a wide operating temperature range anddemonstrate low friction capabilities.They also need compact installationdimensions and to be designed to easeassembly.

Designed to meet demanding requirements

Better than the rest

Pressure MPa

Friction Force N

Competitor U-Cup 1

Competitor U-Cup 1

Zurcon® U-Cup RU9

0 10 20155

200

400

800

1000

1200

600

11

FEA (Finite Element Analysis) clearly demonstrates the outstanding performance of theZurcon® U-Cup RU9 under pressure.

Superior performance under pressure

0 MPa 10 MPa (1450 psi) 25 MPa (3625 psi) 40 MPa (5800 psi)

Zurcon®

U-Cup RU9

CompetitorU-Cup 1

CompetitorU-Cup 2

www.busakshamban.com

Download the Zurcon® U-Cup RU9 brochure andcatalog from the Download Area of

Low heat generation

Superior extrusion resistance

Wide operating temperature range

Almost universal media compatibility

Compact installation dimensions

Designed for easy assembly

Long service life cuts downmaintenance and downtime

Unique patented construction givesexcellent back-pumping ability

Constant lubrication film minimizesbreakaway force

Proven performance under highpressure for extended periods

Superb friction characteristics

Enhanced pressure distribution on rod

Optimum solution for mobile andindustrial hydraulic applications

Advantages of the Zurcon® U-Cup RU9

Mobile Hydraulics

12

Motor Sport

From the Monte Carlo rally to theBrazilian Grand Prix, from MotoGP tothe Daytona 500, Wills Rings® have beentaking pole position. For over 40 years,they’ve helped beat the competition onracetracks around the world.

Taking pole

From IMP to Formula1

The 1963 Hillman Imp might appearto have nothing in common withtoday’s Formula1 cars. In fact, WillsRings®, that helped improve theperformance of the rallying Imps backin the 60s and 70s are widely used tooptimize the capabilities of today’sracing engines.

Yesterday - a world beater

Forty years ago, Hillman Imps wereoften first past the flag. Back then asuccession of ‘Sports Imps’ achievedsuccess in races and rallies worldwide.Their engines were 875 cc (39 bhp)aluminium with an overhead camshaft.An adaptation of the Coventry Climaxracing engine, the designers includedmany new developments to maximizeperformance. One such innovationwas the use of metallic Wills Rings®

seals within the cylinder head.

Today - still a winner

The Imp ceased production in 1976,but today leading race teams stillincorporate Wills Rings® as a standardsealing solution within cylinderheads.

“Wills Rings® were the originalmetallic seal,” says Stuart Moares,who is product manager for therange. He is based at TrelleborgSealing Solutions, Bridgwater, wherethe seals are manufactured. “Thetechnology behind Wills Rings® hasstood up to the test of t ime.Motorsport designers around theworld appreciate their performanceand our exceptional service.”

Delivery direct to the pits

“We’re used to pulling out all thestops for our Formula1 customers,”continues Moares. “There have beencases where we have supplied theproduct directly to the pits. In anemergency situation, we may receivea last minute call. Our customerneeded a special Turcon® Variseal®

urgently. We manufactured theproduct immediately and it was handdelivered to the racetrack in less than24 hours.”

www.busakshamban.com

Download a copy of the Will Rings® catalog from theDownload Area of

13

position!

Finite ElementAnalysis (FEA) isused to select thecorrect design for anapplication

Wills Rings® may havebeen available for 40 years, but the latesttechnology supports ourcustomers

Wills Rings® - the originalmetallic seal

The Wills Rings® generally used in motorsportapplications are of the O section design. Theseare gas filled and offer far greater elasticity andresponse than conventional solid seals orlaminated gaskets. They are able to withstandextremes of temperature, from cryogenic to850ºC (1562ºF) and pressures up to 1000 Mpa(145040 psi). Their ability to operate at theselevels means they can easi ly meet theperformance requirements of high-end racingapplications.

Hydro Power

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energyof the Yangtze

Harnessing the

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Hydro generators from Alstom are turning waterpower intoelectrical energy in the largesthydropower project ever built, the Three Gorges in China. Orkot® bearings, manufactured atTrelleborg Sealing SolutionsRotherham, are helping them to do so.

At the foot of the Alps, located in Grenoble, France is theworld’s number one in hydropower generation.Hydropower was born in the mountains around there. Backin 1854, Casimir Brenier started work on hydraulic turbinesto convert the power of flowing water into electricalenergy. His company is now a subsidiary of Alstom Powerand the global Technology Center for their hydropowerbusiness.

Asia, led by China, is the largesthydropower market

“The US still has the largest hydropower capacity, but Asia,led by China, is the fastest growing market,” says JacquesBrémond, Mechanical Engineering Supervisor at the AlstomTurbine Technology Center. “In Europe and North Americapower generation exceeds the demands of the population,while in China and India increased capacity is desperatelyneeded.”

Filling the energy gap has led tothe biggest hydropower plantin the world, the Three Gorgeson the Yangtze River in China.For this Alstom is supplyingalmost half the turbines andgenerators.

The greatest challenge of Three Gorges dam was its sheer size

“One of our main functions here is to coordinate our globalmanufacturing units on big schemes,” says Brémond. “TheThree Gorges project has involved France, Brazil, Korea,Norway and China. Its greatest challenge was its sheer size.Compare the width of the Three Gorges at 2.4 kilometers(1.5 miles) to that of a typical dam, which is around 100meters (328 feet), and you begin to appreciate the scale ofthe undertaking.

Jacques Brémond

16

Hydro Power

One of the big advantages that Orkot® bearings have isthat they are ‘fish friendly’. Most metal bearings needgrease to make them work properly and duringoperation this lubricant goes into the water. That is notvery good environmentally.Orkot® material has excellent friction characteristicswhich means no grease is required. Greaseless metalbearings are available, but the Orkot® product is avery cost effective and reliable alternative.

An environmentally friendly bearingsolution

“The main part of a hydro turbine is its runner, wherethe water’s flow is converted to mechanical energy.For the Three Gorges, the external diameter of therunner was 23 percent larger than any other we’dproduced before. It was a massive 10.6 meters (35feet) in diameter with a height of 5 meters (17 feet).

Alstom produced larger turbinerunners than ever manufacturedbefore

“It was impossible to produce the runners in theAlstom workshop in Grenoble. This was because whencompleted they needed to be transported over thetown’s bridge. A single runner’s weight of 425 tonswas greater than the bridge’s 300 ton weight limit.

The runners were therefore manufactured in aspecially constructed workshop in La Ciotat, south ofFrance. Transported by sea, once in Shanghai port,the runners were transferred from ocean going vesselsto riverboats. It takes six of these just to carry thedraft tube elbow.

“We were not able to specify Orkot® bearings on theleft bank of the Three Gorges,” says Brémond. “Backin 1997 and 1998 when we were engineering theturbines for that, it was the early days in provingOrkot®. We had little experience of the product andthe customer requested that we design in a knownsolution.”

17

An exciting moment whenthey accepted Orkot®

Installation of Alstom hydro

generator in Three Gorges dam

The runner converts thewater's flow to mechanicalenergy

Olivier Calemard

VeroniqueBastide

A team of three people inBusak+Shamban France is dedicated tosupporting the Alstom Technology Centerand Grenoble Unit design office. JacquesBrémond’s main contacts are OlivierCalemard, Account Manager for Alstom inGrenoble and Veronique Bastide who ison the technical side.

Originally ‘plastic’ bearingswere laughed at

“Ten years ago the only products wesupplied to Alstom were Orkot® WearRings,” said Olivier. “When I first arrivedat Alstom with my ‘plastic’ bearing theylaughed a little. It was so light comparedto the metal ones they used; they couldnot believe it would be strong enough todo a good job.”

Getting Alstom’s business was an uphillbattle for Trelleborg Sealing SolutionsRotherham and the Busak+Shambanmarketing company in France, butCalemard is certainly not one to give up.

Orkot® bearings are used on the majority of Alstominstallations

“We had to prove that Orkot® could standup to the task,” Calemard says. “Alstomwould not risk specifying an unreliablecomponent. The cost of replacement of afailed bearing is huge. It took time andlots of independent research and testdata to convince them to use the product.Now, though, it is regularly used in themajority of their installations.”

“At the beginning I thought that ThreeGorges was too big a project for us,” saysOlivier. “When Alstom recommended theproduct, it was difficult for me becauseI was remote from the end customer.I could do nothing directly to influencetheir decision. I just had to assist insupplying all the information requestedfrom Alstom and wait. It was an excitingmoment when I was told that they hadaccepted Orkot®.”

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There were three mainreasons behind the building ofthe Three Gorges dam. Thefirst was to regulate the flowof the Yangtze. Its notoriousfloods have claimed anestimated one million lives inthe last one hundred years.

The second reason was tomake the river navigable into

the center of China. Oncecompleted the river will bedeep enough to enable 10,000ton ocean going freighters tosail directly inland 2,400kilometers (1,500 miles) for sixmonths of the year.

The third reason for the damwas to generate power. Thehydropower plant is expected

to create as much electricity as18 nuclear power plants. It willprovide an estimated one-ninth of the nation’s energyand replace 40 to 50 milliontons of raw coal combustioneach year.

Three Gorges Dam - China’s biggestconstruction since the Great Wall

An amazing system oflocks and a ship lift willallow boats to ascendthe 175 meters (574feet) high Three Gorgesdam.

Independent test results persuaded Alstom to use Orkot® bearings

“Initially we were cautious about using Orkot® for bearingsbecause we knew metallic ‘greaseless’ bearings worked. Tosupport their product, Trelleborg gave us details of twoindependent tests on Orkot® specifically for this application.In both of these Orkot® was assessed against different typesof materials and results were favorable.

“Based on these reports we were more and more confidentabout the performance of Orkot® and decided to trial it inthe wicket gate lower bushes during refurbishment of aFrancis turbine in the Liu Jia Xia dam in China. After a fewmore tests in application, the product seemed successful andwas first fitted in a big way on turbines supplied to theAlqueva Hydro Power Plant in Portugal commissioned in2004.

Orkot® bearings are specified on theturbines for the right bank of ThreeGorges dam

“When specifying equipment for the right bank of ThreeGorges, Alstom in Brazil was keen that Orkot® bearings wererecommended to the customer,” says Brémond. “We andBrazil worked together to persuade the customer thatOrkot® would be a good alternative. It was not an easy taskrequiring references, samples and test reports. In the end,they accepted the change in technology.”

“As you can see from Three Gorges, which had a time frameof almost ten years from initial discussions to the firstcommissioning, our projects are very long-term. A supplierhas to be patient in their wait for an order. From thebeginning of a contract up until the time of purchase and

19

Hydro Power

How the runner works

In a gravity dam, the water flows down froma reservoir into a hydro turbine. It enters therunner from one side via a spiral case, whichdistributes the water around the turbine.Here, a distributor with adjustable wicketgates controls the flow of water circulating init. The energy of the water (head and flow)transforms into mechanical energy (torqueand rotational speed). This then converts toelectrical energy within the generatorconnected to the same shaft as the turbine.Once the water has been through the runnerit goes down a draft tube back into the river.

beyond, we need technical answers. Some companies onlygive you commercial information, but that is not goodenough. We have refused to deal with suppliers whocannot provide back up. The technical support we receivefrom Trelleborg, along with the product itself, is itsgreatest strength. That is why we are going to continuedeveloping Orkot® solutions for hydro generators withTrelleborg in the future.”

Consistent product whereverit is manufacturedOrkot® bearings are developed and produced atBusak+Shamban associated manufacturing companyTrelleborg Sealing Solutions Rotherham. They are alsomanufactured at Trelleborg Sealing Solutions Eugene forthe American market. Due to the scale of the Three Gorges,the two sites worked together to fulfill the order andshared technology.

“We do bench marking of processes across the two sites,”says Barry Davies, General Manager of Trelleborg SealingSystems Rotherham. “This is to ensure product consistency.Working on a project like Three Gorges brings thisrequirement right to the forefront. All these parts aregoing to be side by side in the one facility. You have got tobe the same because you are supplying the same productto the same end customer.”

www.orkothydro.com

To find out more about Orkot® in hydropowerapplications go to

20

Automotive

Leading sealing technology forEGR systems

Adapting the EGR Valve to diesel fuel, which isheavier and oilier than gasoline, makes sealingof these challenging. The oilier fuel tends tobuild up carbon deposits more quickly than ingasoline engines and the exhaust gases canform as a sticky gum or even hard residue. Thiscontamination often causes premature seal orbearing failure, making the valve inoperable.

“When designing the sealing configuration abalance must be struck between friction andthe response time of the valve,” says JerryZawada, Segment Manager, Electromechanicalof Busak+Shamban. “For example, a gas-tightseal requires more preload and friction, whichdecreases the valve response time. Lighteningup on the preload, though, allows exhaustvapor to pass the seal and congeal on the shaftand bearings, eventually leading to failure.”

Recommending the optimum seal combination

Tolerances are therefore of great importance,and Busak+Shamban offers a variety of sealsthat can match these design requirements.Seals must also be chemically compatible withdiesel fuel and be capable of operating over awide temperature range and pressures.

“We have the experience to recommend theoptimum seal combination for the job,”continues Zawada. “Busak+Shamban is at theforefront of EGR Valve sealing technology andhas come to the aid of many diesel engine andEGR manufacturers in recent years, both inEurope and in the US. Our global presence hasgiven us a competitive advantage on severalapplications. We are uniquely positioned tooffer our customers the most cost effectivesolution to meet their application needs.”

Smog busters

EGR valves on vehicle exhaust systemsaid smog reduction by helping cut downNOx expelled into the atmosphere.Busak+Shamban meets the challenge of sealing these in diesel engines.

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Proven sealing solutions for EGR valves

Environmentallyfriendly fuel handlingsystems

Turcon® Double Delta®

provides significant improvement invalve performance. The excellentfriction characterist ics of ourproprietary Turcon® PTFE-basedmaterial allows the component toride easily on the solenoid shaft. AnO-Ring, typically made of FKM,energizes it.

Turcon® Glydring® II

gives engineers added flexibility intheir design by lowering tolerancesrequired. Here the elastomerenergizer is bonded to the Turcon®

seal. This reduces tolerance stack upand performance variation.

Turcon® Variseal®

is recommended for gas-tight andhigh temperature applications. Herethe Turcon® jacket is energized witha spring. This seal has very goodcompression set and heat agingcharacteristics. Sealing function andfriction are therefore consistentover time, resulting in superior valveperformance.

Scrapers

can be used in conjunction with anyseal in the EGR system. This keepsdebris from building up on the shaftand extends valve and seal life.

Better efficiency, lower emissions

Automotive engineers developed theExhaust Gas Recirculating (EGR)system to reduce these NOx emissions.This diverts exhaust gases back to theair intake to burn exhaust gasestwice. By doing this, emissions aresignificantly reduced. The EGR valve isfitted between the exhaust and airintake and regulates the amount ofexhaust gases that go through thesystem.

These EGR valves are actuated by avacuum, pressure or mechanicalsystem. In recent years, electronicallycontrolled versions have gainedpopularity.

Unburned gases that remain invehicle cylinders after the combustioncycle are vented into the atmospherethrough the exhaust system. Earlydevices to reduce emissions limitedexcessive hydrocarbons and carbondioxide, but tended to encourageformation of oxides of nitrogen(NOx). When in the atmosphere,these cause smog and as the numberof vehicles increased, so did the

amount of air pollution. A moreenvironmentally friendly solution wastherefore required.

www.busakshamban.com

For more details onautomotive applications goto Industries section on

Hydraulics

22

Down deep in the depths of dustywarehouses lurks an invisible enemy.Unseen but deadly, ozone is a killer tothe average seal. Now there is amaterial that is really ‘hard’ and canresist attack.

Are your O-Rings atrisk of attack?

Theeffect of ozoneon elastomers

Ozone is another form of oxygen,where three atoms of oxygen, rather

than two, join to form a molecule.Ozone is formed in the air, for example,from discharges produced by electricalequipment. Since it is chemically very

reactive, in contact with rubbermaterials it causes them to

crack, especially whenunder tension.

Cracking-up in just a fewweeks

Almost half of all O-Rings are usedin ‘outer’ seal, piston sealingapplications, which means that theyare elongated when fitted. Criticalelongation is above a 5 percentexpansion of the inner diameter.Beyond this, in a matter of weeks,ozone cracking will occur unless theseals are protected from the ozoneeffect on storage.

To solve this problem, Busak+Shambanadds a new harder NBR materialto our range of ozone-resistantmaterials. Engineered to preventcracking when O-Rings are stored inan elongated state in a subassembly,this compound, with a hardnessof 90 Shore A, is available in additionto our already successful 70 and 80shore A materials.

All ozone-resistant NBRs have thesame benefits as a standard NBR;an operating temperature (dependingon media) of -30°C to 100°C (-22°F to212°F), good mechanical properties,resistance to mineral oi l andgrease and excellent elongationcharacteristics. Also, the materialshows no ozone cracking whentested to DIN 53509-1. In this test,samples are tested in an ozoneconcentration of 50 pphm (+/- 5)when elongated by 20% for 120 hoursat a temperature of 40°C (104°F) andhumidity of 55 percent (al lpercentages at a tolerance of +/- 2%).

The new 90 Shore A material isavailable as standard O-Rings. The70 and 80 Shore A material can bemanufactured as O-Rings and custom-molded parts.

Busak+Shamban ozone-resistant materials helpprevent cracking and extendseal life

www.busakshamban.com

Download the O-Ringcatalog from theDownload Area of

Seals stored insubassemblies suffer ozoneattackTypical applications are fluid connections, including tube fittings in static or mobile hydraulics. These areoften of a conical design to ensure a connection ismaintained under high pressure. For sealing integrity,these seals have a small cross section compared to theirlarge diameter and are manufactured of NBR, which has good elongation properties. They are designed toelongate in the seal groove between 5% and 17% tostop movement.

Hydraulic tube fittings are usually stored as ready-to-usesubassemblies, with the seals fitted in an elongated state.When stored, the seals will suffer ozone attack andstandard NBR shows signs of cracking, especially whenstored at high temperatures.

23

Manufacturing Spotlight

In August this year Trelleborg SealingSolutions, associated manufacturingcompany of Busak+Shamban,inaugurated their newly constructedmanufacturing facil ity in China’sexpansive Shanghai region. Theincreased production capacity from thisstate-of-the-art plant means Trelleborgis now better able to meet increasingdemand from industry in China.

Serving key markets includingaerospace, chemical processing,

semiconductor and oil & gas, manyof Trel leborg’s proprietary hightechnology sealing products will beproduced at the Shanghai facility. Itwill have around 100 employees by theend of the year, and the total area ofthe plant, designed to meet stringentenvironmental standards, is 10,000square meters (107,640 square feet).

“This is another stage in strengtheningour position in China,“ says ClausBarsøe, President of the Trelleborg

Sealing Solutions business area. “Wenow have a best-in-class facility withenough capacity to meet growingdemand. Alongside manufacturing wewill provide a full service from theShanghai site. This will include technicalsupport on design and productdevelopment in conjunction withresearch and testing for both local andinternational customers.“

The China connectionThe China connectionTrelleborg inaugurates new plant in Shanghai

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Booming Shanghai

Today, China has the second-largesteconomy in the world, and it is alsoone of the fastest growing. It ispredicted that by 2040 China’seconomy will be larger than that ofthe United States on an overall basis,and at the heart of that growth isShanghai.

Built on a swamp at the mouth of theYangtze River, Shanghai was a smallfishing village until it was colonizedin the mid-19th century. Today,greater Shanghai with its 19 districtsand three islands, extends about

120 km (74 miles) north to south and100 km (62 miles) east to west. With aland area of 6,340 sq km (2,448 squaremiles), it is the fourth most denselypopulated city in the world, withnearly 2,900 skyscrapers that are 18stories tall or taller.

Although at around 20 million, lessthan 2 percent of China’s populationlives in Shanghai, the city contributesmore than 11 percent of China’s totalincome. A quarter of all commoditiesin China pass through Shanghai’sport, one of the largest in the world.

Shanghai is now the biggestcommercial center and the largest

industrial base in China. It recordedits 14th straight year of double-digit economic growth in 2005,with strong exports driving grossdomestic product (GDP) to increase by11.1 percent to 912.5 billion Yuan(90 billion Euros).

Shanghai’s economy is primarilybased on manufacturing. Its mainindustries include automobile,electronic and telecommunicationsequipment, manufacturing of powerstation equipment and parts,petrochemical and fine chemicalprocessing, iron and steel and homeelectric appliances.

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Nice & easy does it – Request

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Busak+Shamban has a reallyeasy to use electronic onlinecatalog where you can browsefor seals, fill a shopping cart and request a quotation. Checkit out now!

Find a seal to meet performance requirements

Depending on the seal type selected, you can identify a seal that:

• operates within a specific operatingtemperature range

• works at different pressures either static,dynamic reciprocating or rotating

• by its speed capabilities• is of a particular hardness or color

Request for Quotationonline withBusak+Shambancouldn’t be easier.

This service is not available through all localwebsites. Available for users in Europe andAsia. Coming soon in the Americas!

Searching couldn’t be easier

There are lots of search options:• By product • By item number• Full text search• Seal properties• Compound types• Approvals

You can even use a ‘wild card’ if you don’t quite knowwhat your are looking for.

for Quotation online!

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Extras

All the information yourequire

Once you have the results of your search you can click through to an item information page. In a simple to view page you are given:

• Seal Dimensions• Technical capabilities• Institute approvals• Availability with daily stock figures

You can also access:• Installation drawings and illustrations• General product information• CAD files

Load up your cart

Once you have selected the items yourequire you can load up a shoppingcart. Via email you can requestquotation. Your local Busak+Shambanmarketing company will be informedof your requirement and contact youwithout delay.

The best option for the job

From your search list youcan do a full comparisonof up to four items.

www.busakshamban.com

Visit

and register now to viewthe Electronic Catalog

Part of Trelleborg Sealing Solutions, a business area of the Trelleborg Group

Employees: 5700 (Trelleborg Sealing Solutions)

Research and Development Centers in Europe and America

Over 30 manufacturing plants worldwide

40 Marketing Companies worldwide

Quality Certifications: ISO 9001:2000 and ISO/TS 16949:2002

In-house polytetrafluor-ethylene, polyurethanedevelopment and elastomer development

More than 2000 material formulations

Worldwide distribution network

Contact your local Busak+Shamban Marketing Company at:

www.busakshamban.com

Busak+Shambanat a glance

Contact the editorial team:groove@busakshamban.com

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