IAA Preview: Federal-Mogul to Bring Advanced Sealing Technology to Debut

The Federal-Mogul Group (NASDAQ: FDML) powertrain business uses advanced sealing technology to support more efficient and environmentally friendly engines for commercial vehicles. The sealing technology ensures reliable engine operation at cylinder pressures up to 250 bar and exhaust temperatures up to 1000°C. Federal-Mogul's metal-rubber hybrid cylinder head gaskets enable the integration of mature multi-layer steel (MLS) technology and synthetic rubber fluid seals in the same product, enabling optimal sealing of combustion chamber gases and engine fluids. Even if the exhaust gas temperature exceeds the withstand range of traditional stainless steel and graphite materials, Federal-Mogul High Temperature Alloys (HTA) and High Temperature Resistant Coatings (HTC) still provide reliable exhaust joint sealing. From February 25th to October 2nd 2014 at the Hannover Commercial Vehicles Show in Germany, Federal-Mogul will showcase its advanced gaskets and sealing technology at its booth (Hall 13, Stand C28). Welcome to visit.

Gian Maria Olivetti, chief technology officer of Federal-Mogul Powertrain, stated: “The application of MLS gaskets will apply an optimized sealing load around the combustion chamber, and the metal-rubber hybrid head gasket technology was developed based on this.”

"Because the fluid passage requires a lower sealing load, the use of synthetic rubber seals can concentrate the sealing force to the point where it is most effective. This makes it more likely that we will design a lightweight and robust engine structure while ensuring that The engine can still operate normally with a peak cylinder pressure of 250 bar. Federal-Mogul's expertise in materials science can help us to develop synthetic rubber materials to solve fluid compatibility and temperature cross-over problems.” Federal-Mogul Powertrain Mike Gerulski, Head of Global R&D for Sealing Technology, explained.

Analytical-oriented design optimizes sealing system solutions

The application of metal-rubber hybrid head gasket technology requires a combination of Molex's proprietary analysis-oriented design (ALD) process, which uses a comprehensive approach to systematically optimize cylinder head, cylinder block and gasket construction. ALD can help select the most suitable sealing technology and verification method. After Femmco’s tireless research, the process has been very mature. Therefore, before the engine prototype hardware is ready to start, the company can reliably predict the sealing effect and durability of the cylinder head gasket. "With ALD, we can help customers reduce the costly engineering changes later in the engine development project," Gerulski added.

Engine miniaturization, turbocharging, and exhaust gas recirculation (EGR) can cause the exhaust system to produce constantly changing temperatures and reduce the weight of the system, which in turn reduces the use of conventional static gaskets and causes flange deformation. Therefore, Federal-Mogul also applied ALD to high pressure gaskets for exhaust systems.

High temperature gaskets and high temperature resistant coatings can withstand a wider temperature range

Federal-Mogul HTA gasket materials provide reliable sealing performance at temperatures up to 1000°C, which is far higher than the standard stainless steel temperature in today's industry, and can handle a wide range of temperature challenges. The thermal characteristics of the HTA gaskets fully meet the demanding requirements of a variety of applications such as turbocharging, downcomers, exhaust manifolds, and EGR systems.

Just as important as a reliable joint seal is the HTC coating developed by Federal-Mogul. This coating technology ensures the effectiveness of micro joints. HTC is a water-based, environmentally friendly product that provides a powerful solution at elevated temperatures. "When the temperature exceeds 1000 °C, HTC can still maintain thermal stability, and at this time the traditional coating has long been turned into ash," Gerulski said.

Gerulski also stated: "Mogul's advanced analytical technologies will continue to provide in-depth insights into complex engineering problems and key system crossovers. Our analytical capabilities are helping the continued development of key technologies that will help today and tomorrow. Our commercial vehicle customers are responding to increasingly challenging emissions issues while achieving fuel savings."

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