engineered graphite with KEVLAR High Performance Graphite Beater (NBR) Supplier: Frenzelit Material: novatec HPN Density g/cm³: 1. Sample: 1 Scale: 1 : 1 Position: Transverse Longitudinal Applications engineering Soft material technology Typical mechanical properties Sealing behaviour Test results GASKETS TECHNICAL TEXTILES EXPANSION JOINTS INSULATION NEW MATERIALS Frenzelit-Werke GmbH & Co. KG P.O. Box 11 4 946 Bad Berneck Germany Phone: +49 9273 72- Fax: +49 9273 72-221 info@frenzelit.de www.frenzelit.com
Table of Contents Page Topic 2 Table of Contents 3 The product family of novatec 4 Applications in the automotive sector Material structure of novatec 6/7 Compressibility / Recovery ASTM F 36 J, standard test, data and graphics Thickness. /.8 / 1. / 2. mm 8 Deformation curves residual surfaces (cold) Thickness. /.8 / 1. / 1.2 / 1. / 2. mm 9 Performance graph 2 / / 1 N/mm² thickness. mm 1 Performance graph 2 / / 1 N/mm² thickness.8 mm 11 Performance graph 2 / N/mm² thickness 1. mm 12 Performance graph 2 / N/mm² thickness 2. mm 13 Leakage at thickness.8 mm 14 Leakage at thickness 1. mm 1 Media resistance at thickness.8 mm 16 Media resistance at thickness 1. mm 17 Anti-stick effect PTFE on novatec HPN 1. mm 18 Long-term behaviour of novatec as well as additional information on: Technical data sheet on thickness.8 mm Technical data sheet on thickness 1. mm Author: CBU - 2 - Date: 11/4 HPN_page_2e.DOC
Industrial applications The product family of novatec engineered graphite with Kevlar Automotive applications novatec PREMIUM II SPECIAL novatec LD14 novatec 92 novatec HPN HPS *) δ = 1.7 g/cm³ δ = 1. g/cm³ δ =.97 g/cm³ δ = 1.63 g/cm³ δ = 1. g/cm³ Steam gaskets Chemical industry General industry Facing material cylinder head gaskets High-performance soft gasket material sealing oil, water, fuel General automotive soft gaskets *) swelling properties novatec is entering a market section with a very strong competition between different kinds of non-asbestos materials, graphite and steel gaskets. This new technology of graphite material reinforced by Kevlar fibers combines the best properties of both gasket technologies - graphite and fiber based - and opens engineers a very wide range of successful applications. novatec s technical performance combined with a favourable pricing offers a very good chance of a successful market introduction. Frenzelit wants to offer help in all cases of application questions and can perhaps give support by special testing in their own test laboratories. The exchange of knowledge and experience with the customers is a great chance to optimise present or new products and to develop future material generations suitable for meeting the demands of the market. Author: CBU - 3 - Date: 11/4 HPN_page_3e.DOC
Graphite beater material for automotive soft gaskets The new fibre-reinforced composite material based on graphite for the automotive sector. Application as soft gaskets in engines and gears. Material with excellent adaptability, very good media resistance and a stress relaxation as required in practice. Graphite - state-of-the-art technology combined with suitable gasket materials to perfectly seal off joints. PTFE anti-stick coating (optional). Graphite plus Kevlar plus Know-how ----------------------------------- novatec HPN engineered graphite with Kevlar Author: CBU - 4 - Date: 11/4 HPN_page_4e.DOC
Material Structure under the electron scan microscope graphite flakes with Kevlar fibres In soft gaskets as used up to now undirected fillers are used which have to be closed with a high percentage of binder in order to reach a cross-sectional tightness despite high material densities in the remaining pores. Under long-term conditions these additives make the material brittle and have a deteriorating effect its the hot creep. novatec HPN first consists of undirected graphite lamellae (7%) which form the material structure as shown in the sketch during calendering together with the reinforcing Kevlar fibres, the friction powder and a low percentage of highquality NBR binder. The material is tight. The elasticity of the gasket is guaranteed by the locked-in porosities. locked-in Kevlar fibres and friction powder This production technique creates long-term stable gasket properties like stress relaxation and elasticity. Author: CBU - - Date: 11/4 HPN_page_e.DOC
Graphite Beater Material Compressibility / Recovery ASTM F 36 J These measurements allow information on the mechanical adaptability of gasket materials. In most applications the materials are also exposed to high temperatures that may lead to a considerable deterioration in their adaptability when the gaskets become brittle. Therefore the standard test acc. to ASTM F36 J has been extended by a second series conducted after tempering 2h / 12 C (212 F). In the laboratory the following typical values with regard to compressibility and recovery were measured. a) novatec HPN Graphite beater material, thickness. mm Sample Compressibility Recovery 1 14.8% 42.7% 2 17.2% 41.7% average 16.% 8µm 42.2% 34µm after tempering 18.2% 91µm 43.1% 39µm b) novatec HPN Graphite beater material, thickness.8 mm Sample Compressibility Recovery 1 17.% 41.7% 2 18.% 44.3% average 18.% 144µm 43.% 62µm after tempering 16.3% 13µm 46.% 6µm c) novatec HPN Graphite beater material, thickness 1. mm Sample Compressibility Recovery 1 16.6% 32.3% 2 17.4% 3.7% average 17.% 2µm 34.% 87µm after tempering 14.9% 224µm 34.8% 78µm d) novatec HPN Graphite beater material, thickness 2. mm Sample Compressibility Recovery 1 13.1% 38.2% 2 14.9% 42.8% average 14.% 28µm 4.% 113µm after tempering 14.2% 284µm 39.% 11µm Author: CBU - 6 - Date: 11/4 HPN_page_6e.DOC
Compressibility / Recovery ASTM F 36 J Samples: novatec HPN Graphite Beater Material installation thickness. /.8 / 1. / 2. mm, with optional PTFE coating new after production and after ageing 2h / 12 C: 2 19 18 17 16 1 14 Comparison of Compressibility (%) file kevg1.xls 18,2 18 17 16,3 16 14,9 14 14,2 3 file kevg1.xls 28 26 24 22 Comparison of Compressibility (µm) 2 224 28 284 13 2 12 11 1 9 18 16 14 144 13 8 7 6 12 1 8 8 91 4 3 2 6 4 1 2, mm,8 mm 1, mm 2, mm, mm,8 mm 1, mm 2, mm 8 file kevg1.xls Comparison of Recovery (%) 14 file kevg1.xls Comparison of Recovery (µm) 13 7 6 12 11 1 113 11 4 42,2 43,1 43 46 34 34,8 4, 39 9 8 7 6 62 6 87 78 3 2 4 3 34 39 1 2 1, mm,8 mm 1, mm 2, mm, mm,8 mm 1, mm 2, mm Result : Good adaptability and recovery, these properties remain despite tempering. The mechanical properties correspond to novatec LD14 in tendency when rolled onto tanged metal. Author: CBU - 7 - Date: 11/4 HPN_page_7e.DOC
Deformation curves (cold) Samples: Installation thickness.8 / 1. / 2. mm (. / 1. / 1.2mm extrapolated or interpolated) Density 1.g/cm³ With Frenzelit branding; without coating Test : Frenzelit load / deformation curve 3 samples 33.3 mm x1 mm = 1 mm² p = 1 2 N/mm², Sliding cold forming at more than min. Comparison of values after compensation of system correction factors! The yield point represents a function of the height/width relation of the sample surface pressure (N/mm²) 2 1 HPN.mm yield point >3N/mm² HPN.8mm yield point >2N/mm² HPN 1.mm yield point >22N/mm² HPN 1.2mm yield point 21N/mm² HPN 1.mm yield point 17N/mm² 1 capacity residual surface HPN 2.mm yield point 11N/mm² file hpn_rfv1.xls - 1 1 2 2 3 3 4 4 deflection (µm) Result : novatec HPN shows a good adaptability as a soft gasket with an installation thickness of.8 to 1.6 mm. A gasket with a thickness of.8 mm does not start to flow even at pressures above 2 N/mm² and can thus be used in applications with very high punctual pressures. Autho: CBU - 8 - Date: 11/4 HPN_page_8e.DOC
Performance graph Break point test 2 C with different surface pressures Thickness. mm surface 3 times 1 mm x 33.3 mm = 1 mm² surface pressure 1 > 1 > max. value N/mm² 2 novatec HPN 2 1 N/mm² temperature C 2 1 1 reference deflection 1 >> 1 N/mm² >> max. value -----------> long-term setting 1h values bp test x 1.1 file hpnbp8.xls -3-2 -1 1 2 cold compression 2 min. hot creep 3 min. µm Author: CBU - 9 - Date: 11/4 HPN_page_9e.DOC
Performance graph Break point test 2 C with different surface pressures Thickness.8 mm surface 3 times 1 mm x 33.3 mm = 1 mm² surface pressure 1 > 1 > max. value N/mm² 2 temperature C 2 novatec HPN 2 1 N/mm² 1 1 reference deflection 1 >> 1 N/mm² >> max. value -----------> long-term setting 1h values bp test x 1.1 file hpnbp8.xls -3-2 -1 1 2 µm cold compression 2 min. hot creep 3 min. Author: CBU - 1 - Date: 11/4 HPN_page_1e.DOC
Performance Graph Break Point Test 2 C with different surface pressures Thickness 1. mm surface 1 mm x 33.3 mm = 1 mm² surface pressure 1 > 1 > max. value N/mm² 2 novatec HPN 2 N/mm² temperature C 2 1 1 reference deflection 1 >> 1N/mm², >> max. value ------------> long-term setting 1h values bp test x 1.1 file hpnbp1.xls - -4-3 -2-1 1 2 µm cold compression 2 min. hot creep 3 min. Author: CBU - 11 - Date: 11/4 HPN_page_11e.DOC
Performance Graph Break Point Test 2 C with different surface pressures Thickness 2. mm surface 1 mm x 33.3 mm = 1 mm² surface pressure 1 > 1 > max. value N/mm² 2 novatec HPN 2 N/mm² temperatur C 2 1 1 reference deflection 1 >> 1 N/mm² >> max. value ----------> long-term setting 1h values bp-test x 1.1 file hpnbp2.xls - -4-3 -2-1 1 2 µm cold setting 2 min. hot creep 3 min. Author: CBU - 12 - Date: 11/4 HPN_page_12e.DOC
Leakage at thickness.8 mm Please note: The leakage tests with gas or Fuel A just give an indication of the remaining pore volume as a function of surface pressure. Laboratory and engine tests with the viscous media oil and water / antifreeze have proven that the material seals off perfectly, of course, i.e. the values are too small to be measured in ml/min. or ml/h. a) Leak rate Fuel A: (ASTM F37A, ring 32.3 x 44.3 mm) 3 ml/h 2, 2 1, 1, 1 bar (~ 14.PSI) 4 bar (~ 8PSI) 3.MPa ~ 1PSI 1MPa ~ 14PSI 1MPa ~ 218PSI 2MPa ~ 29PSI b) Leak rate N2: (following DIN 33, ring x 9 mm, without foil) ml/min. 4 3 2 1 1 bar (~ 14.PSI) 4 bar (~ 8PSI) 3.MPa ~ 1PSI 1MPa ~ 14PSI 1MPa ~ 218PSI 2MPa ~ 29PSI Author: CBU - 13 - Date: 11/4 HPN_page_13e.DOC
Leakage at thickness 1. mm Please note: The leakage tests with gas or Fuel A just give an indication of the remaining pore volume as a function of the surface pressure. Laboratory and engine tests with the viscous media oil and water/antifreeze have proven that the material seals off perfectly, of course, i.e. the values are too small to be measured in ml/min. or ml/h. a) Leak rate Fuel A: (ASTM F37A, ring 32.3 x 44.3 mm) ml/h 3 2, 2 1, 1, 1 bar (~ 14.PSI) 4 bar (~ 8PSI) 3.MPa ~ 1PSI 1MPa ~ 14PSI 1MPa ~ 218PSI 2MPa ~ 29PSI b) Leak rate N2: (Following DIN 33, ring x 9 mm, without foil) m l/m in. 4 3 2 1 1 bar (~ 1.PSI) 4 bar (~ 8PSI) 3.MPa ~ 1PSI 1MPa ~ 14PSI 1MPa ~ 218PSI 2MPa ~ 29PSI Author: CBU - 14 - Date: 11/4 HPN_page_14e.DOC
Media resistance at thickness.8 mm a) ASTM oil no. 3 h / 1 C: 4 4 3 3 2 2 1 1 26% 26% 19% 3% 6.N/mm² 6N/mm² K % E % G % D % ZF long. (N/mm²) ZF transv. (N/mm²) b) ASTM Fuel B - h / 23 C: 4 4 3 3 2 2 1 1 4% 2% 14% 3% 4.2N/mm² 3.8N/mm² K % E % G % D % ZF long. (N/mm²) ZF transv. (N/mm²) c) Water / Coolant ( : ) - h / 1 C: 4 4 3 3 2 2 21% 26% 2% Legend: K = compressibility E = recovery G = weight D = thickness ZF = tensile strength The diagrams show typical values 1 1 3% 4.N/mm² 4.3N/mm² K % E % G % D % ZF long. (N/mm²) ZF transv. (N/mm²) Author: CBU - 1 - Date: 11/4 HPN_page_1e.DOC
Media resistance at thickness 1. mm a) ASTM oil no. 3 - h / 1 C: 4 4 38% 3 3 2 22% 2 1 16% 1 4% 7.N/mm².1N/mm² K % E % G % D % ZF long. (N/mm²) ZF transv (N/mm²) b) ASTM Fuel B h / 23 C: 4 4 3 3 2 2 1 1 39% 2% 1% 4% 4.7N/mm² 3.3N/mm² K % E % G % D % ZF long (N/mm²) ZF transv (N/mm²) c) Water/Coolant ( : ) - h / 1 C: 4 4 3 3 2 2 1 24% 24% 21% Legend: K = compressibility E = recovery G = weight D = thickness ZF = tensile strength The diagrams show typical values 1 % 4.2N/mm² 3.1N/mm² K % E % G % D % ZF long (N/mm²) ZF transv (N/mm²) Author: CBU - 16 - Date: 11/4 HPN_page_16e.DOC
Anti-stick effect of the PTFE coating Test: Frenzelit flanges, x 13 mm 1h of tempering as well as anti-stick test in the adhesion tester dissolving force (N) 1 17 RT 18 2 1 2 N/mm² dissolving force (N) 1 22 1 C 28 36 1 2 N/mm² dissolving force (N) 4 3 2 1 4 2 C (strongly varying values) Author: CBU - 17 - Date: 11/4 HPN_page_17e.DOC 6 > 4 1 2 N/mm² Standard values for evaluation: < N/mm² limit of adhesion, very easy to remove > 2N/mm² traces on the surface, still easy to remove > 1N/mm² strong traces on the surface, additional devices necessary for removing
Long-term setting a) 1, h / 4 C novatec base material: 6 stress relaxation surface pressure (N/mm²) 4 3 2 1 novatec asbestos expanded graphite file frg_f38.xls 1 2 4 8 16 2 1 1 1 b) 1, h / 3 C novatec HPN 2 x.7 mm with.2 mm metal foil: Long-term setting acc. to DIN 2913 surface pressure (N/mm²) 4 4 3 3 2 2 1 1 42, 41 4 38, 38 1 1 1 1 1 Author: CBU - 18 - Date: 11/4 HPN_page_18e.DOC