What is a Gasket: Materials, Types, Uses, and Features

Gaskets are essential components in industrial and mechanical systems, designed to create reliable seals between surfaces and prevent leaks of fluids or gases，and keep contaminants at bay in essential processesThe choice of gasket material significantly impacts performance, durability, and suitability for specific applications. Below is a comprehensive overview of common gasket materials, their uses, and key features.

1. Types of Gasket Materials

(1) Elastomers (Rubber-Based Materials)

• EPDM: Known for excellent ozone, weather, and temperature resistance (-50°C to 150°C). Ideal for automotive cooling systems and outdoor applications.

• Silicone: Withstands extreme temperatures (-60°C to 230°C) and offers flexibility. Used in food processing and medical equipment due to non-toxicity.

• Nitrile (NBR): Resists oils and fuels, making it suitable for automotive and petrochemical industries.

(2) Foam and Sponge Materials

• Cellular Foam (EPDM/Polyurethane): Lightweight and compressible, used for sealing irregular surfaces in HVAC and electronics.

• Cork: Natural compressibility and vibration damping; common in low-pressure fluid systems.

(3) Thermoplastics

• PTFE (Teflon): Chemically inert, handles aggressive chemicals and high temperatures (up to 260°C). Used in pharmaceutical and chemical processing.

• Santoprene™: Combines rubber flexibility with plastic durability, ideal for dynamic seals.

(4) Composite Materials

• Spiral Wound Gaskets: Alternating metal (stainless steel) and filler layers (graphite/PTFE) for high-pressure/temperature pipelines.

• Kammprofile Gaskets: Metal core with soft graphite/PTFE layers; used in refining and power generation.

(5) Flexible Graphite

• Resists extreme temperatures (up to 450°C in oxidizing environments) and offers thermal conductivity. Common in heat exchangers and flanges.

2. Key Features to Consider

Selecting the right gasket material depends on evaluating these factors:

Temperature Resistance: Metals and graphite withstand >500°C, while silicones handle rapid thermal cycling.

Pressure Tolerance: Spiral wound and metal gaskets are designed for high-pressure systems (e.g., oil pipelines).

Chemical Compatibility: PTFE and fluoropolymers resist aggressive chemicals like ammonia and acids.

Compressibility and Recovery: Conductive EMI gaskets (e.g., Gore’s tape-and-reel grounding pads) balance resilience with consistent conductivity.

ustainability: Low-carbon energy systems (e.g., fuel ammonia boilers) prioritize materials that reduce emissions and lifecycle waste.

(1) Oil, Gas, and Energy

Spiral wound gaskets dominate here due to their reliability in extreme conditions. The ISO/TS21343:2025 standard highlights their role

in fuel ammonia systems for power generation, where they ensure leak-free seals in boilers handling corrosive, high-temperature fluids.

(2) Chemical and Petrochemical

PTFE and graphite gaskets prevent leaks in reactors and pipelines transporting acids, alkalis, and hydrocarbons.

(3) Electronics and Aerospace

EMI shielding gaskets protect sensitive equipment from interference. Gore’s SMT solutions, for instance, are pre-cut for automated assembly in circuit boards and avionics.

(4) Renewable Energy

As industries shift toward lower-carbon energy, gaskets for hydrogen and ammonia applications require materials resistant to embrittlement and leakage.

Gaskets serve as mechanical seals to prevent process fluids from leaking and to keep contaminants out of sensitive areas. Each system requires a specifically suited gasket, making it essential to choose the right one for each application. It is important to balance various factors when selecting a gasket.

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