Gasket Materials and Selection

Most major manufacturing sectors, including

the automotive, aerospace, electronics,
appliance, and military industries, employ
gaskets in their production methods. A gasket
is a sealing device made of deformable
material usually designed in the form of a ring
or sheet. Gaskets create a pressure-tight seam
between multiple stationary components, relying on a compression seal
to prevent unwanted gas or liquid emissions. These seals are often
intended to be resistant to pressure, temperature fluctuations, and in
some cases, electrical or electromagnetic forces. Since it uses
compression, a gasket is typically more malleable than the components
it joins and is able to conform to the shape of the harder surfaces
between which it is placed.
Gaskets are available in a large number of specifications, making proper
gasket selection an important step in many manufacturing processes.
They can be formed from a wide range of materials, such as metals,
rubbers, plastics, corks, foams, and composite substances. They also
come in numerous designs, including jacketed, double-jacketed, spiral
wound, and Kammprofile varieties. Finding the right combination of
material and design depends on the gaskets specific uses and the cost
parameters of the project.
Is a Gasket Necessary?
While gaskets serve an important function as sealing joints, there are a
handful of similar devices that may be better-suited to certain tasks. An
application requiring a seal that forms a barrier between external and
internal elements, such as a unit to prevent water leakage, usually needs
a gasket. However, to fill small assembly gaps between components,
manufacturers would be better served by a spacer, or shim, which is a
narrow wedge used for packing or leveling purposes.
Likewise, o-rings, though similar to gaskets, have a subtly different
designation. Unlike gaskets, o-rings are made almost exclusively of
synthetic rubber or plastic polymers with elastomeric properties, and
are produced solely in ring form. They are durable and reliable in
sealing matched components by creating a barrier around an area with
leakage potential. In addition, o-rings are distinct for their round or

square cross-sectional configurations, as well as their high pressure

resistance, making them valuable in some applications where a standard
gaskets resistance would not suffice.
Gasket Specifications
After determining that a gasketas opposed to a shim or an o-ringis
the appropriate device for a given application, several other factors must
be taken into account to choose a well-suited design. There are
numerous types of gaskets, though many share similar features and may
be capable of handling related tasks. Some of the most common
varieties of gasket include:
Jacketed Gaskets: This form merges the efficiency and
flexibility of soft gaskets (made of rubber or plastic) with the
resistance and durability of an external metal coating. A
single-jacket has soft filler with metal coverage along one face
of the gasket, while a double-jacketed version has a fully
coated metal facing, providing improved temperature,
pressure, and corrosion resistance. Other variations include
corrugated jacketed gaskets, and French Style jackets, which
provide coating on either the inside or outside of the gasket.
Solid Gaskets: Solid gaskets are typically formed of metal
and are a relatively inexpensive alternative to jacketed
gaskets. They have high thermal and pressure resistance,
though they require higher compression force to form a seal
and are usually effective only against surfaces that are harder
than the metal itself.
Spiral Wound Gaskets: This type of gasket is formed by
combining metal with softer plastics or synthetic rubber in a
winding shape, often reinforced with additional layers of
metal without filler. Its unique design yields high thermal and
physical stress resistance, coupled with flexibility and
resilient sealing. Spiral wound gaskets are often used in
piping, pumping, and heat exchange systems.
Kammprofile Gaskets: The Kammprofile design contains
a corrugated metal core covered with a malleable sealing
material attached to both of its sides. This structure focuses
physical stress onto the surface sealant, creating tight seals
along the gaskets edges while retaining the devices flexibility
and strong tensile core. Kammprofile gaskets provide reliable

support in heat exchange systems and have improved costeffectiveness due to their capacity for repair.
Metal Gaskets
Many types of gaskets are constructed from metal or a mixture of metal
and non-metal materials. These gaskets are typically formed with
aluminum, copper, nickel, steel, stainless steel, or brass. These materials
provide a high level of thermal, corrosive, and pressure resistance, along
with excellent durability and tensile strength. On the other hand, metals
require elevated amounts of compressive force to form a seal and have
limited flexibility for multiple applications. For these reasons, metals
are often used in combination with rubber or plastic compounds,
otherwise known as soft fillers.
Rubber and Plastic Gaskets
Due to its elastomeric properties, rubber is a popular material for gasket
production. Since they can undergo a high degree of deformation
without permanent damage or loss of attributes, rubber gaskets can
form very tight seals within a wide range of applications. Some types of
rubber frequently used in gasket manufacturing include nitril, viton, and
neoprene. Certain polymers, such as thermoplastic elastomer,
thermoplastic rubber, and polyvinyl chloride, display qualities similar to
those of rubber and are also common in gasket production.
Silicone Gaskets
Silicone is a valuable gasket material because it displays strong
resistance to extreme temperatures. Silicone-based gaskets can have
operating temperatures that range between roughly -140 degrees to 480
degrees Fahrenheit. In addition, their resistance to ultraviolet light
makes them useful in outdoor settings, while their flame tolerance
within a certain thickness range has applications in electronics and
transit industries. Silicone gaskets come in foam and sponge varieties,
and can be reinforced with other materials to improve tensile strength
or adjust thermal and electrical conductivity.
Compression Testing
An important characteristic for industrial gaskets is their capacity for
tolerating compressive loads. Evaluations, such as the hot compression

test, can be used to gauge a specific gaskets ability to withstand various

weights and temperatures. Typically, a gasket is placed between the
exertion bolts of a hydraulic press. Temperature is increased, often up to
nearly 600 degrees Fahrenheit, at an incremental rate over a given
period of time while the press exerts constant load pressure on the
gasket. Any decreases in material thickness are measured and used to
assess the gaskets effectiveness. Tests such as this can be helpful in
selecting a gasket or deciding upon a given material or design
configuration.