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Trends and Innovation in SealingMaterials
Media Day 2015, Ernst Osen
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Materials for Global Requirements
New fluids demand materials with improved compatibility
� Global trend towards low viscous oils due to fuel economy
� Next oil generation with aggressive additive packages
� Focus on oils with fuel admixtures and degradation products
Legal and environmental requirements
� Global survey of different regulations:� EU Legislation (e.g.REACh)� TSCA� GADSL� …
� Substitution of critical substances
Technological trends on high performance parts
� CO2-reduction requires low friction materials
� Low wear materials for long time durability
� Broader temperature range of use
� Function integration and metal replacement (2K molding)
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Material innovation derived by market trends
Growing oil & gas segment
Technologies to reduce energy consumption
Alternative energies
Medical technology
Cost reduction
• Reduced friction
• Resistance against alternative fuels and lubricants
• Extended service life
• New, clean materials
• Low cost materials
• Integrated functions
• Intelligent materials
• Processability
Environment and legislation
Ageing society
Energy
Sustainability
Soc
ial a
nd te
chno
logi
cal
prog
ress
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Core competenciesMaterials
Staff employed in Europe Employees
Mixing facilities 240
thereof Weinheim 170
Material development 75
thereof Weinheim 23
Production of elastomer compounds
In Europe 15,000 t pa
Several billion seals produced per annum
Production in Weinheim 8,500 t pa
Supply from compounders 3,500 t pa
Polymers used:NR, SBR, NBR, CR, ECO, HNBR, ACM, AEM, EPDM, FKM and FFKM
Not just standard rubbers but many specialty rubbers as well!
Number of specific compounds 1,810
Number of raw materials/components 1,000
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NBRVery good low temperature flexibility
Good oil resistance up to120 °C
EPDM
For water, steam, acid and bases up to 180 °C
HNBRSimilar to NBR, but better heat
resistance up to 150 °CBetter rigidity
FKM
Good chemical and thermal resistance up to 220 °C
FFKM
Very good chemical and thermal resistance up to 260 °C
VMQ
Very good temperature resistance up to 230 °C; good chemical resistance
up to 200°C
CR, NR etc.
For specific applications, e.g. boots
ACM, AEMGood heat resistance
Excellent oil resistance
The important role of the sealing material
Exceptions: FFKM, FKM, FVMQ (VMQ)These materials can in general be used in polar as well as in unpolar media.
Media resistance of elastomers
not suitable suitable
non polar rubber
NRIRSBRBR
EPMEPDMIIRCIIR
polar rubber
NBRXNBRCR
AU, EUACM/ AEMEVACO/ ECOHNBR
Mineral oilshydrocarbons(Benzine, aromates)
non polar mediumWater / steamAlkohol/ glycole(brake fluid)Acids/ basesEster/ ketone
polar mediumMedium to be sealed
Material
Syntheticlubricants
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Temperature range of elastomersLimits for low and high temperature applications
The operation temperature of a seal is limited by the base polymer. In special cases the temperature ranges can be extended by compound composition.
Extended low temperature
Extended high temperature
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Sealing materials for low temperature applications
O-Rings e.g.70 NBR 888, Tg (DSC) = -55 �
70 EPDM 281, Tg (DSC) = -52 �70 EPDM 291, Tg (DSC) = -51 �
Elastomeric form partse.g. 72 FKM 215824, Tg (DSC) = -29 �
70 NBR 285974, Tg (DSC) = -29 �Bellowse.g. 50 CR 879, Tg (DSC) = -40 �
Diaphragmse.g.60 FKM 285896, Tg (DSC) = -43 �58 PVMQ 534, Tg (DSC) = -117�
Simmerring®e.g. 70 FKM 260737, Tg (DSC) = -30 �
Attention: For the intended use not only the low temperature flexibility is relevant, but also the media resistance and other product specific properties need to be followed.
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New fluids demand materials with improved compatibilityInfluence of new lubricant generations in the case of Simmerrings
Before change the fluid a compatibility test with the elastomer is required!
� higher wear � accelerated ageing� higher shrinkage
� Absence of lubrication� Insufficient netting of the
surface
� higher temperature on the sealing lip� accelerated chemical and physical
interactions
Occurrence of
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High performance materials for Process Technology
Elastomer materials used for food and beverage applications need to fulfill
�Temperature resistance for sterilisation�CIP-/SIP medium and chemical resistance�Hygienic design�Certification and approvals according Food and Drinking water regulations of
various countries
Examples of market specific materials:�Fluoroprene® XP 41 and 43�White EPDM 253815 and white Simriz® 506�Hygienic Usit®
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Innovative material development
►Development of new innovative material concepts for specific customer solutions
►Advanced development of new materials for highest functional requirements
� temperature from –70°C up to +300°C
� aggressive lubricants and media (bio diesel, oil additive, coolant, ...)
� service life (life time, wear)
►Raw material and material characterization with modern analysis methods for a detailed quality analysis of our compounds
►Computer Aided Compounding (CAC) to increase the efficiency in material development
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Activities in Material Development
Simulation of the behavior of a rod seal; comparison of two TPU compound with respect of the resetting of the sealing lip
New low temperature-PU results in faster closure time of the sealing lip and therefore more reliability in usage at low temperature
Modeling / Simulation
� Determination of Tg using different test methods and correlation with part testing in order to improve the accuracy of forecast
� Studies on acidic medias (e.g. blow-by) in order to understand the deterioration mechanism and influence of multi-components fluids
� Studies on various fuels and new lubrication oils
� Long-term compression set tests for pipe couplings according to DIN requirements
Lab testing
� Measurement of leakage behavior of seals on test rigs, e.g. low temperature test rig for Simmerrings
� Test rigs for O-Rings at low temperature:o static without side loado static with side loado Short-term dynamic load
(shock)o Permanent dynamic load
(vibration)
Part testing
Reaction time too long: leakage
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Low and high temperature elastomers
NBR for extreme lowtemperature, very lowcrystallisation Temp andgrease resistance
New high temperatureFKM materials for up to280 °C
70 NBR 286210
70 NBR 286211
Mech. propertiesHardness Shore
A72 74
Density g/cm³ 1,21 1,21Modulus 100% N/mm² 4,9 5,3Tensile N/mm² 12,1 12,4Elongation at break
% 250 254
Tear resistance N/mm 12,9 11,3CS 24h/100°C % 26,8 19,0Tg (DSC) °C -72,3 -72,4
75 FKM 177884
75 FKM 177884
After Heat aging280 °CTIME 168 h 336hMech. Prop./ChangeHardness Shore
A75/0 74/-1
Modulus 100% N/mm² 16/6,7 8,1/-38,2
Tensile N/mm² 16/-29,6 14,4/-38,2Elongation at break
% 205/39,5 224/ 52,4
Vol.Change % -1 -1,6CS (ISO 815) % 28 39
Innovative Sealing Solutions | ZF Friedrichshafen AG – Tech-Day | March 2014 | 14
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75 ACM 380 DF:
CS at higher temperatures of HT-ACM: Reset forces remain significantly longer to ensure sealing function.
High-performance material with higher temperature r ange
Higher C-N bonding enthalpy in in combination with a new polymer design yields higher temperature resistance
S-S 268 kJ/molS-C 289 kJ/molC-N 305 kJ/molC-C 331 kJ/mol
Compression set in air at 170 °C
Bonding enthalpie
Innovative Sealing Solutions | ZF Friedrichshafen AG – Tech-Day | March 2014 | 15
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75 ACM 380 DF:
75 ACM 380
70 ACM 121433
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ACM Standard
ACM HT
175 °CTensile Stress relaxation in Esso Gear Oil MB 317► Material: ACM Standard & ACM HT for Simmerrings► Temperature: 175°C; continuous measurement► Deflexion: 20%
High-performance material with higher temperature r ange
Thermochromic Coating: O-Rings NBR in air
O-Ring coated withThermo- color 1
120°C, 24 h
L*(D65) Light index
O-Ring coated withThermo- color 1
120°C, 6 h / 140°C, 1 h / 120°C, 17 h
30
35
40
45
50
120°C Luft Ring 120/140/120°C Luft
Ring
L*[D65]
L*[D65]
1h at 140 °C
Maximum temperatureson a seal can be identifiedand quantifiedwith an optical device
Further colors and temperature ranges available
Intelligent materials: Electrial conductive Materials
No electrical circuit:Non-conductive rubber
Electrical circuit:Conductive Rubber
Intelligent materials: Dielectrical Materials
Tensile Stress applied to the elastomer sample can be measured on the device.
Idea for the demonstrator : Measurement of the compression of a sealing
Intelligent materials: Dielectrical Materials