Glenn Butcher
15th April 2003, 09:54 PM
Hi there, I found this on another site:
Ceramic Apex Seals
Here is some information for you on the ceramic apex seals that are being produced.
The quality of this material can only be described in one way. No expense has been spared, only the best, the toughest, high temperature ceramic was chosen (gray material).
This product is made with the highest quality material that can withstand temperatures of up to 1400 ºC under continuous use and its’ fracture toughness is fantastic. The material is tested for thermal shock capability by heating it to 1100 ºC then dropping it into a pail of 20ºC water, without breakage. It has been said that no one has been able to thermal shock this material into breaking, i.e. it should be ideal for nitrous. The seals will be machined with 0.0055" overall clearance. Growth of the seal (13B) has been calculated at 420 ºC and is under 0.004". Remember it takes a lot more than 420 ºC to get the ceramic that hot. A second ceramic material (black material) is also offered. This is an automotive grade ceramic used to make intake/exhaust valves, ball bearings etc. This is an excellent material that is very tough and resistant to chipping. So far it has been tested at 15 Lbs boost with great success and I suspect it will handle a good deal more. Thermal shock testing for this material is somewhat lower at 600 ºC without breakage. Growth is somewhat less than the premium material at a given temperature.
Types that will be stocked are, 1 piece 3mm 13B, 2 piece 3mm 13B, 2 piece 2mm 13B and 2 piece 12A seals in both grey and black materials. Three-piece seals will not be made at this time.
The 13B seals have an overall length of 3.1445" +0.0005" -0.000". So there will be a clearance of 0.0055" (0.1mm) +0.0005" (0.0125mm) -0.000"/mm with respect to a dimensionally perfect housing (3.150”). Generally even new Rotor Housings are 0.001” to 0.0015” under the perfect dimension, therefore a housing that is 0.0015” under will still have 0.004” overall clearance (ample for high boost applications). The 12A seals have an overall length of 2.7525” +0.00” –0.0005”. Additional clearance is required for 12A turbocharged engines.
It is possible to customize seal lengths based on accurate measurements of the rotor housings, minimum thickness area. This will be somewhat more expensive due to additional set-up on a small quantity, however it is highly recommended when using large amounts of boost due to the increased heat.
Why ceramics?
Technology has advanced in leaps and bounds over the last 10-15 years. No longer is steel the strongest or first choice for today’s high tech applications. Advanced ceramics have made their way into many Aerospace, Oilfield and Automotive applications with astounding success and now they are available to you in the form of a “SUPER” Apex Seal. Stronger than steel, lighter than steel, less abrasive than steel, less friction, negligible wear, reduced rotating mass, housing friendly and almost unbreakable (save for detonation or engine failure). Is there any other choice?
Application:
Mild to wild, street to strip, when you want to go fast and you want your motor to last, ceramics is the only way to go. Whatever your Porting pleasure, Nitrous or Turbo Charging requirements, there are “NO RULES”, a seal is available for your application.
Similar ceramic seals have stood up to 40 Lbs + boost with a properly tuned engine.
GRAY MATERIAL BLACK MATERIAL
Aspirated- all applications Aspirated- all applications
Turbo- 40+ Lbs boost Turbo- up to 20 Lbs boost
Max Temp Use- 1400 ºC Max Temp Use- 1150 ºC
Thermal Shock Parameter- Thermal Shock Parameter-
1100 ºC 600 ºC
Fracture Toughness- Growth- slightly less than gray
25% higher than black material material
Process:
· Machined as non-aggressively as possible ensuring minimal damage to the ceramic seal surface.
· Machined with longitudinal striations (machining lines) where possible, maintaining maximum fracture toughness in all directions.
· Tested for fractural imperfections using a level 4 Fluorescent dye-penetrant (used in nuclear testing applications, see attached photos). Procedure in accordance with ASTM 165 liquid penetrant inspection method. AITEC quality assurance manual ISO 9002: 1994. Personnel qualified by independent examination to: Can/CGSB II 48.9712 2000, ISO 9712, which is equivalent to the American standard: ACCP, ASTN (American Society For Non-Destructive Testing) Central Certification Program. Microscope inspection follows if necessary.
· Upon completion of inspection are exposed to an oxidizing atmosphere, which oxidizes the surface resulting in increased strength by reducing stress incurred in machining. This process reduces sharp edges slightly and gives a super smooth surface with a cloudy or milky appearance rather than a glass like appearance.
Specifications
Length- (13B) 3.1445” +0.0005” –0.000”
(12A) 2.7525” +0.000” –0.0005”
Height- 0.0360” +0.000” -0.002” to outer spring step
Thickness- (3mm) 0.1155” +0.0005” -0.000”
(2mm) 0.0076” +0.0005” –0.000”
Weight- under 6 grams per piece (3mm 13B)
Outer spring length- stock 3mm 13B
Inner spring length- stock 12A or 13B cut to 12A length
2mm springs are 3mm springs modified to 2mm width
Custom spring kits will be available in the future
Pricing is in American Dollars and is as follows:
Premium (gray material) one-piece seals. Suggested Retail $1195.00 USD.
Premium (gray material) two-piece seals. Suggested Retail $1795.00USD.
Excellent (black material) one-piece seals. Suggested Retail $995.00 USD.
Excellent (black material) two-piece seals. Suggested Retail $1495.00USD.
Springs are not included in the above prices.
Ceramic Apex Seals
Here is some information for you on the ceramic apex seals that are being produced.
The quality of this material can only be described in one way. No expense has been spared, only the best, the toughest, high temperature ceramic was chosen (gray material).
This product is made with the highest quality material that can withstand temperatures of up to 1400 ºC under continuous use and its’ fracture toughness is fantastic. The material is tested for thermal shock capability by heating it to 1100 ºC then dropping it into a pail of 20ºC water, without breakage. It has been said that no one has been able to thermal shock this material into breaking, i.e. it should be ideal for nitrous. The seals will be machined with 0.0055" overall clearance. Growth of the seal (13B) has been calculated at 420 ºC and is under 0.004". Remember it takes a lot more than 420 ºC to get the ceramic that hot. A second ceramic material (black material) is also offered. This is an automotive grade ceramic used to make intake/exhaust valves, ball bearings etc. This is an excellent material that is very tough and resistant to chipping. So far it has been tested at 15 Lbs boost with great success and I suspect it will handle a good deal more. Thermal shock testing for this material is somewhat lower at 600 ºC without breakage. Growth is somewhat less than the premium material at a given temperature.
Types that will be stocked are, 1 piece 3mm 13B, 2 piece 3mm 13B, 2 piece 2mm 13B and 2 piece 12A seals in both grey and black materials. Three-piece seals will not be made at this time.
The 13B seals have an overall length of 3.1445" +0.0005" -0.000". So there will be a clearance of 0.0055" (0.1mm) +0.0005" (0.0125mm) -0.000"/mm with respect to a dimensionally perfect housing (3.150”). Generally even new Rotor Housings are 0.001” to 0.0015” under the perfect dimension, therefore a housing that is 0.0015” under will still have 0.004” overall clearance (ample for high boost applications). The 12A seals have an overall length of 2.7525” +0.00” –0.0005”. Additional clearance is required for 12A turbocharged engines.
It is possible to customize seal lengths based on accurate measurements of the rotor housings, minimum thickness area. This will be somewhat more expensive due to additional set-up on a small quantity, however it is highly recommended when using large amounts of boost due to the increased heat.
Why ceramics?
Technology has advanced in leaps and bounds over the last 10-15 years. No longer is steel the strongest or first choice for today’s high tech applications. Advanced ceramics have made their way into many Aerospace, Oilfield and Automotive applications with astounding success and now they are available to you in the form of a “SUPER” Apex Seal. Stronger than steel, lighter than steel, less abrasive than steel, less friction, negligible wear, reduced rotating mass, housing friendly and almost unbreakable (save for detonation or engine failure). Is there any other choice?
Application:
Mild to wild, street to strip, when you want to go fast and you want your motor to last, ceramics is the only way to go. Whatever your Porting pleasure, Nitrous or Turbo Charging requirements, there are “NO RULES”, a seal is available for your application.
Similar ceramic seals have stood up to 40 Lbs + boost with a properly tuned engine.
GRAY MATERIAL BLACK MATERIAL
Aspirated- all applications Aspirated- all applications
Turbo- 40+ Lbs boost Turbo- up to 20 Lbs boost
Max Temp Use- 1400 ºC Max Temp Use- 1150 ºC
Thermal Shock Parameter- Thermal Shock Parameter-
1100 ºC 600 ºC
Fracture Toughness- Growth- slightly less than gray
25% higher than black material material
Process:
· Machined as non-aggressively as possible ensuring minimal damage to the ceramic seal surface.
· Machined with longitudinal striations (machining lines) where possible, maintaining maximum fracture toughness in all directions.
· Tested for fractural imperfections using a level 4 Fluorescent dye-penetrant (used in nuclear testing applications, see attached photos). Procedure in accordance with ASTM 165 liquid penetrant inspection method. AITEC quality assurance manual ISO 9002: 1994. Personnel qualified by independent examination to: Can/CGSB II 48.9712 2000, ISO 9712, which is equivalent to the American standard: ACCP, ASTN (American Society For Non-Destructive Testing) Central Certification Program. Microscope inspection follows if necessary.
· Upon completion of inspection are exposed to an oxidizing atmosphere, which oxidizes the surface resulting in increased strength by reducing stress incurred in machining. This process reduces sharp edges slightly and gives a super smooth surface with a cloudy or milky appearance rather than a glass like appearance.
Specifications
Length- (13B) 3.1445” +0.0005” –0.000”
(12A) 2.7525” +0.000” –0.0005”
Height- 0.0360” +0.000” -0.002” to outer spring step
Thickness- (3mm) 0.1155” +0.0005” -0.000”
(2mm) 0.0076” +0.0005” –0.000”
Weight- under 6 grams per piece (3mm 13B)
Outer spring length- stock 3mm 13B
Inner spring length- stock 12A or 13B cut to 12A length
2mm springs are 3mm springs modified to 2mm width
Custom spring kits will be available in the future
Pricing is in American Dollars and is as follows:
Premium (gray material) one-piece seals. Suggested Retail $1195.00 USD.
Premium (gray material) two-piece seals. Suggested Retail $1795.00USD.
Excellent (black material) one-piece seals. Suggested Retail $995.00 USD.
Excellent (black material) two-piece seals. Suggested Retail $1495.00USD.
Springs are not included in the above prices.