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ZylinderkopfdichtungenAdvanced MLS-Technology – Leistungsfähigkeit in jeder Lage

Sealing systemsAdvanced Sealing Technology – Trends, concepts, and materials

Treat it rough, make it tough:

While your customer enjoys a fast drive, our

gaskets endure a grueling test. It’s good to know

they’re made by VICTOR REINZ.

Contents

3 Sealing Products – VICTOR REINZ

4 Systematic quality

5 Development services

10 Sealing system trends

11 Other things you should know

12 Survey of materials and concepts

16 Beaded metal gaskets with

elastomer coating

24 Beaded metal gaskets with

fiber-reinforced elastomer coating

26 Beaded metal gaskets

30 Metal/rubber gaskets

36 High-temperature gaskets

38 Fiber composite gaskets

46 Molded rubber gaskets

48 Special solutions

52 Future concepts

54 Product range

55 The DANA network

¬ 3

For more than 50 years, VICTOR REINZhas been an established name amongthe world’s top automobile manufac-turers. Reliable, top-quality productsand on-time delivery are as much apart of VICTOR REINZ as our innovativedesign and systems competence.At VICTOR REINZ, good ideas continueto evolve and our gaskets continue toimprove. This spirit of innovation en-ables us to consistently find new waysto upgrade the performance of ourgaskets – and, in turn, your engine.We will continue to meet the demandsof engine builders now and in the fu-ture.

Beyond our competitorsIn order to meet the sealing demandsplaced by modern engines, you need tobe an expert in your trade. By contin-ually improving our products, we fre-quently discover solutions that deter-mine future market developments andprovide a perfect balance between per-formance and economy. We call this“Advanced Sealing Technology”.However, we don’t stop there. We uti-lize the most advanced equipment, themost rigorous testing standards, finiteelement analysis, simulations, and ex-tensive expertise to provide productsthat truly stand out in the marketplace.Equally important, every employee atVICTOR REINZ is truly committed toserving our customers.

When you choose VICTOR REINZ, youdecide for intelligent sealing concepts –plus the highest level of consulting, de-velopment, production, logistics, andservice competence.

Sealing Products – VICTOR REINZ:A global presenceIn 2003, Dana Corporation consolidatedand reorganized its five gasket, shieldingsystem, and cylinder head cover modulefacilities into a central, clearly definedgroup: Sealing Products – VICTOR REINZ.As a world leader in gasket production,Dana now provides worldwide serviceand support from 19 locations in Europe,North America, South America, and Japanthrough subsidiaries and affiliates. You’llfind us in every important automotivemanufacturing hub providing the mostinnovative system solutions in the world.

Performance defined:VICTOR REINZ

¬ Recognized for providing the world’smost innovative gasket solutions

¬ Top-quality products and high process reliability

¬ Total systems competence¬ Worldwide access to consulting, de-

velopment, production, logistics, andservicing at the highest level throughthe DANA Sealing Products network

Better ideas. Manufactured by VICTOR REINZ.

ALWAYS A STEP AHEAD

¬ 4

Systematic quality: The high standard of our quality management system is reflected by the many honors bestowed upon us by our customers. The environment also benefits from our work,as evidenced by a growing number of environmental compatibility certificates.

Nissan: NX 96,Next 21 Recogni-tion Award

Volvo Cars Awardof Excellence

Spirit of Innovation

DIN EN ISO14001

Steinbeis-Initia-tive «Customersevaluate suppliers»

DANA Leader-ship Award

ISO/TS 16949: Our quality standards include DIN EN ISO 9001,VDA 6.1 and EAQF 94 as well as specific customer require-ments from GM, DaimlerChrysler, and all German auto makers.

Every business strives to perform fasterand better, but this is especially criticalin the rapidly changing automotive world.

Smart responseIf required, we can deliver installation-ready gaskets directly to your assem-bly line – based solely on the engine'sdesign data. Our design system is com-patible with your in-house CAD system,whether it’s CATIA, ProEngineer, IDEAS,or Unigraphics.Time and again, our customers aresurprised by the short lead times atVICTOR REINZ. We do this by employ-ing all necessary experts in-house,from development to series production.As a result, handling times are greatlyreduced. In addition, we can performall the important validation tests on-sitewith our own equipment.

Smart combinationsIngenious matching of conventional de-velopment tools to each other can resultin significant time savings.

One example: At VICTOR REINZ we notonly test and simulate entire sealingsystems with computers – we also usemodern prototyping procedures to buildfunctional models at a very early stage.When testing the specific sealing func-tions, these prototypes supply extreme-ly valuable data. This enables us todetermine in advance whether a gas-ket’s performance is maximized, so thatindividual functions don’t require opti-mization later.

Nonetheless: Even something goodcan be improvedSince approximately 70 percent of anautomobile’s components come fromexternal suppliers, the quality of a ve-hicle depends greatly on the quality ofthe supplied products. Because qualitycannot be improved later, we understandthat intelligent product design, exactplanning, and compatible engineeringfrom the start will ensure quality as-surance in product development andmanufacturing.

Partners with the bestVICTOR REINZ’s expertise has beenvalued by the European automotiveindustry for decades. From the MCCSmart to the Maybach V12 engine andthe high-tech gaskets for Formula Oneracing, VICTOR REINZ supplies com-plete gasket systems that are un-matched for quality and performance.Our aim: To be partners with the best.Which is why our reference list readslike a »Who’s who« of European automakers. For details, see our referencelist at www.reinz.com.

Always faster, always better –from initial concept to series production

STREAMLINED PRODUCTION CYCLES

¬ 5

Logistics

Testing

Series productionrelease

Calculation

Prototyping

Design & construction

Manufacturing

»Built-in«understanding

Assessment ofrequirements

»Design that's right the first time«

STEPS TO OPTIMUM PRODUCT DESIGN

Transforming vision into realityOur project teams consist of applicationengineers who work with developers,designers, manufacturing and qualityexperts, logistics specialists, and buyersto find the best solution.In this way, the expertise of each par-ticipant is taken into account from thebeginning. This close collaboration ex-emplifies the value we place on our re-lationship with our customers.

Flexible and fast – the optimized development process atVICTOR REINZ. This enables us to avoid errors during everyphase of product development. The viability of our process-es is borne out when the first prototype goes into seriesproduction practically unchanged. At VICTOR REINZ, repeattrial-and-error prototyping is a thing of the past. Today,clear and direct communication with the customer alongwith computer-aided analysis reduces testing time and en-sures that our designs are correct from the start.

¬ 6

Assessment of requirements:The earlier the better

Every gasket involves many specificfunctions, so it pays to consult with usearly. Frequently, the object is not onlyto provide sealing from different media,but also to minimize component defor-mation. If all functional requirementsare considered from the beginning, com-plications and loss of time are greatlyreduced during subsequent projectstages.

This attention to detail begins rightaway, during your first consultationwith our application and developmentengineers. Design procedures arestraightforward. We require just a fewparameters: Operating temperature,internal pressure, dynamic behavior,number of fixing screws, plus a fewdetails on the materials used for thesurrounding components, their surfacefinish, and their geometry.That's it – our engineers determine the rest.

Responsibility from beginning to end

PROACTIVE DEVELOPMENT PARTNERSHIP YOU CAN TRUST

Assessment ofrequirements

We look forward to being your partner throughout the designand production process, and welcome open dialogue at anytime – whether it’s contract development or purposeful, ob-jective product consultation. The scope of VICTOR REINZ ex-pertise covers all aspects from development to logistics.Here are a few examples:

¬ 7

Prototyping: Equal to the final product

Take metal gaskets, for example: Weuse close-to-production tooling from thestart. After the sheets have been coatedon series production plant, and the gas-ket contour has been cut with lasers,even the most complex beads can bestamped with our embossing tools. Ofcourse, all these tools are produced onour premises quickly and cost-effective-ly. Your advantage: Prototypes are of thesame quality as the later series gaskets– with few deviations. Modern CNC-con-trolled measurement equipment ensuresoptimum quality monitoring.Subsequently, all relevant data are re-corded in a technical document.

Design & construction:Built to fit

While vehicles are not built around thegaskets, they are still critical compo-nents. Attention to product design com-bined with high-quality materials is thebest foundation for functional, reliable,high-quality gaskets.

Thinking ahead is part of going the extramile for customer at VICTOR REINZ.During the gasket’s design phase, wesimulate the automated assembly se-quence in the production line or duringservicing, and also consider the pack-aging aspects. Even recycling issuesand clean separation of the materialsused is factored in.

Interfaces: “Built-in” understanding

Sealing systems from VICTOR REINZnot only fit the vehicles for which theyare designed; they also fit the 3D com-puter-design worlds of our customers.We speak the same language as yourdesigners and supply geometrical dataof the required cylinder head cover inthe specified data format, using thefastest available online data transmis-sion methods.

Finite Elements Analysis(FEA): Working smarterfrom the start

Ever more often, increasingly complexdesigns are required for metal gaskets.Whether in the exhaust train, in turbo-chargers, or special gaskets for high-pressure diesel fuel pumps – suitablesealing is ensured by half beads, fullbeads, and the patented Wave-Stopper®.Not an easy task. If requested by thecustomer, we conduct FEA calculationsof the entire sealing system, i.e. thegasket and the components to be sealed.The advantage: During FEA calcula-tions early in the design phase, all rel-evant functional parts and critical areasof the entire sealing system are exam-ined in detail to ensure optimum gas-ket development in the shortest time.Moreover, FEA calculations supply valu-able details on component stiffness,distortion, and pressure distribution.

VICTOR REINZ development engineersthink and work in conjunction with ourcustomers' development departments.This leads to the high efficiency thatgives our customers a leading edge,and permits our products to be adapt-ed quickly to changing conditions.

Scientific methods instead of chance: The application of FEA

makes many empirical approaches superfluous during the

design of a sealing system.

An entirely new level of quality for prototypes – made

possible by VICTOR REINZ with close-to-production

tooling.

Design & construction

»Built-in«understanding

Calculation Prototyping

Tougher than practical use

Along with the latest engine testingmethods, we conduct extensive testingin our chemical and physical laborato-ries whenever necessary. As a custom-er, you have the choice of numeroustesting and simulation possibilities,allowing you to determine the testingscope and budget. This ensures that youreceive optimum value during the test-ing phase.

Testing

¬ 8

In addition, through Dana Sealing Prod-ucts and its four development centersin Neu-Ulm, North America, Japan, andBrazil, we have worldwide access to 27engine test stands and associated labo-ratories for analysis and static/dynamicpre-testing.

All activities are coordinated by theCompetence Center R & D in Neu-Ulm,to ensure your testing benefits from themost advanced technology »Made inEurope«.

Laboratory tests (excerpt)

¬ RPM 1) 510-3D: The setting behav-iour (creep resistance) of a gasket isdetermined as a function of surfacepressure and temperature. The re-sulting (derivable) loss of bolt load isdecisive for the sealing behaviour.

¬ RPM 1) 511-S: The distribution ofsurface pressure on the surroundingcomponents is determined by meansof a computer-controlled hydraulictest stand. With metal gaskets, forexample, a test program with repeat-ed loading/unloading cycles is usedto determine the bead characteris-tics, which are then compared withthe calculated FEA values from thesimulation.

¬ RPM 1) 528: By means of resonancepulsers and simulators, various oper-ating conditions (temperature, pres-sure, dynamics) are simulated, andconclusions are drawn about the gas-ket's durability.

¬ RPM 1) 535: Determines a gasket'ssealing potential, depending on thecomponent's surface roughness, itsflatness, and the bolt force. Sealtightness is tested with nitrogen orwith liquid media such as engine oilor antifreeze.

¬ RPM 1) 550: By means of a pressure-sensitive film (Fuji film), the distribu-tion of surface pressure over thegasket is determined, scanned, andevaluated electronically.

Of course, we conduct any additionallaboratory tests requested by the cus-tomer. These range from investigatingthe media resistance of the materialused, through porosity, roughness, andevenness tests of the sealed compo-nents, up to special examinations ofresidual particles, e.g. if gaskets fordust-sensitive components such ashigh-pressure injection pumps are tobe packaged under cleanroom condi-tions.

DocumentationFor detailed communication: All testresults are summarized and explainedin a comprehensive test report. Thissimplifies and speeds up subsequentfine-tuning with your engine designersand builders.

15

10

5

300250200150100

50

0 1030

5075

Material 1

Material 2

Determination of surface pressure distribution with RPM 1) 550. Hot-creep behaviour of different elastomer-coated gaskets according to RPM 1) 510-3D.

Test set-up to determine

the sealing potential

according to RPM 1) 535.

From icy cold to burning

hot – thermal shock test

causes engine and gas-

kets to age several years

within hours.

RPM 1) = REINZ-Prüf-Methode (REINZ Test Method): Numerous laboratory test procedures are described in corresponding RPMs,

and represent testing methods that are widely accepted in the industry.

Fiber composite gasket Beaded metal gasket withelastomer coating

Hot c

reep

[%]

Test temperature [°C] Surface pressure [N/mm2]

¬ 9

Quality assurance:Beyond the standards

Intelligent quality management for ra-tional zero-error production ensuresmanufacturing reliability and efficiency– we call it Systematic Quality. Duringthe testing phase, we simulate the man-ufacturing process by using close-to-series tooling. This enables us to testgaskets close to their final state with-out delay, complete with a detailed testreport and quality certificates for allthe materials used, as required for sam-ple approval.

Subsequently, we can immediately be-gin pre-series and series production.VICTOR REINZ has already been certi-fied in accordance with the latest (2002)issue of ISO/TS 16949, which is accep-ted by all automobile manufacturers –worldwide. Moreover, our EnvironmentalManagement System complies withDIN EN ISO 14001 for the use of en-vironmentally compatible technologies.

Obviously, these standards and officialcertificates have high practical signifi-cance, but equally important is ourinternal approach to ensuring productquality and environmental awareness.

Rest assured that our employees aretruly committed to maintaining thestrong relationships and high level ofconfidence we’ve developed over theyears with our customers – it’s some-thing that can’t be measured, but whichwe continually provide.

Manufacturing: Efficientand cost-effective

Flexible, fast, and cost-effective manu-facturing is made possible at VICTORREINZ by utilizing the most modernmanufacturing technologies in our pro-duction lines and cells. The gasket'sfinal properties are influenced decisive-ly and specifically by the individualprocessing stages and their sequence.In this way, our head gaskets provideoptimum customer value: Excellent man-ufacturing that leads to top quality andmaximum functionality and durability.

Logistics and packaging:Custom-designed foryour line

VICTOR REINZ delivers your gasketspacked and ready for installation direct-ly to your assembly line, thus simplify-ing your logistics. We also design pack-aging to maximize economic, ecologi-cal, and logistic aspects. To ensure that

»just-in-sequence« really means quali-ty up to the assembly line, we employlogistic tracking systems such as DLL,CMMS3, and eCAP.

All of our technical efforts and the bestproduct quality would be in vain, if thelast link in the chain is not just as per-fect as all the preceding ones. That’swhy every day at VICTOR REINZ, westrive to turn satisfied customers intodelighted customers.

Welcome to VICTOR REINZ.

Series productionrelease

Concentrated performance – our entire development

knowledge is focused on high-end products.

Highly automated production lines minimize time and cost. Worldwide product availability: Wherever your facility

is located, you'll find us close by.

Manufacturing

Logistics

Put us to the test!

¬ Responsibility from beginning toend from a single source

¬ State-of-the-art development andprototyping tools

¬ Worldwide access to services¬ Coordination through the Compe-

tence Center R & D in Neu-Ulm¬ Systematic quality assurance –

from production at VICTOR REINZup the customer's assembly line

¬ 10

Trends apply for almost everything.For automobiles just as for the compo-nents used to build them – and forgaskets, of course. Hereby, the trendis clearly toward pure metal and coat-ed metal gaskets. Apart from the func-tionality, durability, and maintenancefreedom of these gaskets, another majorreason for this trend is the suitabilityfor automated assembly, i.e. simplehandling with robots and automaticmanipulators. Naturally, this doesn'tmean that VICTOR REINZ does not offerfiber composite as an alternative.Because they remain to be essentialfor many applications.

Make sure its VICTOR REINZVICTOR REINZ recognizes these de-mands at an early stage, and respondsto trends with new products. Regard-less of the equipment that needs agasket – we always have more thanone good solution in stock.

Why you should play it safeA growing number of automotive man-ufacturers are placing their trust in VICTOR REINZ sealing systems. In addition to meeting all of the abovedemands, our gasket materials andsealing concepts are so reliable thatthey perform their tasks throughoutthe vehicle’s lifespan. We help youbuild better automobiles.

Sealing systems for the entire power train –everything else is secondary

ABOUT TRENDS

More engine output, higher packing densities, tougher environmental legislation. Sealing systems from VICTOR REINZ

ensure better performance. Regardless of the working conditions.

Essential features of sealing systems

¬ Advanced sealing technology withspecial core, coating, and designelements

¬ Handling high temperatures,aggressive media, and high com-ponent dynamics

¬ Sealing concepts for modernengines, e.g. new materials suchas magnesium alloys, or compactconstruction with extremely nar-row sealing contours

¬ Coverage of widely different appli-cation areas in the entire powertrain – from engine and transmis-sion to the final drive train up tothe complete exhaust gas system

¬ Demand-oriented and cost-opti-mized technologies

Survey of materials and concepts PLEASE TURN THE PAGE

¬ 11

Correct material selection and optimumdesign are decisive criteria for thefunctionality and durability of gasketsand seals.Depending on application area and am-bient conditions, different requirementsare placed on the selected material andthe design.

¬ Temperature resistance¬ Media resistance¬ Corrosion resistance¬ Recovery behavior¬ Setting behavior¬ Easy installation¬ Recyclability

Surface texture of the surrounding componentsOne important basic requirement foroptimum sealing is the surface textureof the components to be sealed. Surfacetexture is determined according to DINEN ISO 4287 and DIN EN ISO 4288 usingthe profile method to generate an en-velope profile from which the followingvalues are defined:

¬ Primary profile Pt

¬ Waviness profile Wt

¬ Roughness RZ

¬ Maximum roughness Rmax

Ensuring a high surface texture quality is an important basic requirement for afunctioning sealing system.

With critical surface texture qualities, werecommend a leakage test using volumeflow measuring equipment.

Gasket selectionWith VICTOR REINZ, selection of a suit-able sealing concept is really simple.We require just a few parameters:

¬ Application area¬ Ambient conditions¬ Temperature range (peak temper-

ature, continuous temperature)¬ Conformability¬ Internal pressure stress¬ Dynamics

The following pages show all the relevant information.

Other things you should know

DEMANDS PLACED ON SEALING SYSTEMS

Primary profile Pt

Waviness profile Wt

Z1 Z2 Z3 Z4 Z5

Max. roughness Rmax

RZ = (Z1 + Z2 + Z3 + Z4 + Z5) / 5 section roughness RzRoughness Rz

Exemplary envelope

profile to describe the

surface texture of a

flange.

¬ 12

1) Normally, gaskets are designed with beads (half of full beads)2) based on stainless steel or galvanized carbon steel3) based on fiber composite gaskets4) based on RETALL® FPM plus, RETALL® F51 with non-stick coating5) based on metal gaskets with elastomer coating with fiber-reinforced

elastomer coating6) based on RETALL® HRS, RETALL® HTS7) based on metal gaskets with elastomer coating, with fiber-reinforced

elastomer coating or plain metal gaskets8) based on carbon steel or aluminium

1

2

3

Step 1 Select your application area

Select your specific application area: From A for airbag hous-ing to W for water pump. The range of VICTOR REINZ gasketmaterials and sealing concepts is equally diversified as theapplication possibilities in modern engines. The ideal solutionfor every application. Typical for VICTOR REINZ.

Step 2 Check the ambient conditions

Select the operating temperature range (accordingly shorterpeak temperature and lower continuous temperature), con-formability (depending on component distortion and rough-ness), and the permissible internal pressure – just a fewmarginal conditions are enough to limit the possible choices.

Step 3 Check the details

Detailed information on material construction, specific prop-erties, general application areas, as well as typical applicationexamples and present trends are given on the following pages.The reference table is helpful.

Find your optimum sealing system in three steps. Start by getting an overall impressionof our comprehensive sealing product range. All the relevant information on applica-tion areas and ambient conditions are given on this page.

Quick survey: Selection

of the ideal material and

the best sealing concept

is dictated by the spe-

cific application area.

Fine tuning: The ambient

conditions are decisive

for optimum perfor-

mance of the correct

gasket material and

sealing concept.

Detailed information on

material construction,

specific properties, gen-

eral application areas, as

well as typical application

examples and present

trends are given on the

following pages. The ref-

erence table is helpful.

Our application experts look forward to your phone call.

Any more questions?

Our application experts will help you quickly, efficiently, andcompetently. We will be pleased to discuss your special ap-plication. Simply give us a call.

+ 49 (0) 731-70 46-0

Innovation included: Survey of materials and concepts

THREE STEPS TO FIND THE OPTIMUM SEALING SYSTEM

Beaded metal gaskets with elastomer coating 1)

PROGRESSION® CA

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

130

- 40 up to + 120

++

0

-

240

- 40 up to + 200

++

+

0

240

- 40 up to + 200

++

++

++

300

- 40 up to + 280

++

++

++

280

- 30 up to + 240

++

++

++

300

- 40 up to + 220

+

+

+

300

- 40 up to + 220

++

++

++

SLS (1 x 0.38 mm)

SLS (1 x 0.38 mm)

SLS (1 x 0.38 mm)

SLS (1 x 0.38 mm)

SLS (1 x 0.38 mm)

SLS (1 x 0.38 mm)

SLS (1 x 0.38 mm)

SLS (1 x 0.38 mm)

SLS (1 x 0.38 mm)

SLS (1 x 0.38 mm)

SLS (1 x 0.38 mm)

SLS (1 x 0.38 mm)

SLS (1 x 0.38 mm)

SLS (1 x 0.38 mm)

SLS (1 x 0.38 mm)

SLS (1 x 0.38 mm)

SLS (1 x 0.38 mm)

SLS (1 x 0.38 mm)

SLS (1 x 0.38 mm)

SLS (1 x 0.38 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.35 mm)

SLS (1 x 0.25 mm)

SLS (1 x 0.25 mm)

SLS (1 x 0.25 mm)

SLS (1 x 0.25 mm)

SLS (1 x 0.25 mm)

SLS (1 x 0.25 mm)

SLS (1 x 0.25 mm)

SLS (1 x 0.25 mm)

SLS (1 x 0.25 mm)

SLS (1 x 0.25 mm)

SLS (1 x 0.25 mm)

SLS (1 x 0.2 mm)

SLS (1 x 0.23 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

SLS (1 x 0.5 mm)

Appl icat ion area (excerpt)

Airbag housing

Automatic manual transmission (AMT)

Automatic transmission

Camshaft adjuster

Catalytic converter

Charge air damper

Compressor

Door lock

EGR mixing chamber

EGR valves

Electronic connector

Exhaust manifold

Exhaust pipe

Fuel pump

Gearbox cover

High-pressure diesel pump cover

High-pressure diesel pump flange

Hydraulic pump

Intake duct

Intake manifold (4-duct)

Oil cooler

Oil filter bracket

Oil pan

Oil pump

Oval flange

Retarder

Soot filter

Steering servo pump

Throttle flap

Timing cover

Turbocharger

Universal drive shaft

Vacuum pump

Valve cover

Water pump

Ambient condit ions

Temperature range

Peak temperature (short-term) [°C]

Continuous temperature [°C]

Conformability (depending on

roughness and distortion)

Permissible internal pressure

Dynamics

Detai ls on page

PROGRESSION® CS PROGRESSION® CSplus

RETALL® FPM plus RETALL® F51 MatriCS®

X8)

X8)

RETALL® F52 MatriCS® plus

Beaded metal gasket with fiber-reinforcedelastomer coating 1)

Beaded metal gaskets with elastomer coating 1)

PROGRESSION® CAPROGRESSION® CS PROGRESSION® CSplus

RETALL® FPM plus RETALL® F51

280

- 30 up to + 240

++

++

++

RETALL® F52 MatriCS® MatriCS® plus

Beaded metal gasket with fiber-reinforcedelastomer coating 1)

16 16 18 20 22 22 24 24

700

650

-

+

++

950

950

0

+

+

1000

+

+

++

250

- 25 up to + 230

++

+

+

250

- 40 up to + 200

++

+

+

160

- 40 up to + 150

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+

+

950

950

+

+

0

400

250

+

++

++

300

250

++

+

+

300

250

++

+

+

DLS (2 x 0.25 mm)

SLS (1 x 0.2 mm)

DLS (2 x 0.2 mm)

DLS (2 x 0.25 mm)

MLS (3 x 0.2 mm)

MLS (4 x 0.2 mm)

DLS (2 x 0.25 mm)

SLS (1 x 0.2 mm)

SLS (1 x 0.2 mm)

MLS (3 x 0,2 mm)

DLS (2 x 0.3 mm)

SLS (1 x 0.25 mm)

DLS (2 x 0.25 mm)

DLS (2 x 0.3 mm)

MLS (3 x 0.25 mm)

MLS (3 x 0.3 mm)

DLS (2 x 0.3 mm)

SLS (1 x 0.3 mm)

DLS (2 x 0.3 mm)

MLS (3 x 0.25 mm)

Substrate Retall® HRS

or 1.4828

DLS (2 x 0.2 mm)

DLS (2 x 0.25 mm)

MLS (3 x 0.2 mm)

MLS (4 x 0.2 mm)

Substrate Retall® HRS

oder 1.4828

DLS (2 x 0.2 mm)

DLS (2 x 0.25 mm)

Substrate Retall® 1.4828

SLS (1 x 0.3 mm)

DLS (2 x 0.3 mm)

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

with inner bead

with inner bead

with inner bead

with inner bead

1.0 mm

1.5 mm

0.3 mm

0.5 mm

0.75 mm

0.5 mm

1.5 mm

0.5 mm

1.0 mm

1.5 mm

1.0 mm

1.5 mm

1.5 mm

1.0 mm

0.5 mm

1.0 mm

0.5 mm

1.5 mm

1.5 mm

1.0 mm

1.5 mm

0.3 mm

0.5 mm

RETALL® HRS RETALL® HTS thermo-glide® FPM 70 HTV 50ACM 50 und ACM 60 Xtreme® plus AFM® 30 AFM® 31 AFM® 32/2

Beaded metal gaskets 1) Metal/rubber gaskets 2) High-temperaturegaskets

Fiber compo

RETALL® HRS RETALL® HTS thermo-glide® FPM 70 HTV 50ACM 50 und ACM 60 Xtreme® plus AFM® 30 AFM® 31 AFM® 32/2

Beaded metal gaskets 1) Metal/rubber gaskets 2) High-temperaturegaskets

Fiber compo

26 26 28 30 32 34 36 38 40 42

150

- 30 up to + 90

++

++

++

220

- 50 up to + 180

++

+

0

150

- 10 up to + 130

++

++

++

160

- 40 up to + 150

++

0

+

120

110

++

-

-

250

- 24 up to + 230

++

-

0

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

Detai ls on page

Screen printed SH 3) Screen printed QE 3) Screen printed SF 3) ACM 50 and ACM 60 Firmly bonded sealingcompounds DX 4)

Firmly bonded sealingcompounds F52 5)

Wave-Stopper® 6) Fixing/clamping claw 7)

Molded rubber gaskets

Special solutionssite gaskets

Screen printed SH 3) Screen printed QE 3) Screen printed SF 3) ACM 50 and ACM 60 Firmly bonded sealingcompounds DX 4)

Firmly bonded sealingcompounds F52 5)

Wave-Stopper® 6) Fixing/clamping claw 7)


Special solutionssite gaskets

44 44 44 46 48 48 50 51

Appl icat ion area (excerpt)

Airbag housing

Automatic manual transmission (AMT)

Automatic transmission

Camshaft adjuster

Catalytic converter

Charge air damper

Compressor

Door lock

EGR mixing chamber

EGR valves

Electronic connector

Exhaust manifold

Exhaust pipe

Fuel pump

Gearbox cover

High-pressure diesel pump cover

High-pressure diesel pump flange

Hydraulic pump

Intake duct

Intake manifold (4-duct)

Oil cooler

Oil filter bracket

Oil pan

Oil pump

Oval flange

Retarder

Soot filter

Steering servo pump

Throttle flap

Timing cover

Turbocharger

Universal drive shaft

Vacuum pump

Valve cover

Water pump

Ambient condit ions

Temperature range

Peak temperature (short-term) [°C]

Continuous temperature [°C]

Conformability (depending on

roughness and distortion)

Permissible internal pressure

Dynamics

Constructional layers of PROGRESSION® CS and PROGRESSION® CS plus. Design versions with half and full beads.

Non-stick coating

Full-surface NBR coating

Bonding agent

Core material carbon steel orstainless spring steel(type 1.4310) Half bead

Full bead

¬ 16

PropertiesApart from excellent conformability touneven sealing surfaces, PROGRESSION®

CS and PROGRESSION® CS plus ensureoutstanding sealing against liquids andgases. Both gasket materials are resis-tant against oils, fuels, antifreeze, re-frigerants, and biologically degradablelubricants.PROGRESSION® CS plus exhibits muchhigher elasticity and recovery thanPROGRESSION® CS, and even bettermechanical strength and corrosion re-sistance.

Application areasPROGRESSION® CS is the standard so-lution for static applications with medi-um bead loads, whilst PROGRESSION®

CS plus is intended for highly dynamicapplications with high bead loads. Bothmaterials are suitable for working tem-peratures up to 200 °C.

Therefore, these gasket materials pro-vide perfect solutions e.g. for intakemanifolds and areas subjected to highmechanical and/or thermal loads, aswell as particularly narrow sealing faceswith low surface pressures. Other typ-ical applications are oil pans, trans-mission flanges, housings, and pumps.

Application exampleFor stable systems with low bolt forcesand low thermal expansion, PROGRES-SION® CS offers an attractive price/per-formance ratio, e.g. as a flange gasketon the engine intake side.PROGRESSION® CS plus is intendedprimarily for systems with high dynamicloading and high alternating pressuresup to 120 bar, e.g. in the power steer-ing pump.

TrendPROGRESSION® CS and PROGRESSION®

CS plus are the answer to increasingpressures and dynamics in modern,high-performance engines. Both gasketmaterials offer numerous possibilitiesfor integration, and have sufficient re-serves for future sealing concepts.

MaterialPROGRESSION® CS and PROGRESSION®

CS plus are metal gaskets with an elas-tomer coating on both sides. Moreover,both sides of the gasket material havea non-stick surface.PROGRESSION® CS has a core of 0.25 mmthick steel sheet, coated on both sideswith a 65 µm layer of nitrile rubber(NBR). PROGRESSION® CS plus differsin that its core is of 0.2 mm thick stain-less spring steel (material 1.4310) witha 75 µm layer of NBR on both sides.PROGRESSION® CS and PROGRESSION®

CS plus gaskets are always beaded.

Beaded metal gaskets with elastomer coating

PROGRESSION® CS AND PROGRESSION® CS PLUS – STANDARD SOLUTION FOR AN ATTRACTIVE PRICE

High quality thanks to clean-cut edges.Integral clips ensure simple (overhead) installation. Beads (half beads) provide higher line pressures.

¬ 17

PROG

RESS

ION

®CS

PR

OGRE

SSIO

N®

CS p

lus

Construction

Core

Core thickness

Thickness of NBR coating (each side)

Weight per unit of surface area

Creep resistance to DIN 52913

16 h, 300 °C

Swelling to ASTM F146

- in oil IRM 903; 5 h, 150 °C

Thickness increase

in ASTM Fuel B; 5 h, RT

Thickness increase

- in water / antifreeze (50:50); 5 h, 100 °C

Thickness increase

Peak temperature (short-term)

Continuous temperature

Surface pressure (max. at 200 °C)

PROGRESSION® CS

Carbon steel

0.25 mm

65 µm

~ 2.15 kg/m2

> 45 N/mm2

< 7 %

< 10 %

< 5 %

240 °C

-40 up to +200 °C

75 N/mm2

PROGRESSION® CS plus

stainless spring steel

1.4310

0.2 mm

75 µm

~ 2.15 kg/m2

> 45 N/mm2

< 7 %

< 10 %

< 5 %

240 °C

-40 up to +200 °C

75 N/mm2

Technical data 1)

Gaskets according to drawing, dimensions provided, or other agreements

Nominal thickness

Tolerances

PROGRESSION® CS

Max. width 500 mm

0.38 mm

±0.04 mm

PROGRESSION® CS plus

Max. width 500 mm

0.38 mm

±0.04 mm

Dimensions and forms of delivery

1) The above technical data are valid for the material "as delivered",

without any additional treatment.

Guaredisch ndeunfeg sit dolor sit ament. Guaredisch ndeunfeg sit dolor sit ament.

PropertiesPROGRESSION® CA has outstanding spe-cific properties: Low weight, high ther-mal conductivity, excellent corrosion re-sistance. Particularly when used to sealaluminium components, the identicalthermal expansion coefficient is of deci-sive importance.Due to its unique combination of alu-minium, elastomer, and beads, PRO-GRESSION® CA offers all the featuresrequired for good conformability touneven surfaces, high sealing integritywith liquids and gases, high elasticity ofthe installed gasket (recovery), plusgood media resistance.

Application areasPROGRESSION® CA is the preferred gas-ket material for all lightweight compo-nents, and temperatures up to 120 ºC.Its special advantages become apparentwhen used with Al and Mg flanges, asthere is no corrosion.

Application exampleThe high performance potential of PRO-GRESSION® CA is not only due to thematerials used. Especially because oflow surface pressures and occasionalhigh values of surface roughness, thisgasket material is used e.g. in chargeair dampers and other mechanical com-pressors.

TrendThe trend toward lightweight constructionwill increase. Engines and individual com-ponents of aluminium or magnesium aredetermining factors in automotive en-gineering. PROGRESSION® CA effectivelysupports this development. Also in future.

MaterialPROGRESSION® CA is a metal (alumini-um) gasket material, with an elastomercoating on both sides. Moreover, bothsides of the material have a non-sticksurface. PROGRESSION® CA has a coreof 0.20 mm thick aluminium sheet(Al/Mg alloy), coated on both sides witha 75 µm layer of nitrile rubber (NBR).Normally, PROGRESSION® CA is beaded.

Constructional layers of PROGRESSION® CA. Design versions without bead, and with half or full bead.

Non-stick coating

Full-surface NBR coating

Bonding agent

Al/Mg alloy core

without bead

Half bead

Fullbead

¬ 18

PROGRESSION® CA – LIGHTWEIGHT WITH A BRIGHT FUTURE

Guaredisch ndeunfeg sit dolor sit ament. Guaredisch ndeunfeg sit dolor sit ament. Guaredisch ndeunfeg sit dolor sit ament.

Technical data 1)


Nominal thickness

Tolerances

PROGRESSION® CA

max. Breite 500 mm

0,35 mm

±0,04 mm




High sealing potential with lightweight construction.

¬ 19

Construction

Core

Core thickness




16 h, 300 °C


- in oil IRM 903; 5 h, 150 °C

Thickness increase

- in ASTM Fuel B; 5 h, RT

Thickness increase

- in water/antifreeze (50:50); 5 h, 100 °C

Thickness increase




PROGRESSION® CA

Al/Mg alloy

0.20 mm

75 µm

~ 0.70 kg/m2

> 47 N/mm2

< 5 %

< 10 %

< 5 %

130 °C

-40 up to +120 °C

75 N/mm2

PROGRESSION® CA

Max. width 500 mm

0.35 mm

±0.04 mm

PROG

RESS

ION

®CA

Constructional layers of RETALL® FPM plus. Design versions with half and full beads.

Non-stick coating

Full-surface FPM coating

Bonding agent

Core of stainless spring steel(type 1.43010)

Half bead

Full bead

¬ 20

PropertiesThe special coating of RETALL® FPM plusis a guaranteed combination of hightemperature resistance up to 280 °C,and excellent media resistance. Otherfeatures are outstanding conformabilityto uneven surfaces, very high sealingintegrity with liquids and gases, highelasticity of the installed gasket (recov-ery), plus mechanical strength. All ofthese sealing properties are due to thecombination of an elastomer-coatedmetal core and beads.

Application areasRETALL® FPM plus is used for sealedjoints that place high demands on me-chanical and thermal loading. Theseinclude EGR, intake manifold, engineancillaries, and valves.

Application exampleThanks to its high temperature resis-tance, RETALL® FPM plus is the preferredmaterial for valve gaskets in exhaustgas recirculation (EGR) systems. Thegaskets are fitted with clamping claws,e.g. for clipping them to oval flanges.Screw retainers greatly simplify over-head installation.

TrendThe demand for environmentally com-patible engines with optimized emis-sion values leads to increasingly highoperating temperatures for EGR sys-tems. RETALL® FPM plus is a gasketmaterial that has been designed spe-cifically for the demands placed byEGR systems.

MaterialRETALL® FPM plus consists of a sheetsteel core that is coated on both sideswith a high-quality elastomer. More-over, both sides of the gasket materialhave a non-stick surface. RETALL® FPMplus has a core of stainless spring steel(type 1.4310), and a thin elastomercoating of fluorine rubber (FPM). Thegaskets are always beaded.

RETALL® FPM PLUS – TEMPERATURE & MEDIA UNDER CONTROL

Fixing clip for easier installation. Quality pays off – temperature and media-resistant coatings.

¬ 21

Construction

Core

Core thickness




16 h, 300 °C


- in oil IRM 903; 5 h, 150 °C

Thickness increase


Thickness increase


Thickness increase




RETALL® FPM plus


1.4310

0.20 mm

25 µm

~ 1.65 kg/m2

> 45 N/mm2

< 5 %

< 5 %

< 5 %

300 °C

-40 up to +280 °C

100 N/mm2

Technical data 1)


Nominal thickness

Tolerances

RETALL® FPM plus

Max. width 500 mm

0.25 mm

±0.02 mm



without any additional treatment.RE

TALL

®FP

M p

lus

Constructional layers of RETALL® F51 and RETALL® F52. Design versions of RETALL® F51 with half and full beads.

Non-stick coating

Partial FPM coating

Bonding agent

Core of stainless spring steel (type 1.43010), of carbon steel, or aluminium Half bead

Full bead

¬ 22

e.g. in the vicinity of the head bolts, andreliable clamping conditions. RETALL®

F51 has good conformability, high elas-ticity, very good sealing integrity withliquids and gases, plus outstandingthermal resistance up to 240 °C contin-uous temperature.RETALL® F52 also has good conforma-bility, excellent creep resistance, is re-sistant to automatic transmission fluids(ATF), and temperature resistant up to240 °C.Thanks to possible coating thicknessesup to 500 µm, component distortionscan be optimally compensated.

Application areasRETALL® F51 and RETALL® F52 offer all the features required for demandingspecial solutions. In combination withspecial bead designs, RETALL® F51 is

used e.g. in high-pressure fuel pumps,where peak pressures in excess of2400 bar are possible, whilst RETALL®

F52 is used e.g. in the control modulesfor automatic transmissions.

Application exampleThe combination of pulsating internalpressures, low bolt clamping forces,and wide bolt spacing is a challengefor every gasket. Thanks to the pro-nounced plastic-elastic behavior of thepartial coating, RETALL® F52 is the idealsealing concept for automatic transmis-sion control modules, as it providesoptimum compensation of componentdistortions.

TrendWhen it comes to contamination fromparticles or dust, high demands areplaced on precision components suchas high-pressure fuel pumps. VICTORREINZ was the first gasket manufactur-er to introduce automatic cleaning &packaging processes for gaskets, thusmeeting customer demands in terms of cleanliness.

MaterialRETALL® F51 and RETALL® F52 are met-al gasket materials, which have beenpartially coated with fluorine rubber(FPM) using the screen-printing process.RETALL® F51 has a core of corrosion-proof stainless steel (type 1.4310), whilstwith RETALL® F52 it is made of carbonsteel or aluminium.RETALL® F51 gaskets are always bead-ed.

PropertiesThe partial coating of RETALL® F51 guar-antees extremely low setting behaviour,

RETALL® F51 AND RETALL® F52 – OPTIMUM SEALING WITH PARTIAL COATING

Increased safety through highly precise positioning of the coatings (RETALL® F51). With RETALL® F52, high coating thicknesses provide optimal compensation of

component distortions.

¬ 23

Construction

Core

Core thickness


Density of FPM coating

Hardness to DIN 53505



- in oil ATF

- in oil IRM 903; (replaces oil No. 3) 5 h, 150 °C




RETALL® F51


1.4310

0.20 mm

5 up to 40 µm

~ 1.90 g/cm3

70 Shore A

~ 1.55 kg/m2

resistant

resistant

resistant

280 ˚C

-30 up to +240 ˚C

RETALL® F52

Carbon steel

Aluminium

0.80 up to 1.8 mm

60 up to 500 µm

~ 1.90 g/cm3

70 Shore A

~ 1.55 kg/m2

resistant

resistant

-

280 ˚C

-30 up to +240 ˚C

Technical data 1)


Nominal thickness

Tolerances

RETALL® F51

0.20 mm

acc. to EN 10258-10259

RETALL® F52

0.80 up to 1.8 mm

acc. to EN 10258-10259




TALL

®F5

1RE

TALL

®F5

2

Constructional layers of MatriCS® and MatriCS® plus. Design versions without bead, and with half or full bead.

Non-stick coating

Full-surface reinforced NBR coating

Bonding agent

Core material carbon steel orstainless spring steel

Without bead

Half bead

Full bead

¬ 24

PropertiesMatriCS® and MatriCS® plus combinemechanical strength and outstandingcreep resistance with high compress-ibility and excellent recovery. MatriCS®

and MatriCS® plus stand for high tem-perature and media resistance, in particular with regard to mineral and synthetic oils, fuels, antifreeze, and re-frigerants.With its stainless steel core, MatriCS®

plus offers additional advantages. Thegasket is corrosion-proof, has an evenlonger service life, and due to its evenbetter recoverability, it features opti-mized dynamic behavior.

Application areasMatriCS® and MatriCS® plus are de-signed to withstand high mechanicaland thermal loads. Therefore, thesegasket materials provide universalsealing solutions for engines, engineancillaries, and for drivetrains.MatriCS® is the standard answer for

rough sealing surfaces, whilst MatriCS®

plus sets new standards in the damp-ing of component dynamics. Typicalapplications for MatriCS® are intakemanifolds, oil pans, EGR systems, andgearbox covers; for MatriCS® plus theyinclude timing chain covers, oil pans,and water pumps.

Application exampleThe strengths of MatriCS® and MatriCS®

plus come to bear especially with flex-urally weak components that exhibitlow sealing pressures and poor pressuredistribution. With gearbox covers, forexample, beaded gaskets provide high-ly reliable and durable sealing evenwith low bolt forces and rough sealingfaces.

TrendLightweight construction and downsiz-ing concepts require increasingly widebolt spacing and higher temperatures.MatriCS® and MatriCS® plus boost theperformance potential of elastomer-coated metal gaskets by means of significantly improved conformability,and low setting at high temperatures.

MaterialMatrix Coated Steel – MatriCS® for short– is the unique combination of a sheetsteel core and a fiber-reinforced elas-tomer coating. MatriCS® has a carbonsteel core, whilst MatriCS® plus usesstainless steel. A coating of fiber-rein-forced, temperature-resistant elastomeris rolled onto both sides of the sheetcore. Hereby, a primer layer ensures aperfect and durable rubber-metal bond,and a non-stick gasket surface guaran-tees optimum disassembly properties.MatriCS® consists of a 0.25 mm thicksteel sheet, coated on both sides witha 0.125 mm layer of high-quality, fiber-reinforced nitrile rubber (NBR).MatriCS® plus differs from MatriCS® inthat the core material is 0.2 mm stain-less spring steel (type 1.4310) with aslightly thicker elastomer coating of0.15 mm.

Beaded metal gaskets with fiber-reinforced elastomer coating

MATRICS® AND MATRICS® PLUS – PERFECT CONFORMABILITY

Reliable joint between core and coating thanks to bonding agent. Integral clips ensure simple (overhead) installation.Beads (full beads) provide higher line pressures.

¬ 25

Construction

Core

Core thickness




16 h, 300 °C

Zusammenpressung und Rückfederung to ASTM F36J

Zusammenpressung

Rückfederung


- in oil IRM 903; 5 h, 150 °C

Thickness increase


Thickness increase


Thickness increase




MatriCS®

Carbon steel

0.25 mm

125 µm

~ 2.20 kg/m2

> 45 N/mm2

4 up to 10 %

< 40 %

< 5 %

< 5 %

< 5 %

300 °C

-40 up to +220 °C

100 N/mm2

MatriCS® plus


1.4310

0.20 mm

150 µm

~ 1.80 kg/m2

> 45 N/mm2

4 up to 10 %

< 40 %

< 5 %

< 5 %

< 5 %

300 °C

-40 up to +220 °C

100 N/mm2

Technical data 1)


Nominal thickness

Tolerances

MatriCS®

Max. width 500 mm

0.5 mm

±0.05 mm

MatriCS® plus

Max. width 500 mm

0.5 mm

±0.05 mm



without any additional treatment.M

atri

CS®

Mat

riCS

®pl

us

Constructional layers of RETALL® HRS and RETALL® 1.4828. Single-layer (SLS), two-layer (DLS), and multi-layer (MLS) design versions.

Sheet steel type 1.4310 or 1.4828

¬ 26

results are obtained at working temper-atures up to 650 ºC, and up to 950 ºCwith RETALL® HTS.

Application areasThe application areas of RETALL® HRSand RETALL® HTS depend on the spe-cific requirements. RETALL® HRS is thebest choice for working temperaturesup to 650 ºC and high demands onelasticity, whilst RETALL® HTS is idealfor working temperatures up to 950 ºCbut with lower demands on recovery.Both material types are used mainlyfor exhaust manifolds, turbochargers,EGR flanges, diesel particle filters, andcatalytic converters.Especially for series production, RETALL®

HRS and RETALL® HTS are the standardsolution for exhaust system applica-tions.

Application exampleRETALL® HRS is preferably used fortwo-layer exhaust manifold gaskets.Special designs with beads and stop-

pers ensure good recovery, as requiredby high component dynamics as wellas occasional extreme thermal expan-sion. Stoppers relieve the beads so thatthey are not fully compressed, and thedefined working range is maintained.The stopper serves as a pre-sealingelement and reduces the dynamics atthe component surfaces.For applications on and around the tur-bocharger, the strengths of RETALL®

HTS play a decisive role. The material'shigh temperature resistance sets newstandards in this area.

TrendHigh dynamics and temperature stress-es with increasing exhaust gas backpressures – these requirement specifi-cations for modern turbocharged en-gines are met by gaskets made withRETALL® HRS and RETALL® HTS.

MaterialRETALL® HRS and RETALL® HTS arepurely metal gasket materials with oneor more layers, made of stainless springsteel or stainless high-temperaturesteel. With multilayer versions, the in-dividual layers are spot-welded and,depending on the application, they arebeaded.

PropertiesRETALL® HRS and RETALL® HTS exhibithigh temperature resistance and highdurability. With RETALL® HRS, the best

Beaded metal gaskets – now up to 1100 °C

RETALL® HRS AND RETALL® HTS – LESS CAN BE MORE

Tip!For applications with extreme oper-ating conditions, the new RETALL®

HRTS with a high-temperature steelcore can be used. This gasket mate-rial withstands temperatures up to1100 °C, whilst exhibiting good re-covery behaviour.

Beads (full beads) provide higher line pressures. Integral screw retainer.

¬ 27

Material no.

RETALL® HRS

1.4310 acc. to EN 10088-2

RETALL® HTS

1.4828 acc. to EN 10059

Technical data 1)


Nominal thickness

Tolerances

RETALL® HRS

0.2 mm, 0.25 mm, 0.3 mm

other thicknesses on request

acc. to EN 10258/10259

RETALL® HTS

0.2 mm up to 0.6 mm

other thicknesses on request

acc. to EN 10258/10259




TALL

®HR

S RE

TALL

®HT

S

Constructional layers of thermo-glide®. Single-layer (SLS), two-layer (DLS), and multi-layer (MLS) design versions.

Optional cover layer

Full-surface, high-temperature-resistant slip coating

Blank stainless steel core

¬ 28

PropertiesThe high-temperature-resistant thermo-glide® coating reduces friction andimproves the gasket's conformabilityto micro-roughnesses. This ensuresconsiderably better sealing integrity.thermo-glide® resists temperatures upto 1000 °C.Thanks to the simultaneous use of sev-eral wear and friction-reducing lubri-cants, thermo-glide® exhibits optimalslip characteristics in a wide tempera-ture range. It provides lasting protectionfrom surface damage due to cold weld-ing, as the frictional wear of the gasketand component surfaces under thermaland dynamic loading is significantlyreduced.

Application areasthermo-glide® is particularly suitablefor sealed joints that must provide goodmicro-sealing under high dynamic andthermal loading. Main application areasare for components subjected to differ-ent thermal expansion rates: e.g. ex-haust manifold gaskets, turbochargergaskets, highly stressed gaskets forEGR systems, and other gaskets in theexhaust train.

Application exampleModern exhaust manifold gaskets be-tween cylinder head and manifold mustprovide perfect sealing in spite of hightemperature variations and frictionalmovement. Even during cold tests,thermo-glide® has very low leakagevalues, and in its role as a problem-solving layer, it prevents damage to thebeads caused by frictional movement.

TrendIncreasingly tough emission regulationsplace new demands on the sealing in-tegrity of the entire exhaust train. Al-ready today, special bead technology incombination with thermo-glide® ensuresthe compliance with future emissionlegislation involving reduced leakagerates for lower exhaust gas emissions.

Materialthermo-glide® is a powder-coated layerof lubricating lacquer for metal gas-kets. The combination of high-temper-ature-resistant resins and special or-ganic lubricant materials is used toincrease the potential of RETALL® HRSand RETALL® HTS.Normally, thermo-glide® is applied tothe gasket surface that is exposed tothe hotter and/or rougher side of thesealed joint.

THERMO-GLIDE® – PERFECTLY TIGHT IN SPITE OF HIGH DYNAMICS AND TEMPERATURES

Multi-layer design for high component dynamics. Maximum sealing with minimum friction.

¬ 29

Construction

Base material: plain gaskets with stainless steel core

Thickness of thermo-glide® coating (each side)

Component roughness RzMax. operating temperature

thermo-glide®

30 µm

< 20 µm

1000 ºC

Technical data 1)


Nominal thickness

Tolerances

thermo-glide®

0.20 mm up to 3.00 mm

acc. to DIN 28091-1



without any additional treatment.th

erm

o-gl

ide®

Constructional layers of FPM 70. Surface molded, edge molded, and backbone molded elastomer profiles.

Stainless steel orgalvanized carbon steel

Edge-molded FPMSurface Molded

Edge Molded

Backbone Molded

¬ 30

PropertiesRegarding media resistance, FPM 70 isan outstanding combination providingresistance to fuels, water/antifreeze,and lubricating oil. The gasket materialis designed for a wide temperaturerange from -24 °C up to +230 °C.Other positive features are low settingand bolt load loss (also in case of widebolt spacing), low clamping force re-quirements for high sealing potential,plus high elasticity and durability.

Application areasFPM 70 is particularly suitable for si-multaneous sealing of different mediafrom each other, e.g. in oil filter cool-ing modules. Other application areasare sealed joints in the intake duct,the throttle flap, or in transmissions.

Application exampleThe edge-molded version of FPM 70permits the oil and water channels inoil filter cooling modules to be sealedin a simple manner. For applicationspreviously requiring the use of differ-ent elastomer materials, FPM 70 istoday's answer. Hereby, the fluorinerubber molded onto the metal coreadapts to component distortions with-out overpressing.

TrendGaskets with a large surface also needto be manufactured cost-effectively insmall quantities. Alternatives to one-piece gaskets are inserts of FPM 70around coolant or oil channels, whichare laser-welded onto the gasket.

MaterialFPM 70 consists of a metal core withmolded-on FPM elastomer profiles. Thecore is made of stainless steel (e.g.type 1.4303) or galvanized carbon steel.Media-resistant fluorine rubber with ahardness of 70 Shore A is used aselastomer.Hereby, the fluorine rubber can be sur-face molded, edge molded, or backbonemolded. The elastomer elements arealways used with controlled compres-sion, whereby travel limiting is ensurede.g. by means of a groove in the com-ponent.

Metal/rubber gaskets

FPM 70 – INCLUDING FLEXIBLE MEDIA AND TEMPERATURE RESISTANCE

Utmost functionality thanks to high processing quality.

¬ 31

Construction

Core of stainless steel or galvanized carbon steel

Surface-molded elastomer

Edge-molded elastomer

Backbone-molded elastomer


Compression set to DIN 53517

16 h, 150 °C

Low-temperature value to DIN 53545



Media resistance

Oil

Fuels

Water/antifreeze agent (50:50)

FPM 70

X

X

X

X

70 Shore A

< 40 %

up to < -24 ºC

250 ºC

230 ºC

+

+

+

Technical data 1)

Molded-on metal/rubber gaskets according to drawing,

dimensions provided, or other agreements

FPM 70

max. size

800 mm x 500 mm




etal

/rub

ber

gask

ets

FPM

70

Constructional layers of ACM 50 and ACM 60. Surface molded, edge molded, and backbone molded elas-

tomer profiles.

Stainless steel orgalvanized carbon steel

Edge-molded ACMSurface Molded

Edge Molded

Backbone Molded

¬ 32

PropertiesACM 50 and ACM 60 are characterizedby very good resistance against oil in awide temperature range between -30 °Cand +150 °C. Other positive featuresare low setting and bolt load loss (alsoin case of wide bolt spacing), low clamp-ing force requirements for high sealingpotential, plus high elasticity and dura-bility.

Application areasACM 50 and ACM 60 provide a highsealing potential at low clamping forces.Similarly, setting tendency and boltload loss are low, even with wide boltspacing. As a result, this gasket mate-rial is preferred for flexurally weak com-ponents with low surface pressures,e.g. for oil pans and valve cover modules.

Application exampleThe metal/rubber material ACM 50 isused for backbone-molded gaskets onvalve covers. Ensuring top quality: Toposition the core sheet precisely duringthe production process, it is held bymeans of special locating pins. Apartfrom perfect sealing, the subject of NVH(noise, vibration, harshness) also playsa decisive role.ACM 50 – a solution that's not only tight,but also quiet.

TrendACM 50 and ACM 60 provide cost-ef-fective standard solutions not only forall classical applications, but also cus-tomized solutions for modern enginedesign. In short – an excellent tip.Moreover, ACM 50 and ACM 60 arefinding increasing use in applicationswith very high demands on durability,and for components with distortion pro-blems.

MaterialACM 50 and ACM 60 consist of a metalcore with molded-on ACM elastomerprofiles. The core is made of stainlesssteel (e.g. type 1.4303) or galvanizedcarbon steel. Acrylic rubbers with ahardness of 50 Shore A or 60 Shore Aare used as elastomer.Hereby, the acrylic rubber can be sur-face molded, edge molded, or backbonemolded. The elastomer elements arealways used as force shunts, wherebytravel limiting is ensured e.g. by meansof a groove in the component.

ACM 50 AND ACM 60 – THE COST-EFFECTIVE STANDARD SOLUTION

Utmost functionality thanks to high processing quality.Integral screw retainer.

¬ 33

Construction







16 h, 150 °C




Media resistance

Oil

Fuels


ACM 50/60

X

X

X

X

50/60 Shore A

< 20 %

< -30 ºC

160 ºC

150 ºC

+

0

-

Technical data 1)



ACM 50/60

max. size

800 mm x 500 mm




etal

/rub

ber

gask

ets

ACM

50

and

ACM

60

Construction of edge-molded HTV 50.

Stainless steelor galvanized carbon steel

Edge-molded silicone

¬ 34

PropertiesDue to its outstanding flow properties,HTV 50 is very simple to apply andprocess, so that retro-vulcanization isnot necessary. Its temperature resis-tance lies in the range between -40 °Cand +200 °C. Other positive featuresare low setting and bolt load loss (alsoin case of wide bolt spacing), low clamp-ing force requirements for high sealingpotential, plus high elasticity and dura-bility. The material is conditionally oil-resistant.

Application areasHTV 50 is the ideal solution for all stan-dard applications. In particular for seal-ing tasks involving covers and electricalconnectors.

Application exampleWith engines designed using magne-sium, corrosive electrochemical poten-tials arise along the bare punched edgesat the outer contours of the gasket'sindividual metal layers.In combination with a special insulatingcoating, a circumferential sealing lip ofHTV 50 is molded along the outer punch-ed edges to provide effective corrosionprotection.

TrendSimple processing without retro-vulca-nization is a cost-effective sealing so-lution for special cases. HTV 50 is theindividual gasket material for specialrequirements.

MaterialHTV 50 consists of a metal core withmolded-on silicone elastomer profiles.The core is made of stainless steel (e.g. type 1.4303) or galvanized carbonsteel. Silicone rubber with a hardnessof 50 Shore A is used as elastomer.HTV stands for High Temperature Vul-canization.The silicone rubber is edge-molded tothe metal core. Hereby, the moldingsare always used as force shunts, where-by travel limiting is ensured e.g. bymeans of a groove in the component.

HTV 50 – THE SIMPLE SOLUTION FOR SPECIAL PURPOSES

¬ 35



Construction







16 h, 150 °C




Media resistance

Oil

Fuels


HTV 50

X

X

50 Shore A

< 30 %

< -40 ºC

220 ºC

200 ºC

0

-

-

Technical data 1)



HTV 50

max. size

800 mm x 500 mm


Met

al/r

ubbe

r ga

sket

sHT

V 50

Utmost functionality thanks to high processing quality.

Constructional layers of Xtreme® plus. Design versions without bead, with simple and with extended edge beading.

High-temperature coatingExpanded mica

Tanged metal coreStainless steel type 1.4828

without beaded edge

with simple edge beading

with extended edge beading

¬ 36

PropertiesXtreme® plus withstands high temper-atures up to 950 °C, and provides ahigh sealing potential over the entiretemperature range. Due to its high com-pressibility and elasticity, this gasketmaterial is extremely conformable,compensates component deformationsin an optimal manner, and exhibits con-stant material properties also underchanging operating conditions.Further advantages are high creep re-sistance, i.e. a low setting tendency,good media resistance, high gas tight-ness, and good thermal insulation witha low coefficient of thermal conductance.Under extreme mechanical loads, theoptional internal bead permits higherinternal pressures and provides bettercross-sectional sealing.Wider beads reduce the gasket's settingbehaviour. If required, a one-sided beadup to the gasket's outer contour in-creases mechanical strength and im-proves the gliding properties throughspecial measures.

Application areasXtreme® plus was developed especiallyfor high-temperature applications, andtherefore provides optimum solutionsfor all tasks in the exhaust area. It isparticularly suitable for turbochargergaskets, but also for installation betweencylinder head and exhaust manifold, inthe downstream flanges of exhausttrains, and for components in EGR sys-tems.

Application exampleThe preferred use of Xtreme® plus is for turbocharger gaskets. Here, Xtreme®

plus compensates component move-ments caused by large temperaturevariations very well. For special solu-tions, the gaskets usually have metalbeaded edges.

TrendTighter emission regulations have adecisive influence of engine develop-ment, whilst engines are becomingmore compact and have higher outputs.This leads to higher exhaust gas tem-peratures and simultaneously highercombustion pressures. In summary,the engine has fewer opportunities forcooling down. The high-temperaturegasket material Xtreme® plus is ideallysuited to meet these demands.

MaterialXtreme® plus consists of a tanged steelcore, onto which a fiber-reinforced micalayer is rolled from both sides. The corematerial is a 0.20 mm thick stainlesssteel (type 1.4828) sheet that has beentanged. Apart from expanded mica,the coating material contains tempera-ture resistant fibers as well as a smallamount of high-grade elastomers asbinder. Due to the special properties ofthe mica material, which prevents thegasket from burning-in or baking tothe sealing surface, a non-stick coat-ing is not necessary.The material is available in overall thick-nesses of 1.2 mm and 1.6 mm.

High-temperature gaskets

XTREME® PLUS – WHEN EXTREME TEMPERATURES REPRESENT AN ABSOLUTE CHALLENGE

Optional inner bead permits higher internal pressures and provides better cross-sectional sealing.

¬ 37

Construction

Core

Core thickness

Creep resistance; 16 h, 300 °C to DIN 52913

Nominal thickness 1.2 mm

Nominal thickness 1.6 mm

Compressibility and recovery to ASTM F36 J

Compressibility

Recovery


- in oil IRM 903; 5 h, 150 °C

Thickness increase

Weight increase


Thickness increase

Weight increase


Thickness increase

Weight increase

Max. operating temperature


Xtreme® plus

Stainless steel 1.4828

0.20 mm and 0.30 mm

~ 42 N/mm2

~ 38 N/mm2

5 % up to 15 %

> 40 %

< 5 %

< 15 %

< 5 %

< 10 %

< 10 %

< 18 %

950 °C

75 N/mm2

Technical data 1) 2)


Nominal thickness

Tolerances

Xtreme® plus

1.2 mm and 1.6 mm

±0.01 mm



without any additional treatment.2) For critical applications, an inner bead is advantageous.

Xtre

me®

plus

Constructional layers of AFM® 30.

High-friction layeron both sides

Synthetic fibers,elastomers, filling media.

¬ 38

Both sides of AFM® 30 are coated witha high-friction layer as standard, whichfacilitates dismantling and makes addi-tional surface treatment unnecessaryin most cases.

PropertiesAFM® 30 is a standard quality that meetshigh operational demands. This com-posite gasket material provides reliablesealing against gases, oils, fuels, andantifreeze agents; moreover, it exhibitsgood conformability, high tensile andshear strength, as well as mechanical/

thermal resistance. AFM® 30 is suitablefor short-term peak temperatures up to400 ºC, and continuous temperaturesup to 250 ºC.

Application areasAFM® 30 is used primarily for sealingtransmission, hydraulic, refrigerant, andengine oils, as well as fuels. Other usesfor AFM® 30 are found in oil pans, oilfilter housings, water pumps, and aircompressors.

Application exampleThe good conformability and low settingtendency of AFM® 30 is particularly use-ful when sealing automatic transmis-sions. Moreover, the material exhibits ahigh coefficient of friction for torquetransfer.

MaterialAFM® 30 is a composite gasket materi-al based on synthetic fibers. This asbes-tos-free gasket material contains aramidfibers and other temperature-resistantasbestos substitutes that have been pro-cessed together with high-grade elas-tomers under increased pressure andelevated temperature.

Fiber composite gaskets

AFM® 30 – MEDIUM-HARD STANDARD SOLUTION FOR DEMANDING OPERATING CONDITIONS

Screen-printing for improved sealing effect and higher internal pressure loads.

¬ 39

Tensile strength (cross grain) to ASTM F 152


16 h, 300 °C

Compressibility and recovery to ASTM F 36 J

Compressibility

Recovery

Gas permeability with nitrogen to DIN 3535, Part 6 FA



Thickness increase

Weight increase


Thickness increase

Weight increase


Thickness increase

Weight increase


Max. operating pressure

AFM® 30

> 12 N/mm2

~ 36 N/mm2

7 % up to 15 %

> 50 %

~ 0.5 cm3/min

< 10 %

< 10 %

< 10 %

< 10 %

< 5 %

< 10 %

250 ˚C

100 bar



Nominal thickness

Tolerances

AFM® 30

0.30 mm up to 5.00 mm

acc. to DIN 28091-1



without any additional treatment.2) Max. operating temperature and max. pressure may not occur

simultaneously.AF

M®

30

Constructional layers of AFM® 31.


Synthetic fibers,elastomers,and filling media

¬ 40

Both sides of AFM® 31 are coated witha high-friction layer as standard, whichfacilitates dismantling and makes ad-ditional surface treatment unnecessaryin most cases.

PropertiesFurthermore, AFM® 31 is a very confor-mable gasket material that is highlycompressible and flexible. Worth notingis the very good sealing effect againstgases and liquids, such as oils, fuels,and antifreeze agents – also with lowbolt clamping forces. AFM® 31 is suit-

able for short-term peak temperaturesup to 300 ºC, and continuous tempera-tures up to 250 ºC.

Application areasAFM® 31 is used mainly for sealing jointsbetween components that are easilydeformed, and have relatively low clamp-ing pressures, such as oval flanges, oilpans, and gearbox covers.

Application exampleFrequently, the sealing surfaces of oilpans are flexurally weak, so that highclamping pressures are not possible. Thecomposite material AFM® 31 achievesoptimum sealing results with wider boltspacings combined with low clampingpressure.

MaterialAFM® 31 is a composite gasket materi-al based on synthetic fibers. This asbes-tos-free gasket material contains aramidfibers and other temperature-resistantasbestos substitutes. AFM® 31 is man-ufactured together with high-grade elas-tomers under increased pressure andelevated temperature.

AFM® 31 – STANDARD COMPOSITE SOLUTIONS WITH HIGH SEALING POTENTIAL

High quality thanks to clean-cut edges.

¬ 41

AFM

®31



16 h, 175 °C


Compressibility

Recovery




Thickness increase

Weight increase


Thickness increase

Weight increase


Thickness increase

Weight increase



AFM® 31

> 8 N/mm2

~ 24 N/mm2

14 % up to 23 %

> 50 %

~ 0.1 cm3/min

< 10 %

< 20 %

< 15 %

< 20 %

< 5 %

< 15 %

250 ˚C

80 bar



Nominal thickness

Tolerances

AFM® 31

0.30 mm up to 2.00 mm

acc. to DIN 28091-1




simultaneously.

Constructional layers of AFM® 32/2.


Synthetic fibers,elastomers,and filling media

¬ 42

Both sides of AFM® 32/2 are coated witha high-friction layer as standard, whichfacilitates dismantling and makes addi-tional surface treatment unnecessaryin most cases.

PropertiesAFM® 32/2 has very high mechanical-thermal stability and tensile strength.The material is highly conformable, andis especially suitable for sealing oilsand other liquid media. AFM® 32/2 issuitable for short-term peak tempera-tures up to 400 ºC, and continuoustemperatures up to 250 ºC.

Application areasAFM® 32/2 is frequently used to sealjoints subjected to high mechanicalloads. Typical application areas areintake manifolds, compressor flanges,and components that must withstandsevere vibration, such as the chassis.

Application exampleAs an optimum solution for applicationsinvolving high mechanical loads, AFM®

32/2 is also the classical material usedfor door lock pads. Hereby, the materi-al is used as an underlay (sometimeswith an adhesive layer) to provide scratchprotection. In these applications, thehigh-strength material also absorbsvibrations and provides corrosion pro-tection.

MaterialAFM® 32/2 is a composite gasket ma-terial based on synthetic fibers. Thisasbestos-free gasket material containsaramid fibers and other temperature-resistant asbestos substitutes that havebeen processed together with high-gradeelastomers under increased pressureand elevated temperature.

AFM® 32/2 – STANDARD SOLUTION FOR APPLICATIONS WITH HIGH MECHANICAL LOADS

Adhesive layer on one side serves as an assembly aid.

¬ 43



16 h, 175 °C


Compressibility

Recovery




Thickness increase

Weight increase


Thickness increase

Weight increase


Thickness increase

Weight increase



AFM® 32/2

> 15 N/mm2

~ 36 N/mm2

7 % up to 12 %

> 50 %

~ 1.0 cm3/min

< 8 %

< 12 %

< 7 %

< 10 %

< 5 %

< 15 %

250 ˚C

150 bar



Nominal thickness

Tolerances

AFM® 32/2

0.30 mm up to 3.00 mm

acc. to DIN 28091-1




simultaneously.AF

M®

32/2

Constructional layers of SH, QE, and SF screen-printed gaskets.

SH screen-printing

QE screen-printing

SF screen-printing

¬ 44

MaterialScreen-printed gaskets are manufac-tured by applying polymer compoundbeads onto a substrate material, andsubsequent vulcanization of the com-pact or foamed elastic sealing beads.Depending on the application and thesubstrate material, special bondinglacquers are used, which also act ascorrosion inhibitors with carbon steelsubstrates.The substrate material can be metal orcomposite, i.e. carbon steel, stainlesssteel, or aluminium, as well as AFM® –our asbestos-free composite materialbased on synthetic fibers.Also depending on the application, thebeads have different specifications.

PropertiesScreen-printed gaskets achieve signifi-cantly better micro and macro-adapta-tion, and therefore improve the sealingeffect and internal pressure resistanceof flat gaskets. The printed beads canbe applied on one or both sides of thegasket.SH-type material exhibits good resis-tance to mineral oils and greases, hashigh mechanical strength, and thereforepermits high line pressures.QE is resistant to a wide range of media,is temperature resistant and non-aging.Moreover, the sealing bead is highly con-formable and only requires low clamp-ing pressure to obtain good sealingresults.Due to the foaming process, SF-typematerial is extremely conformable, andhas a medium temperature resistance.

Application areasScreen-printed gaskets are always usedwhen conventional gaskets are unableto provide adequate sealing results.Even the standard design with constant

sealing/supporting bead heights andwidths ensures good sealing integrity,especially with flexurally weak compo-nents and/or low clamping pressures.By varying the bead geometry, it is pos-sible to control the surface pressureprecisely, e.g. for joints between differ-ent pressures or media.For timing covers, oil pans, or hydraulicpumps, screen-printed gaskets enablepractically every bead shape to be im-plemented without complex tooling.

Application exampleDue to uneven pressure distribution aswell as the partially low clamping pres-sure, flexurally weak components placehigh demands on flat gaskets. Elasticpolymer sealing beads can solve thesetasks optimally, for example on timingcovers.

TrendInnovative engine concepts depend ongaskets that are matched to the specificapplication. Screen-printed gasketspermit special solutions to be realizedquickly and unconventionally. Due tothe line pressure effect, high-integritysurface and cross-sectional sealing isachieved. Consequently, the componentstiffness or clamping pressure requiredfor a good seal can be lower than withsimple flat gaskets.

SCREEN-PRINTED GASKETS SH, QE, AND SF – INDIVIDUAL TUNING FOR FLAT GASKETS

Screen-printing for improved sealing effect and higher internal pressure loads. Highly precise positioning thanks to perfected manufac-

turing processes.

¬ 45

Construction

Metal substrate

Composite substrate

Bead height

Polymer type

Color

Temperature resistance

SH screen-printing

Carbon steel

Stainless steel,

aluminium

AFM® 30

AFM® 31

AFM® 32/2

0.05 mm up to 0.25 mm

Polyurethane

blue

-30 up to +90 ºC

QE screen-printing

AFM® 30

AFM® 31

AFM® 32/2

0.05 mm up to 0.25 mm

Silicone

gray

-50 up to +180 ºC

SF screen-printing

Carbon steel

Stainless steel,

aluminium

AFM® 30

AFM® 31

AFM® 32/2

0.1 mm up to 0.8 mm

Epoxy

(slightly foamed)

red-brown

-10 up to +130 ºC

Technical data 1)

Gaskets

SH screen-printing

with sealing bead according to a drawing

QE screen-printing SF screen-printing



without any additional treatment.SH

scr

een-

prin

ting

QE s

cree

n-pr

intin

gSF

scr

een-

prin

ting

Design versions with B, Double B, and H 100 profiles.

H 100 profile

B profile

Double B profile

¬ 46

PropertiesACM 50 and ACM 60 provide a highsealing potential at low clamping forces.Similarly, setting tendency and bolt loadloss are low, even with wide bolt spac-ing. The cost-effective standard solutionis suitable for a wide temperature rangebetween -30 °C and +150 °C, and hasvery good resistance against oil.Equally convincing are the elasticity anddurability of ACM 50 and ACM 60.

Application areasThe properties of ACM 50 and ACM 60are perfect for reliable sealing of flex-urally weak components, as thesecases only permit limited clampingforces.

ACM 50 and ACM 60 are used mainlyfor valve cover gaskets, but also for oilpans and timing covers.

Application exampleEspecially with valve cover gaskets, re-liable sealing must be ensured in spiteof wide bolt spacing or unfavorablecreep behavior in the case of plasticvalve covers. In combination with thespecial 'H' profile, ACM 50 and ACM 60achieve an optimum overall perfor-mance. Due to its high recovery rate,a wide working range, and a definedbuckling characteristic, the profile ispushed up automatically to ensure atight seal.

TrendAlso in future, flexurally weak plasticcomponents will play an important rolein modern lightweight engines. ACM50 and ACM 60 provide good standardsolutions that can also be used for plas-tic components with a tendency tocreep. Similarly, this gasket material isfinding increasing use for housing cov-ers made of aluminium or magnesium.

MaterialACM 50 and ACM 60 are molded rubbergaskets using acrylic rubber. The elas-tomer elements are always used as forceshunts, whereby travel limiting is en-sured e.g. by means of a groove in thecomponent or with threaded buffers.Profile geometries matched preciselyto the application are the guarantee foroptimum functionality. ACM 50 andACM 60 have different hardness grades.The hardness of ACM 50 is 50 Shore A,whilst that of ACM 60 is 60 Shore A.


ACM 50 AND ACM 60 – MAXIMUM SEALING POTENTIAL WITH MINIMUM CLAMPING FORCE

Complex designs thanks to perfected manufacturing technology.

¬ 47



16 h, 150 °C




Media resistance

Oil

Fuels


ACM 50/60

50/60 Shore A

< 20 %

< -30 ºC

160 ºC

150 ºC

+

0

-

Technical data 1)

Gaskets

ACM 50/60

according to drawing




olde

d ru

bber

gas

kets

ACM

50

and

ACM

60

Design versions of firmly bonded sealing compounds DX and F52.

DX

F52

¬ 48

PropertiesThe sealing compounds DX and F52are temperature resistant up to 120 °Cand 240 °C respectively, and resistantto various media such as engine oiland coolants. Both compounds havegood bonding properties.

Due to their outstanding flow charac-teristics, the compounds extrude intothe smallest cavities, surface rough-nesses, and gaps without causing apartial reduction of the gasket'smounting surface pressure.

Application areasWhen applied in the form of a bead, DXis used to seal highly uneven and roughsurfaces. F52 is used in situations in-volving high component dynamics and/orelevated temperatures, and requiringchemical resistance.

Application exampleThe firmly bonded sealing compound DXis used typically for the joints of vacu-um pumps, whilst F52 is used e.g. incritical sealing conditions with oil pans.

TrendComplex engine designs increasinglyrequire gaskets with additional seals.The aim is to eliminate the need toapply the additional seal during instal-lation, and to deliver the gasket com-plete with compound as a »modularsolution« instead.

MaterialCritical sealing conditions arise in casesof component deformation, high surfaceroughness, and in separation areas.These difficulties can be solved by ap-plying highly plastic sealing compoundsto the gaskets. During installation, thecompound is compressed, thus ensur-ing a reliable seal also in critical situa-tions.For this purpose, either the firmly bond-ed and cured DX compound based onpolyurethane (PU) or the foamed fluorinerubber (FPM) F52 compound are used.

Special solutions

FIRMLY BONDED SEALING COMPOUNDS DX AND F52 – RELIABLE SEALING IN CRITICAL SITUATIONS

Highly precise positioning thanks to perfected manufacturing processes.

¬ 49

Construction

Metal substrate

Composite substrate

Bead height

Polymer type

Color

Temperature resistance

DX

PROGRESSION®-Series,

MatriCS® (plus)

AFM® 30

AFM® 31

AFM® 32/2

1.1 mm

Oligomers

Polyurethane compound

transparent

up to 120 ºC

F52

PROGRESSION®-Series,

RETALL®-Series

MatriCS® (plus)

up to 0.6 mm (foamed)

FPM

blue

-30 up to +240 ºC

Technical data 1)

Gaskets

DX

with sealing bead according to a drawing

F52



without any additional treatment.Fi

rmly

bon

ded

seal

ing

com

poun

dsD

X/ F

52

Single-layer (SLS), two-layer (DLS), and multi-layer (MLS) design versions.Design versions. Topographic adaptation using the plastic/elastic characteristics of

the Wave-Stopper®.

¬ 50

PropertiesThe Wave-Stopper® exhibits pronouncedplastic/elastic behavior, which can bematched precisely to the gasket's work-ing environment. Moreover, the waveheight profiles can be varied, thus per-mitting a topographic adaptation.Consequently, the available bolt clamp-ing forces are utilized to better effect,and component distortions are reduced.

Application areasThe Wave-Stopper® is used primarily in combination with gaskets that mustachieve high line pressures due to yield-ing components or because of high tem-perature stresses. Thanks to the indi-vidual adaptability, a highly uniform

pressure image can be created in thecritical areas. Due to the great degreeof design freedom, the Wave-Stopper®

is able to adapt perfectly to changingcomponent stiffness. This permits pres-sure peaks to be equalized, and thepressures on adjacent components aredistributed evenly. Typical applicationareas are exhaust manifold, exhaustpipe, and turbocharger.

Application exampleWave-Stopper® achieves excellent re-sults in turbochargers with thermal dis-tortion of the sealed joints. Togetherwith additional beads, the plastic/elas-tic behaviour ensures adequate sealingpressure levels under all operating con-ditions, and thus provides optimumsealing.

TrendNot only the design of MLS cylinder headgaskets has been affected decisivelyby the Wave-Stopper®. The Wave-Stop-per® is a cost-effective alternative forcomplex and critical applications in theexhaust train.

MaterialNormally, the Waver-Stopper® consistsof several concentric individual waves.The wave characteristics are influencedby various design criteria, and the coresheet thickness. By means of partiallyterminated waves, the gasket can beindividually adapted to the componentstiffness and contour.

WAVE-STOPPER® – PUTTING PRESSURE ON THE LINE

Design versions using a clip or dome. Integral clips ensure simple (overhead) installation.

Clip

Dome

¬ 51

PropertiesClips and fasteners serve to hold flatgaskets securely in place. This is alwaysnecessary if the gasket is preassembledby a systems supplier, or if it must beprevented from falling during installationon the assembly line.

Application areasClips, claws, and fasteners are used incountless applications – from A for air-bag housing to W for water pump. Inshort: Whenever the loss of gaskets frompreassembled engine components mustbe prevented, or their installation on theassembly line is to be simplified.

Application examplePositioning and securing. Occasionally,combinations of different types of clips,claws, and fasteners are used, for ex-ample in complex oil filter cooler mod-ules. During installation, the gasket mustbe positioned precisely (dome), beforeit can be secured overhead (clip or claw)to prevent it falling.

TrendFaster, simpler, and safer are today'skey words. Detailed solutions using in-novative fasteners are extremely usefulduring efforts to simplify installation orassembly, thereby reducing overall costs.

MaterialVarious types are available, such as theREINZ fixing claw, the REINZ dome, orother special versions of clips and fas-teners.

Basically, all the different types and ver-sions can be used with all beaded metalgaskets – with and without elastomercoating.

CLIPS, CLAWS, AND FASTENERS – FAST, SIMPLE, AND SECURE

Wav

e-St

oppe

r®Fi

xing

/cl

ampi

ng c

law

¬ 52

HELPING CREATE FUTURE ENGINE CONCEPTS

By constantly evaluating market andtechnology trends, VICTOR REINZ ishelping make visions become reality.In fact, many of today’s engine stan-dards are based on innovative solu-tions from VICTOR REINZ. So it's nowonder that VICTOR REINZ has devel-oped a strong reputation for ongoing,outstanding product innovations in theautomotive industry.

TWO EXAMPLES OF THE AUTOMOTIVE FUTURE

The amount of vehicle electronics con-tinues to increase. Measurement andcontrol will play an essential role inmodern engines. For example, integrat-ed sensors enable fuel consumptionand emissions to be reduced significant-ly. However, this also involves new de-mands on sealing technology for modernengine designs. In future, sensors inthe head gasket will measure tempera-ture and pressure directly in the com-bustion chamber, to supply data aboutthe combustion process to the enginemanagement system. Electronic com-ponents inside the engine control fuelinjection, the ignition, and/or the valves,which means that the electric signalsmust be fed to the outside via the gasket.

Solutions for the automotive future comefrom VICTOR REINZ. The active cylinderhead gasket SensoriCS® for pressureand temperature measurement, and theWindow Gasket for the feedthrough ofelectronic signals are just two outstand-ing examples of VICTOR REINZ innova-tion.

SENSORICS®

In the future, a cylinder head gasketwill no longer be simply a sealing ele-ment – it will be an intelligent compo-nent in the overall engine system. Infact, at VICTOR REINZ the future isnow: SensoriCS® – the intelligent MLShead gasket with integrated pressureand temperature sensors – helps pro-vide an intelligent engine managementand cooling system.

Pressure measurement ΔpTo further reduce emissions and improvefuel consumption in future IC engines,measuring the combustion pressures isa must. This measurement will permitthe engine management system to in-fluence the combustion process far moreprecisely. Through active control factorsincluding injection time and quantity, aswell as EGR ratio, the engine operatesonly in the optimum map area, so thatemissions and fuel consumption are re-duced. What's more, this system enablesthe engine's combustion parameters tobe adapted effectively and flexibly todifferent fuel qualities.

Temperature measurement ΔTAlso here, temperature sensors supplydata to the engine management system,directly from inside the engine – permit-

A vision for the future

High temperature gradient for fast attainment of the ideal operating temperatures of engine

and catalytic converter.

Stays tight. And in touch with the future: SensoriCS®. Fast temperature signals to the engine

management system.

Tem

pera

tur

[°C]

Zeit [min]

0 1 2 3 4 5 6 7 8 9 10

Component temperatureNormal coolant flowComponent temperature withSensoriCS® (reduced coolant flow)

160140120100806040200

Time [min]

Tem

pera

ture

[°C]

144 145 146 147 148 149 150 151 152 153

Component temperature closeto cylinders with SensoriCS®

Coolant temperature atconventional locationEngine output

Time [min]

180

160

140

120

100

80

60

40

20

0

Tem

pera

ture

[°C]140

120

100

80

60

40

20

0

Engi

ne o

utpu

t [k

W]

With VICTOR REINZ, automotive visions come true.

¬ 53

SensoriCS® – reduced harmful emissions, lower fuel consumption, and longer service

life of critical engine components.

Window Gasket – the future for gaskets with electronic

signal feedthrough.

ting the coolant flow to be controlledfor optimum exploitation of the generat-ed heat. Exact, requirement-dependentheat management of the coolant circuitenable the engine and catalytic conver-ter to reach their ideal operating tem-peratures much faster. Similar applica-tion possibilities are also possible in theareas of optimized combustion and on-board diagnostics. These technologicaladvances will provide higher engineefficiency while simultaneously reducingharmful emissions, lowering fuel con-sumption, and lengthening the servicelife of critical components.

WINDOW GASKET

The VICTOR REINZ Window Gasket al-lows the simple feedthrough of electro-nic signals without additional holes, e.g.in the engine block, and the risk of leak-age channels. This unique conceptpermits the installation of one or morecable harnesses as well as the use ofvariable plug-in connections, such aspower leads for solenoids, switches,fuel injection, or sensors. Moreover,through the use of thermoplastics forthe substrate in combination with high-temperature resistant elastomers forthe sealing elements, the design exhi-bits excellent performance. Typicalapplication areas for this new technol-ogy are valve cover seals, oil pan gas-

kets, gearbox gaskets, and similar seal-ing functions. The Window Gasket avoidspotential leakage paths due to conven-tional installation methods, reducescomponent complexity, is easy to install,and ensures simple disassembly andreassembly, for example during repairoperations.

WHAT WILL THE FUTURE BE LIKE?

Naturally, we cannot predict the futureof the automobile. But we do have clearconceptions about the future of gasketsand sealing technology. Because thefuture already exists in our developmentdepartments. You can learn more aboutthese exciting developments by request-ing more information; simply give us acall and we will send an informationpackage to you.

Our contributions toward the future of the automotive industry:

¬ Systematic evaluation of marketand technology trends

¬ Continuous adaptation of currenttechnologies to changing conditionsin order to meet the developmen-tal trends of modern combustionengines

¬ Development of intelligent productinnovations (active SensoriCS® headgasket for measuring pressure andtemperature differences, WindowGasket for feedthrough of electronicsignals)

¬ Contribution toward weight reduc-tion in engine designs through newmaterials

¬ Contribution toward emission re-duction through distortion-opti-mized solutions

Publication: Cylinder Head Gaskets for the New AI/Mg

Composite Construction, MTZ Issue 12/2004

Publication: Enhanced Functionality for Cylinder Head

Gaskets. Advanced Development of the Wave-Stopper®,

MTZ Issue 10/2003

Publication: Cylinder Head Gasket with Integrated Tem-

perature Sensors. Detecting Component Temperatures in

the Heart of the Engine, MTZ Issue 12/2002

Publication: New Technology for Multi-Layer Steel

Cylinder Head Gasket, MTZ Issue 10/2001„Facts made by VICTOR REINZ.“

¬ 54

The VICTOR REINZ product range

EXCELLENT IN ALL AREAS

When it comes to the powertrain, wefeel completely at home. So it's no won-der that our specialties are not limitedto sealing technology for modern en-gines. The name VICTOR REINZ standsfor innovative sealing systems – fromengine and transmission to the entiredrive train and the exhaust gas system– including high-tech shielding and valvecover systems.

The entire world of gasket technology

¬ Multi-layer steel (MLS) cylinderhead gaskets

¬ Metal gaskets¬ Coated metal gaskets¬ High-temperature gaskets

(Xtreme®, thermo-glide®)¬ Metal/elastomer gaskets¬ Composite gaskets (AFM®)¬ Screen-printed gaskets¬ Molded rubber gaskets¬ Sensor gaskets for temperature

and pressure measurement(SensoriCS®)

¬ Gaskets with signal feedthrough(Window Gasket)

¬ Shielding systems for thermal and acoustic insulation

¬ Multi-functional valve cover systems with efficient removal of oil mist

¬ Customized solutions for commercial vehicle applications

¬ Special solutions

Innovative technologies for the powertrain come from VICTOR REINZ.

»Thanks to VICTOR REINZ, we are using innovations that are just being invented elsewhere.«

¬ 55

Solution for the future: Series-ready bluepack® fuel cell

stack »Made in Neu-Ulm«.

SYNERGY AND TECHNOLOGYTRANSFER BENEFITS OUR CUSTOMERS

As part of the Dana Corporation, VICTORREINZ has the resources to provide thebest solutions worldwide – includingideas, service, and products in auto-motive manufacturing hubs located inpoints around the globe.

All our facilities are networked in orderto maximize our knowledge and efficien-cies to serve you better.

AUTOMOTIVE ORIENTATION INTHE XXL FORMAT

As one of the largest independent auto-motive suppliers, the Dana Corporationis represented on every continent. Alone3,900 specialists within Dana SealingProducts, who are part of the 45,000Dana employees worldwide, develop andmanufacture innovative sealing systemsfor the international automotive indus-try on four continents. We also serveemerging markets providing worldwideaccess to Dana’s expertise.

Our experts in every division of the DanaCorporation, together with our customers,develop the most advanced innovationsbased on true company synergy. Thismulti-discipline approach allows us tosee the big picture, supplying state-of-the-art components, modules, systems,and complete assemblies matched tothe needs of the global automotivemarket.

As a result of this company synergy, weat VICTOR REINZ have become evenfaster, more innovative, and more com-petitive than ever before. Our purchas-ing, development, and sales advantagesare passed on directly to our customers.And that's not all.

TRENDSETTING CELLS – TECHNOLOGICAL MILESTONE

The Dana Corporation is committed topromoting mobility, today and into thefuture. At our facility in Neu-Ulm, VICTORREINZ is already engaged in the produc-tion of series-ready components for fuelcells. We are on the threshold of a tech-nology that will no longer be hamperedby emissions challenges in regard to to-day’s combustion engines. Companieswho play a leading role in these techno-logies have a bright future.

For these developments and anythingelse the future holds in store, you canbe confident that with VICTOR REINZ,you’ll always benefit from the most ad-vanced developments inspired by theclose cooperation of our experts world-wide.

Today. Tomorrow. And as long as thereare automobiles.

VICTOR REINZ in the Dana network

REINZ-Dichtungs-GmbH

Reinzstrasse 3-7

89233 Neu-Ulm

Germany

Phone +49 (0) 731-70 46-0

Fax +49 (0) 731-71 90 89

www.reinz.com

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