GASKET, SEALANT, O RINGS AND OIL SEALS

GASKET VS. O-RING: DIFFERENCES AND COMMON

APPLICATIONS
While gaskets and O-rings serve a similar purpose of sealing out air or liquid, the two are designed for
different situations and vary in appearance. Here, the team at Mercer Gasket & Shim will explain the
differences between these sealing solutions to help you determine the best one for your application.

What Are Gaskets and O-Rings?

askets are flat pieces of material used to make a seal between two flat surfaces, usually with a bolted
joint. O-rings are round, ring-shaped pieces that must set in a groove to create a seal between two
parts. While gaskets are most commonly circles, they are also manufactured in a variety of other shapes.
Both gaskets and O-rings are made using flexible materials, but gaskets can also be made out of other
rigid polymers and metals. The thickness of an O-ring can be customized to fit unique specifications,
while gaskets may be layered with different coatings to work best for various applications.

Common Applications for Gaskets

 Electrical motors, power generators, and transformers
 Electronics
 Handheld communication devices
 Telecommunications equipment
 Aerospace and defense industry
 Transportation and automotive
 Medical devices
 Food and beverage industry

Common Applications for O-Rings

 Hydraulic seals
 Pipe joints
 Equipment with fluid seal points
 HVAC – Heating, Ventilation, and Air Conditioning
 Oil seals
 Fuel systems
 Food processing
 Pharmaceutical and medical industry
 Pulp and paper industry
Everything You Need to Know About O-Rings
And Seals

How do O-ring seals work?

Whether sold individually, in large wholesale batches or - as is
increasingly common - as part of a highly flexible range of o-ring kits,
the basic form and role of o-rings are generally the same across the
board.

Their name, as implied, simply refers to a classic doughnut or torus

shape, and they exist purely to create a better, more leak-proof
seal between two other components, with the aim usually being to
prevent the unwanted escape of gases or liquids. In this sense,
they’re effectively a type of gasket - the main difference being that o-rings are more commonly used in
very high-pressure environments, where a normal cork, paper or rubber gasket would likely be prone to
failure.

In very basic terms, o-ring seals work by sitting in a groove or channel between two
surfaces/components that are going to be mated or pushed together. The o-ring, generally made of
some form of elastomer, sits in the join between these two parts, and becomes compressed in order to
help form a tight seal.

The more internal pressure is applied to this join, the more the o-ring is distorted inside its groove,
which can improve its overall sealing force up to a point - but beyond a certain pressure, or under more
dynamic workloads, this can cause failure of the seal. It’s important to get the balance right between o-
ring material, size and working environment in order to fulfil the role you need it to perform.

How to use O-ring seals

O-rings are very commonly found in pumps, cylinders, connectors and valves, helping to seal joins
between separate parts and prevent leaking of fluids and gases. They’re used with static, dynamic,
hydraulic and pneumatic components, making them an especially versatile solution to a very widespread
engineering issue.

As noted above, you’d use an o-ring very similarly to the way you’d use any other type of gasket: the
elastomer-based circular cross-section sits in a specially engineered groove (the geometry of which is
fairly universal), where it becomes compressed between two or more parts once they’re assembled and
interlocked. The resulting o-ring seal is both economical and reliable, as well as relatively resilient and
easy to maintain/replace when needed.
One of the key strengths of an O-ring-type seal is that after the parts it joins are disconnected and the
compression forces acting on it are removed, it will return to its original shape. Over time, repeating this
process will start to have an effect on the resilience and uniformity of the materials and the torus shape
of the seal, and ultimately the o-ring will need swapping out for a new one if the seal is to remain tight.

Under pressure, the o-ring will shift in its groove towards the lower-pressure side of the seal, forcing it
more and more tightly against the inner and outer walls of the gland created between two components.
Up to a point, this will create a tighter and tighter seal, but it’s vital not to put more stress on an o-ring
than it’s designed to handle, as too much deformation will eventually cause the seal to start leaking
again.

What is the difference between static and dynamic O-ring

seals?
Static and dynamic O-ring seal design differs in a few key ways. A static O-ring is any o-ring designed to
contact with two or more surfaces that do not move relative to one another, whereas a dynamic O-ring
is one that helps form a seal between moving parts.

On the whole, static o-rings are created from less robust and hard-wearing materials than their dynamic
equivalents. It’s also important that the components being joined together in a dynamic environment
are carefully designed and finished, such that they will not abrade, shear and eventually destroy the O-
ring positioned between them. This is less of a concern for o-rings used in static applications, as the only
stress force they’ll be under is usually compression (to which they tend to be fairly resilient).

While all o-rings require some degree of lubrication in order to perform to optimal levels, dynamic o-
rings require heavier and more frequent lubrication (as well as more regular checking, maintenance and
replacement) than static versions. Different types of dynamic movements - for example, rotary,
reciprocating and oscillating - demand that o-rings be manufactured with different material qualities to
perform to the optimal level.

What are O-ring seals used for?

In this section, we’ll look a little more closely at what o-rings do, and some of the applications that
they’re very often used for.

O-rings for high-temperature sealing

High-temperature sealing o-rings are, as the name implies, designed to
withstand extreme heat while continuing to provide a reliable seal between two
surfaces or components.
 This makes them ideal for demanding industries and environments such as oil
and gas refineries, chemical processing, or any other scenario where a high-temperature
seal is required, such as performance transport applications like turbo engines and
aerospace engineering.

Best O-ring seal materials for high temperatures

There are a number of popular high-temperature o-ring material choices,
including nitrile, hydrogenated nitrile, silicone rubber, polyacrylate and more. Securing
the best choice in any given scenario will generally be a balancing act between the
specific operating temperature needed, and the most economical material option at
that performance point.

For more detail on all types of O-ring materials and designated temperature
ranges, feel free to contact our expert support team any time - they’ll be glad to offer
further advice and assistance on specific high-temperature seals, materials and
applications.

O-ring seal temperature ranges

Again, all industrial o-ring purchases should be carefully planned with direct
reference to the specific role and environment the seal is required to perform in.
However, as a rough guide to o-ring temperature rating and use limits, some of the
more popular materials on sale generally operate within the following sorts of
temperature ranges:

 Nitrile: anywhere from -50 C to 120 C

 Hydrogenated nitrile: anywhere from -45 C to 150 C
 Polyacrylate: anywhere from -25 C to 175 C
 Ethylene-propylene: anywhere from -50 C to 135 C
 Chloroprene: anywhere from -40 C to 120 C
 Butyl (petroleum compound): anywhere from -55 C to 205 C
 Fluorosilicone: anywhere from -60 C to 205 C
 Fluorocarbon: anywhere from -25 C to 205 C

O-rings for high-pressure sealing

High-pressure resistance is a common requirement of industrial o-rings, along with
reliable performance in high temperature and dynamic environments. For a high-pressure seal
to work to optimal levels, o-ring design and manufacture again depends on choosing specific
materials for better performance under specific conditions.
 O-rings function on the principle that even pressure placed on the (more or less
incompressible) o-ring material creates predictable deformation patterns around the perimeter
of the gasket in its groove. This means there’s a fairly uniform mechanical stress placed on all
contacting surfaces of an o-ring.

Provided the internal pressure from fluids being contained stays below a given O-ring's
contact stress rating, it’s largely impossible for leaks to occur, even under high pressure.
However, mechanical failure under high pressure can easily cause extrusion or destruction of
the o-ring, which is why it’s important to choose the right material for the precise environment
you’re looking to use it in.

O-ring seals for engines

An engine o-ring, especially one used in high performance or turbo engines, is a good
example of a product that has to be rugged enough in design and material construction to
handle various challenging requirements of temperature, pressure and chemical compatibility.

Many basic rubbers and polymers aren’t suitable for use with oils, fuels or solvent-based
compounds. For use in an engine, an oil o-ring has to be created specifically from compatible
hybrid materials that allow it to maintain crucial o-ring properties (flexibility, incompressibility)
while offering more robust resistance to heat, pressure, o-ring leaking and chemical attack than
a standard elastomer typically could.

For more advice and information on suitable products to use as engine o-rings, feel free
to contact our customer service team through the support pages on our site.

O-ring seals for plumbers

Plumbing o-ring choices are widespread, given the range of materials, sizes and gauges
available for use in ducting and pipework applications, as well as to form tight waterproof seals
around taps and other fittings. Choosing the best product for the job depends on finding the
correct size and shape for the specific role you have in mind.

Food Grade O-ring seals

Food-grade o-rings have been manufactured to more exacting standards of material
composition, such that they’ve been officially declared ‘food safe’ for use in the production and
preparation of meals, beverages and dining products.

Best food grade O-ring seal materials

An approved food-grade o-ring must only consist of the material(s) declared and
approved as food safety compliant in the country of manufacture/sale. In the UK, this applies to
natural and synthetic rubbers, elastomers and polymers.
 To achieve food grade approval, an o-ring manufacturer must also take into account
extractable ingredients/compounds if the seal is to be used in direct contact with aqueous,
acidic or fatty foods and drinks. Some common food-safe o-ring materials include EPDM,
fluorocarbon, nitrile, neoprene and silicone.

O-ring seals for CO2

Carbon dioxide often presents an issue for many types of o-rings, as softer materials
have a tendency to absorb the gas over time and swell up. This can lead to an unreliable seal in
the short term, and over time the CO2 will actually cause the o-ring to start to break down from
within.

Some popular choices for use in applications where the o-ring will have extended CO2
contact include polyurethane, PTFE, nitrile, and fluoroelastomers. However, the best choice will
always depend on the consideration of other environmental or application factors.

O-ring seals for aircrafts

Aircraft o-rings and aerospace o-rings generally need to be highly chemically resistant,
and able to operate within a wide range of temperatures and pressures in order to keep an
aerospace craft’s powertrain running cleanly, efficiently and smoothly. Typical applications
include fuel cap gaskets, fuel system o-rings, and valve cover seals.

Common elastomers for use in aerospace-type applications include nitriles, ethylene-

propylene, fluorosilicones and more. Because there are so many different sizes and gauges of o-
ring distributed throughout most aircraft engines and systems, most sales for aerospace and
aeronautics are through bulk orders of multi-size o-ring kits.

Different O-ring seal materials

As we’ve seen in some of the above sections, there are many different o-ring materials
in widespread use, and picking the right sort for the precise task in question is very important if
you want it to perform reliably over time. In this section, we’ll take a quick look at the various
different o-ring material types.
Viton® O-ring seals

Viton® o-rings are a popular alternative to the widely-used nitrile seals. O-ring kits from Viton®
suppliers are actually made from fluorocarbon rubber, making them excellent for withstanding higher
temperatures and offering stronger chemical resistance (petroleum oils, acids, silicone fluids and
gases) than most basic nitrile o-rings can cope with.
Viton® O-ring seal temperature range
In general, depending on a number of factors including grade of o-ring and precise application, the
Viton® seal working temperature range is held to be between -26 C and +205 C, although they can
withstand higher temperatures for short periods.

Nitrile O-ring seals

Nitrile o-rings are a popular type of rubber seal gasket that’s used in a wide range of applications and
environments - they’re broadly seen as a general-purpose o-ring type, with reasonably resistant
sealing properties against water, gasoline, petroleum oils, crude oil, propane and some hydraulic
fluids.
Nitrile rubber o-rings are a tough and fairly robust type of seal that holds up well in physically
demanding roles. Phosphate ester hydraulic fluids, brake fluids and halogenated hydrocarbons are
damaging to nitrile, and it’s not the best choice for high temperature or pressure demands

Nitrile O-ring seal temperature range

The nitrile o-ring temperature range is usually anywhere from -50 C to 120 C
Rubber O-ring seals

Rubber o-rings are perhaps the most common type, serving an enormous array of purposes and
functions in less specific or demanding applications than some of the higher-tech variants seen in
heavy industrial environments.
O-ring rubber seals are available in a very wide range of gasket and o-ring types, including natural
rubber as well as a large array of other elastomer and compound products.

Silicone O-ring seals

Silicone o-rings are very much a gasket/sealant industry standard today. Silicone rubber compounds
typically offer very good resistance to ozone, acids, water, and decent resistance to weathering and
heat, making them great for outdoor applications. They offer little shear resistance or tensile
strength, although silicone seals made from compound grades with much better tear resistance than
standard silicones are often offered by manufacturers.
Standard silicone o-ring temperature range is generally quite wide, from very low to reasonably high.
Typical operating ratings on most UK silicone o-ring kits and products run anywhere from about -50 c
to 200 c.

Fluorocarbon elastomer O-ring seals

Fluorocarbon o-rings are a subgroup of elastomer seals usually known as Viton®, as detailed in a
separate section above. They offer good resistance to high temperatures (up to 210 C), but are prone
to failure below -15 C in dynamic applications when they tend to become too stiff and inflexible.
Resistance to petroleum oils, acids, silicone fluids is good, and Viton® is highly resistant to oxidation,
UV damage, fungus, ozone, oils, and petroleum-based lubricants.
Metal O-ring seals

Metallic o-rings and metal o-ring seals are often found where an extra hard-wearing gasket is
required in high temperature or high-pressure components, in heavy machinery and industrial
sectors. As such, they’re considered an ‘extreme’ performance o-ring sealing solution, designed to
offer optimal reliability under, especially tough conditions.

Stainless steel O-ring seals

Metal O-rings are typically created from tubing, which very often contains stainless steel. They’re
commonly used due to the inherent resilience of stainless steel o-rings, which means seals can spring
back promptly once pressure is reduced. They provide excellent and robust sealing properties in
static applications but are often unsuitable for dynamic environments; metal o-rings are best when
used as standard gaskets.

NBR O-ring seals

Nitrile - also known as NBR - is probably the most widely used elastomer in the seal industry at the
time of writing. NBR o-ring kits and NBR seals are found in a staggering number of applications.
Finding the correct nitrile o-ring for the job will depend on getting the right grade to stand up to the
task at hand.
When an o-ring compound contains the standard 32% nitrile content, it is said to be made from
‘medium nitrile’. At 50% or more it becomes a ‘high nitrile’ product, intended for use in hydrocarbon
applications, while below 18% is considered ‘low nitrile’ for use in very low-temperature systems.
 NBR 70 O-ring seals

NBR 70 o-rings are ideal for uses where oil resistance and low-temperature functionality are required
- as such, they’re often found in military applications and automotive or aircraft fuel systems. NBR 70
o-rings are also suitable for food-grade use once compounded appropriately.

NBR O-ring seal temperature range

Working NBR o-ring temperature range is anywhere from about -35 c to 120 c.

Buna-N O-ring seals 

Like NBR, Buna-N o-rings are also nitrile products. Like their fellow elastomers, they’re widely used in
many industries where they’re prized for excellent abrasion and tear resistance, suitability for use
with some solvents, and for being considerably cheaper than fluoroelastomers.
Potential drawbacks of NBR, Buna-N and other nitrile o-rings include limited ability to withstand
particularly high temperatures, and weaker ozone, UV and weather resistance than many other o-
ring types.

WHAT IS A GASKET IN A CAR?

From the front to back bumpers, your vehicle features hundreds of parts, both large and small. It takes
all these parts to make your car run smoothly on the road. Gaskets are one of those small parts that you
might not give much thought to.

Automotive gaskets are sealing and cushioning material, frequently placed between two surfaces joined
by bolts. Mechanics commonly replace a gasket when performing major work on the engine. In order to
better understand what automotive gaskets are and how they function, we’ll examine two major
components of the internal combustion engine: the engine block and cylinder head.
ENGINE BLOCK WITH CRANKCASE – THE BOTTOM OF AN ENGINE

An internal combustion engine begins as a single block of aluminum, iron or alloy (a mixture of the main
metal and other metals or non-metals). Cylindrical combustion chambers or cylinders occupy the top of
the block and lead to a well or crankcase in the lower part of the block. The cylinders house pistons that
provide compression during the combustion process. The crankcase derives its name because it contains
the crankshaft.

• Four cylinder engines have four cylinders centered in the engine, evenly spaced front to back.

• Six cylinders can be arranged as an inline six cylinder engine or positioned in a V-shape with three
cylinders on the right and three on the left.

• Eight cylinders are aligned right and left and are commonly referred to as a V-8.
CRANKSHAFT

The crankshaft is a steel bar with four, six or eight uniformly U-shaped counterweights and lobes or
journals spaced equally from front to back. Piston assemblies, smaller cylinder-shaped blocks connected
to rods at movable wrists, connect to the crankshaft at the crankshaft journals. This is where the circular
motion of the crankshaft is transformed into the up and down strokes of the piston. The front of the
crankshaft is connected to the camshaft (located in the cylinder head) by way of gears, timing chains,
and timing belts. 
PISTONS

Piston assemblies are manufactured from aluminum, iron or alloy. They are fitted with rings that act as
guides as each piston rides up and down the inside of a cylinder. The size of the cylinders and the fitness
of the pistons translate into horsepower or energy output.

OIL PAN GASKET

When the engine is running, oil flows through by way of oil ports; the oil lubricates all the moving parts
inside the engine. The oil is held in the oil pan, which is bolted to the bottom of the crankcase. The oil
pan gasket sits between the oil pan and the crankcase providing a cushion and a seal.

The oil pan gasket is made from durable materials such as aluminized steel coated in rubber or a rubber
compound. The seal compensates for expansion and contraction caused by changes in heat. The cushion
prevents wear and tear during vibrations.
CYLINDER HEAD AND VALVE COVER – THE TOP OF AN ENGINE

The cylinder head is cast in much the same way as the engine block. It contains the camshaft and valves
that provide air-mixed fuel to the cylinders, valves that allow exhaust to escape, and spark plugs that
ignite the fuel in the cylinders at the peak of compression. Air-mixed fuel, spark and compression are the
three fundamentals of the internal combustion engine.

The cylinder head or heads (in a V-shaped engine) are bolted to the top of the engine block. The
camshaft, lifters, springs and rocker arms are bathed in engine oil. In order to contain the oil, a
removable valve cover ‌manufactured from considerably thinner aluminum, steel or alloy is bolted on
top of the head.

 
HEAD GASKET AND VALVE COVER GASKET 

Like the oil pan, the head and valve covers are removable and require gaskets to seal properly. Much
like the oil pan gasket, the valve cover gasket is a relatively thin one-piece gasket that lines the outer
edges of the valve cover where it meets the cylinder head.

The head gasket not only lines the outer edge of the head, but also lines areas in between the cylinders,
around coolant and oil ports, bolts and guide pins. Like the oil pan gasket, the valve cover and head
gaskets are made from a variety of durable materials such as steel, stainless steel, or aluminized steel
coated in rubber or some form of rubber compound.
What Is Engine Sealing?

What is engine sealing?

The engine gasket is a key component. It contributes to an efficient, safe and cost-effective engine
running. Gaskets are highly technical and complex engine components. They are used in many different
forms and material compositions in modern combustion engines and assemblies. Professional engine
sealing is a good way to ensure that your engine components are staying in tip-top shape for many
kilometers to come. Your car’s head gasket is an important part of the engine. It seals the cylinder head
to the engine block. The cylinder head houses the engine valves while the engine block contains the
crankshaft and pistons. Over time, head gaskets can start to leak. These leaks vary in terms of severity,
and while a minor leak may simply increase oil or coolant consumption, a more severe leak or blown
head gasket can cause complete loss of compression. It can also cause your cooling system to fail and
make your car’s engine overheat. At Pfaff Tuning in Vaughan, ON, we can take care of your engine
sealing and resealing needs. Keep your engine and all its components in the best shape possible with
Pfaff Tuning! 

It is important to know how the head gasket works if you are opting for engine sealing or resealing
services. Below, we have included some facts about the head gasket part of the engine makeup.
Function 
The primary task of gaskets is to seal off the various media in the engine including gases, water, and oil
from both one another and the outside world. However, gaskets also function as power transmission
links. For example, the cylinder head gasket between the engine block and the cylinder head has a
significant impact on power distribution within the entire tensioning system and the resulting
component deformations.

Engine seal damage 

Drivers usually only notice components of the engine sealing system that they cannot see in the event of
a leak. However, in such cases, the failure of the seal is not the cause of the leak. In most cases, it is
damage to surrounding components that exposes the sealing element to excess stress and strain. The
engine overheating, for example, can trigger a gasket fault.

Safety 
Gaskets that are in perfect working order are a contributing factor in vehicle safety. They stop hot gases
escaping and getting into the engine and passenger compartment, for example.

Engine depreciation
To prevent damage to the engine and maximize service life, it is important that no functional failures
occur in or around gaskets and appropriate measures are taken to avoid damage to gaskets. If
irregularities are identified in various engine operating states, appropriate action should be taken
immediately.

Protection of the environment 

A sealing system in perfect working order prevents operating fluids such as fuels, transmission oils or
lubricating oils from escaping and being released into the environment. Innovative technologies and
sophisticated product solutions are ensuring efficient, safe and cost-effective engine running.

Engine sealing and resealing is an often overlooked but very important maintenance process. If you are
wanting to ensure the health of your vehicle engine for the long term, and the health of the
environment, then professional engine sealing and resealing services are very beneficial, and quite
frankly, crucial. For more information about what engine sealing is, feel free to contact our Pfaff Tuning
representatives today.