PAGE 1 THE GASKET FABRICATOR · Rubber, Rib Matting and Diaphragm material. These rubber compounds are available in gauges from 1/32" thick to 2" thick and everything in between

PAGE 1THE GASKET FABRICATORMARCH 2010

Volume 29 Number 1 MARCH 2010

IN THIS ISSUEPresident's Message

Page 1

New Association MembersPage 2

Future Meeting SchedulePage 2

MACtac® to Supply Adhesives for Solar

Technology Manufacturing

Page 2

Company Profi lesPages 3 & 5

Chemical Vs. Mechanical Gaskets:

Part 2Pages 6-7

Torque Vs. Preoad: The Short-Form Equation

Pages 9-10

Benchmarking ReportPage 10

PRESIDENT'S MESSAGEClem Foley

Time has really fl own by, as this is my last meeting as President and also my last newsletter. At fi rst, I was very nervous and dreaded the public speaking and newsletters. It did not take long to get accustomed to it and now I feel like I want to be President for life. I guess that is what dictators feel. I don't want to go...it's been so much fun. The incoming President is Steve Hanson of Precision Gasket Company and the new Vice President is Terry Galanis Jr. of Sealing Devices Inc. Our new secretary/treasurer will be Ken

Stober of Mueller Die Cut Solutions. We are proud to have these dedicated people as members of the Gasket Fabricators Association and their hard work and contributions have been rewarded with a bunch of additional tasks. That is what happens when you speak up and attend meetings. New faces, but nothing really changes. This is not like the Democrats beating out the Republicans. We get our direction and suggestions from our various committees. If you look at the many improvements and changes, you will see that the offi cers and directors listen and implement the valuable contributions of these committees. Each member is encouraged to attend any or all committee meetings. You can be a regular member of these committees or if you want, just a spectator so you can assess and see for yourself which one suits you best. When looking at the people who attend these meetings, you will note that many of our members attend several of them. You only get out of this Association what you put into it and we sincerely advise you to participate. It can be a lot of fun and educational too. You all must be doing something right because membership just keeps on growing and our 3rd Gasketing/Converting Expo in March is well on its way to having over 100 exhibitors and over 500 attendees. This looks like it will be the best one so far and the past two have been huge successes for the members, and especially for the exhibitors. All this in a lousy economy. If I can leave you all with just one short message it would be, "Try and integrate fun into everything you can and don't take yourself too seriously. When people are having fun, they collaborate more, they communicate more and they achieve better results. They will be more creative and come up with better solutions to complex problems." Thank you for the opportunity to enjoy myself at the GFA. It was well worth it. A special thank you goes to Pete Lance for all his help and guidance and to his very capable assistant, Bob Ecker. Gary Fell, our Past President, was a great mentor to me and led in many areas. We wish our co-sponsors at the Gasketing/Converting Expo '10, the International Association of Diecutting and Diemaking (IADD) and the Fluid Sealing Association (FSA), all the success and results that were experienced with the past two Expos. Thanks again.

THE GASKETFABRICATOR www.gasketfab.com

PAGE 2 MARCH 2010THE GASKET FABRICATOR

NEW ASSOCIATION MEMBERS

Fabricator

s.a.s. IndustriesManorville, NY

www.SASIndustries.com

suppliers

Contitech elastomer CoatingsNortheim, Germanywww.contitech.de

I.r.P. Industrial rubber ltd.Mississauga, ON, Canada

www.irprubber.com

longwood elastomersGreensboro, NC

www.longwoodindustries.com

national rubber technologies Corp.Toronto, ON, Canada

www.nrtna.com

Pinnacle elastomeric technologyLula, GA

www.pinnacleelastomers.com

ttarp Industries, Inc.Buffalo, NY

www.ttarp.com

GFA FUTURE MEETING SCHEDULE

Fall 2010 semi-annual meetingSeptember 28-30, 2010

JW Marriot Resort & Spa Las Vegas, NV

As new uses for solar energy continue to grow, and advancements in technology require even more effi ciency and durability, solar module manufacturers need assembly solutions that will increase throughput and reliability. As one of the leading global suppliers of pressure-sensitive adhesives to numerous technical industries, MACtac® Specialty Products now offers a new line of pressure-sensitive adhesive solutions designed specifi cally for solar cell assembly applications. After years of research and development in the solar bonding process, MACtac has launched fi ve primary solar assembly products, along with additional adhesive solutions to address related needs for solar cell manufacturing. “For years, MACtac Specialty Products has offered engineered, pressure-sensitive solutions for bonding and mounting in the electronics, medical, appliance, and automotive industries,” said Steve Dominak, business development manager, MACtac Specialty Products. “Our new line of adhesive systems was created after many years dedicated to formulating the best pressure-sensitive adhesives to meet the specifi c requirements of the solar industry. Our expertise in research and development was benefi cial in formulating solutions for this growing market where superior adhesive performance is a necessity.” MACtac's line of solar products will enable manufacturers to use pressure-sensitive adhesives in the assembly of concentrating, fl at and fl exible solar applications, such as: • Concentrating and fl exible applications that are subject to high-ranging temperatures and environmental conditions, like withstanding dry desert heat or extreme cold • Securing slanted, concentrated solar energy mirrors in place to heat water or direct light toward one source • Flat solar energy for rooftop applications • Flexible solar energy for remote locations, transportability and charging small appliances such as cell phones and travel lights MACtac pressure-sensitive adhesives are customized for specifi c customer needs and applications for complete solar cell protected solutions. All of MACtac Specialty Products' adhesive systems for solar cell assembly are manufactured in the United States. For more information, call 800.328.2619, e-mail [email protected] or visit www.MACtac.com/Technical.

MACtac® to Supply Adhesives for Solar Technology Manufacturing

PRESS RELEASE


COMPANY PROFILES

I.R.P. Industrial Rubber LTD. has been distributing quality rubber products since 1950. Our imported sheet rubber program consists of a wide range of compounds including Neoprene, EPDM, Nitrile (white and black), Pure Gum, Butyl, Hypalon, Silicone, Viton, SBR, Red Sheet Packing, Scraper Rubber, Rib Matting and Diaphragm material. These rubber compounds are available in gauges from 1/32" thick to 2" thick and everything in between. I.R.P. offers our sheet rubber in full roll quantities or cut to width custom lengths and/or fabricated to your needs. These items are stocked in our main warehouse, which is located near Toronto, Ontario, Canada close to the USA/Canada border. For customers located near the Pacific coast, I.R.P. has a warehouse located near Vancouver, British Columbia to serve your needs. We are a ISO9001:2008 registered company and incorporate 5S practices into our daily routines to ensure the most competitive pricing for our customers. To learn more about I.R.P., please visit our website at www.irprubber.com.

CONTITECH Elastomer-Coatings is a leading manufacturer of printing blankets, coated fabrics, diaphragm materials and engineered products for industrial applications. ContiTech AG – part of the Rubber Group of Continental – is the world’s largest specialist for rubber and plastics technology in the non-tire rubber sector. ContiTech Elastomer-Coatings develops and manufactures coated fabrics consisting of textiles or other reinforcement materials with elastomer coatings for nearly every requirement and application. These products can be found in the automotive industry, marine applications, rail transport, systems construction, structural and underground engineering, aircraft or the textile industry. In our Northeim, Aachen and Waltershausen plants in Germany, we develop and manufacture durable products according to our own standards and specifically

tailored for the demands of customers. We provide our customers support in all areas: planning, development, production, application advice. We are certified to ISO 9001 and ISO/TS 16949.

Pinnacle Elastomeric Technology’s interest in joining the GFA stems from our many successes and achievements in supplying and supporting many gasket fabricators with fluoroelastomer (Viton) and other high performance elastomers rubber compounds. FSA, MIL-AMS specification, and FDA are only a few of the sheet goods compounds being sold regularly into this sector of the rubber industry. Pinnacle was started in 1998 by Bob Rathbun and Dennis Lancaster, both long time rubber industry veterans. At that time, both saw a need in the marketplace for a fluoroelastomer (Viton) mixer to service the small to medium size user. A one stop shop for a customer’s mixing and compound development and anything technologically challenging for a particular company. In 2001, the company was purchased by Rex-Hide Industries and has since grown to be one of the largest and premier custom mixers of high performance elastomers (Viton, AFLAS, HNBR, FFKM) in North America. Pinnacle offers an extensive library of compound formulas and correlated data to meet a myriad of industry applications. Pinnacle’s expertise in creating precision custom compounds that conform to exacting processes and part demands is what has earned Pinnacle a reputation for high performance products at a reasonable price. Pinnacle Elastomeric Technology is ISO 9001 certified and is complete with a full service R&D lab, capable of performing many of the industries key tests. We are driven by the importance of quality and consistency within the rubber industry and have developed strict guidelines to ensure that superior product is being developed, manufactured, and delivered to our customers. Since the beginning, Pinnacle has conservatively built our customer base while proving our capabilities. We can proudly say that we are delighting each and every customer that has entrusted us with their compounding, mixing, and technical responsibilities.

Company Profiles Continued on Page 5...


Industrial Rubber Sheeting, Extruded & Molded Products

• Turn to FLEXcon for Bonding, Laminating, Fabricating and more... • Custom PSA solutions for transfer, single and double-coated tapes.

• Join the wide variety of industries that rely on FLEXcon’s experience.

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Providing Solutions in Pressure-Sensitive Films and Adhesives

ACRYLIC & RUBBER BASED GASKET ATTACHMENT SOLUTIONS

800-343-1076www.venturetape.com

More Capable • More Affordable

Ttarp Industries, Inc. • Since 1981

Automatic steel-rule die cutting pressesfor non-metallic materials.

60" heat laminators for heat-activated or cold-bondingadhesive products.

Contact us for specifications and pricing: 800-871-7596 • www.Ttarp.com

Ttarp GFA Ad 393-1004:Ttarp GFA Ad 393-1004 1/27/10 4:30


Ttarp Industries designs and manufactures automatic steel rule die cutting systems, laminating equipment for applying adhesive tapes, vertical band saws, and horizontal splitters. Our equipment is used for fabricating and converting gaskets, foam, rubber, packaging materials, pressure-sensitive adhesives, and other materials into parts and components for the automotive, medical, toy, sporting goods, electronic, appliance and packaging industry. Our standard products can be customized with various accessories and options to suit your specific needs. Since 1981, all of our equipment has been manufactured in the USA and sold factory-direct, ensuring that you receive competitive pricing and expert technical support. For more information and to see videos, please go to our web site at www.ttarp.com, call us at 800-871-7596 or email us at [email protected].

COMPANY PROFILES(Continued from Page 3...)

As a service to members, the GFA, in collaboration with the International Association of Diecutting and Diemaking (IADD), offers TechTeam™, a dedicated and experienced team of industry professionals who stand ready to assist you.Their mission is to quickly research and answer GFA Members' technical diecutting and diemaking questions in an unbiased, confidential, current, and direct manner. Using the TechTeam™ will save you time, money, and materials and can make you look like a hero to your customer or company. Contacting the Team is easy. Submit a question, track it, and follow up using an easy web-form in the Members Only area of the GFA website. The first response to questions generally comes within the first 24 hours of a question being asked. GFA Members can access the service by clicking on Members Only on the GFA's home page (www.gaketfab.com). Members who have forgotten their user name and password should contact the GFA office at 610-971-4850 or [email protected].

National Rubber Technologies Corp. is a world class, vertically integrated manufacturer of high-performance Symar® masticated and rebonded crumb rubber sheets and rolls, and engineered rubber and plastic products. Our customers include distributors, converters, and OEM’s in the automotive, industrial, construction, flooring, agricultural, and transportation industries. Typical products made from Symar rubber include load bearing pads, splash guards, gaskets, stone shields, air deflectors, closeouts, chutes, seals, vibration pads, motor mounts, and many more. Symar masticated rubber is a fully cured, fiber reinforced masticated rubber made from recycled tire crumb. It is a highly durable, flexible and resilient

thermoset rubber available in sheet, roll or molded form. Our unique combination of rubber compounds and fiber reinforcement creates a product that cannot be matched by rubber products alone. During the manufacturing process, fibers are added to the base rubber compounds to create an internal strengthening, much like steel reinforced concrete. This mesh delivers superior tensile strength, stiffness, tear resistance, durability, and unique directional properties. Symar rubber sheets and rolls can be made up to 7 feet wide and can be made with cloth inserted fabrics or laminated surface fabrics for more demanding applications. National Rubber Technologies processing and manufacturing capabilities include sheet and roll manufacturing, compression and injection molding, rubber to metal bonding, die cutting, assembly operations, rubber formulation and compounding calendering and preforming, and tire recycling. National Rubber Technologies Corp. and Koneta Inc. are subsidiaries of KN Rubber.


In the November issue of The Gasket Fabricator, I compared the chemical and physical properties of Chemical and Mechanical gaskets. In this part, the effect that these gaskets have on Joint Characteristics will be covered. Now that we are aware of the myriad properties associated with the die cut gasket and with chemical gaskets, we can consider some common joint characteristics and problems.

Flange Unevenness: This can be caused by heat distortion of the casting; improper machining of the flanges; and in the case of stamped covers, nonuniform stressing and straining of the metal. At any rate, the result is variation in the joint gap. Die Cut or Preformed gaskets – To accommodate varying joint gap, compressibility and thickness can be varied. Sealing load must be sufficient to provide a surface seal and reduce porosity, if present. To keep torque loss and cost to a minimum, the thinnest gasket is most desirable, but the volume of gasket material required to fill the gap is still several times the gap volume. Chemical gaskets – The viscosity must be great enough so that the gasket material does not flow out of the gap, and enough material must be applied to fill the gap. The time required to develop a state of cure sufficient for sealing must be determined. The amount of material required to fill the gap is equal to the volume of the gap plus a small excess to assure complete filling of the gap. Too much material will produce a sloppy looking joint and the excess may even be detrimental by clogging moving parts.

InDUCeD Flange DIstortIon: Due to weakness in castings and covers, plus uneven bolting patterns and variations in the sequence that bolts are tightened, distortion and unevenness in the joint gap can be induced. Die Cut or Preformed gaskets – Any compressible material placed between the flanges will increase flange distortions. Increasing the thickness of the gasket, or the load applied to the bolts will normally increase flange distortion. When flange distortion is encountered, the approach is to reduce thickness and/or compressibility to arrive at a point where the flanges will make contact with the gasket, and will seal.

Chemical gaskets – Since the flanges are assembled and bolted together while the material is well, metal to metal contact is achieved between the flanges. Upon curing, the gasket material is under zero compressive load and does not contribute to induced flange distortion.

resIlIenCe In oPeratIng envIronment: In many applications, there are pressure surges that result in a repositioning of the mating surfaces due to vibration and thermal expansion. In some cases, thermal effects can cause distortion of castings and covers. The material used to bridge the gap must follow there motions. Die Cut or Preformed gaskets – The properties associated with this ability are percent recovery and ability to follow relative movement, if any, between flanges. In addition, the motion of the gasket must be in phase with the flange motion for effective sealing. Chemical gaskets – Here the sealing technology is radically different. Since the material is not under load, it has no desire to follow the flanges as they try to separate unless it is bonded to the flanges and either the adhesion is strong enough to prevent motion, or the gasket material has enough extensibility to follow the motion without breaking the bond. RTV silicones are rubber and do have high extensibility, but the thickness between the flanges is very small. With elongation at breaking point of 400%, the practical amount of extensibility is less than four times the thickness. RTV silicones are also low strength materials with limited ability to prevent motion. Because of this, joints which have mechanically designed gap of predetermined thickness is preferable for RTV use. The anaerobic compounds have very low extensibility, but much higher strength than silicones, and thus a greater ability to prevent motion between the flanges. Applications where the flanges are subjected to cyclic separating forces, whether dynamic or thermal, should be thoroughly evaluated before adapting chemical systems.

relIabIlIty anD Cost: The real competition between the two technologies is going to take place in the areas of reliability, and costs of materials and application. reliability – This simply means being able to do the job over and over again with no failures, or as least a statistically insignificant number of failures. In a sense, reliability and sameness are synonymous.

Continued on Page 7...

CHEMICAL VS. MECHANICAL GASKETS: PART 2By: Larry Pyle, LFP Technologies


Chemical Vs. Mechanical Gaskets: Part 2

(Continued from Page 6...) Die cut and molded gaskets have a high degree of sameness. With proper control of physical properties, these devices have high reliability. Their function is unaffected by moderate contamination of fl ange surfaces. If a leak develops, whether due to improper tightening of the bolts or torque loss, retightening often corrects the leak. Add to this good handling strength and minimum possibility of damage ring installation, and they have a degree of reliability diffi cult for chemical systems to match. Chemical gaskets are applied wet to the fl anges. Enough material must be applied to the mating fl anges to fi ll the joint gap. Squeezing material out of a tube with a nozzle on the end leaves room for operator error. To remove operator error, anaerobics can be accurately applied by silk screening or stenciling. RTV silicones, because of their sensitivity to moisture, cannot be silk screened, but can be applied with a pantograph or tracing type machine. Robot application also removes a lot of this error by applying a precise amount to a precise location. After application of the material, the fl anges must be carefully assembled to avoid wiping the uncured material off. In addition, assembly of the chemically sealed joint must be done as soon as the material has been applied in most cases. Material which has dried or cured on the surface may have problems of adhesion and thus sealing performance. If a leak develops, the unit must be disassembled and the sealing operation repeated. Additionally, there is a difference in ease of application on the original build where automated equipment is often used, but in the repair shop hand application is the usual means of applying the material. Cost of materials – RTV silicones are expensive, and anearobics are even more expensive, but so little is required for sealing that the material cost per unit is usually a fraction of the cost of the mechanical gaskets. With chemical gasket systems, there is no need to maintain inventories of many different part numbers as is required for mechanical gaskets. Cost of application – The labor required to apply a bead of RTV silicone or anaerobic by squeezing a tube is much greater than installing a precut or preformed gasket. However, pantograph robots used to apply RTV silicones, and silk screening

and stenciling units used to apply anaerobics require little labor and lend themselves to higher automation than now used to install mechanical gaskets.

some FInal Comments: Many so-called preformed gaskets are in reality multifunctional parts. Besides sealing, they may be shims, spacers or fl uid passage walls, or they may contain open or restricted orifi ces for fl uid passage or metering. These are applications where the use of mechanical gaskets will continue. Between the fl anges, as sealing members only, chemical gasket systems are being used successfully on assembly lines at a cost reduction. But reliability in maintenance and repair situations can be a problem. Some manufactures use a chemical system in the original assembly, and supply a preformed gasket for repair work. Chemical gaskets are not suitable for every application, but they deserve consideration as another tool for the sealing specialist to use. They will not supplant the preformed gasket, but they defi nitely have a place in the sealing technology.

NEWSLETTER

The Gasket Fabricator is published by the Gasket Fabricators Association and distributed to all members and prospective members of GFA.

President ................................................................Clem FoleyVice President ...................................................Steve HansonExecutive Director....................................... Robert H. EckerAdministrative Director/Newsletter Editor...............Peter LanceCommunications Committee Chair.....................Chris Brand

Members are encouraged to contribute articles and items of interest to the Gasket Fabricator. All contributions should be addressed to: Executive Director, GFA, 994 Old Eagle School Road, Suite 1019, Wayne, PA 19087-1866, Phone (610) 971-4850, Fax (610) 971-4859, Home Page: www.gasketfab.com, E-mail: [email protected].

Articles appearing in this publication may not be reproduced without written consent from the Association. Articles appearing in the Gasket Fabricator are the views of the authors and not necessarily those of the Association.

© Copyright 2010 Gasket Fabricators Association


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TORQUE VS. PRELOAD: THE SHORT-FORM EQUATIONBy: Larry Pyle, LFP Technologies

Clamp load is the thing which does the sealing of all gaskets. Most joints use bolts or other fasteners to achieve this clamp load, usually by tightening to a certain torque. The consistency of the resulting clamp load for any torque and fastener is critical. The so-called short-form equation for this relationship is:

tin = Fp (KD)

Where TIN = input torque (lb-in not lb-ft) Fp = achieved preload (lb) D = nominal fastener diameter (in.) K = “nut factor” (dimensionless)

The discussion which follows assumes no prevailing torque, which is usually the case. Note that the “nut factor” K is not a coeffi cient of friction. It is, instead, a general-purpose, experimental constant which is found by experimentally applying torque to fasteners and measuring the achieved preload. What is convenient about K is that it summarizes anything and everything that has affected the relationship between torque and preload in our experimentation—including friction, torsion, bending, plastic deformation of threads, and any other factor that may or may not have been anticipated. The unfortunate thing about K is that it can only be determined experimentally and experience shows that it should be determined for each new application. Even then, it does not produce a singe number. Experience shows that for accurate prediction of preload, a number of experiments need to be made to determine the mean K, standard deviation, etc. Having done this we can indeed predict the minimum and maximum preload achieved for a given input torque, at a predictable confi dence level. The following fi gure depicts the variations encountered in the K value for as-received steel fasteners. The standard deviation for this data is 0.5, and the mean is 0.199. Plus and minus three standard deviations would yield a range of 0.15 to 0.25 for K. The data suggests a scatter of +/-26% in the preload expected for a given torque, a fi gure often quoted of +/-30%.

Whereas the above discussion works well with new fasteners and threads, actual fi eld data in a repair or reuse application may differ. This merely refl ects the fact that the nut factor (K) does not summarize such things as tool accuracy, operator skill, bolting procedure, as well as the obvious factors such as lubricity and thread condition. The fi gure below illustrates the effect on the nut factor (K) by repeated assembly of fasteners many times. This shows that as the fi nishes on the threads on both the bolt and threads in the fl anges become smoothed or “burnished” with each application of torque. What is plotted is the torque required to tighten to a preload of 46,000 lbs. The fastener becomes easier to tighten with each time it is reused.

Continued on Page 10...


Torque Vs. Preload: The Short-Form Equation

(Continued from Page 9...)

In the table below are some typical values for the nut factor (K) for some common fastener conditions and with/without lubrication. Note that lubrication tends to reduce the variation in K.

reported nut factors (K)alloy steel Fasteners and coatings

min. mean max

As received, mild or alloy steel on steel

0.158 0.2 0.267

Black oxide 0.109 0.179 0.279Cadmium plate (dry) 0.106 0.2 0.328Cadmium plate (waxed) 0.17 0.187 0.198Copper plate anti-seize 0.08 0.132 0.23Machine oil 0.1 0.21 0.225Moly paste or grease 0.1 0.13 0.18Solid fi lm PTFE 0.09 0.12 0.16

BENCHMARKING REPORT

Below are the results from the Benchmarking Survey, which was undertaken to give GFA members a thumbnail sketch of how other members are fairing at this time.

We had 32 out of 63 Fabricator responses.

1. Most Recent Quarter Sales Compared to Previous Quarter

UP DOWN SAME20 8 462.5% 25% 12.5%

2. Current Quarter Sales Projection Compared to Last Quarter

UP DOWN SAME23 1 872% 3% 25%

We had 25 out of 66 Supplier responses.

1. Most Recent Quarter Sales Compared to Previous Quarter

UP DOWN SAME15 4 660% 16% 24%

2. Current Quarter Sales Projection Compared to Last Quarter

UP DOWN SAME17 3 568% 12% 20%

visit us online at: www.gasketfab.com

If you have technical questions you would like to see answered in future issues, please send them by e-mail to

[email protected].


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Documents

PAGE 1 THE GASKET FABRICATOR · Rubber, Rib Matting and Diaphragm material. These rubber compounds are available in gauges from 1/32" thick to 2" thick and everything in between