Metal Seal Performance & Optimization Laboratory

Bostec’s Force, Bake and UHV Lab is unique in the world, dedicated entirely to metal seal testing.  We have the ability to conduct force tests to 1 million pounds total load while simultaneously validating UHV performance with or without bake, and conduct wearability tests for glands and knife edges.  Where required, UHV tests may also be combined with external pressure to simulate real-world high pressure environments.

For c-seal replacement projects, we start with developing a force profile of your existing c-seals.  To  accomplish this, we produce a replica of your junction (gland) and run multiple crush cycles using your existing c-seals.  We use calibrated digital force testing equipment for measurements.  The empirical data produces a curve showing crush force vs compression from the unloaded state to full crush.

Based on that empirical force data, we produce XE replacement seals tuned to operate at higher or lower force values.  Most customers prefer lower forces and we can generally cut the crush force from 20% to 50% of your current loading.  The XE-Seals are a drop-in replacement of the c-seal you have been using, but the XE-Seals are 100% reliable.  Drop-in replacement means you do not need to change your existing gland.  The XE-Seal drops right in.

To validate your new XE seals, we can perform additional tests that include bake and helium leak testing to 2.5x10E-10 torr.  If required we can UHV test through the full room temperature to bake and to cool-down cycle.

For H-Seal projects, we conduct the same force, bake and UHV tests, but with the objective of reducing penetration forces by tuning the knife angle and penetration depth.

Force Testing

Offers several advantages beyond simply determining the compression force required for seal contact. Here are some additional benefits:

  1. Optimized Seal Performance: By precisely measuring the compression force required for full contact metal-to-metal gland closure, customers can ensure optimal seal performance. This helps prevent leaks and ensures reliable sealing over the lifespan of the seal.
  2. Enhanced Seal Lifespan: Force testing allows us to fine-tune the compression force of replacement seals to match or slightly reduce the force of the original c-seal. This optimization can help extend the lifespan of the flanges by minimizing wear and fatigue, ultimately reducing the frequency of replacements and associated maintenance costs.
  3. Improved Efficiency and Cost Savings: Reducing the compression force required for sealing not only minimizes the size and number of fasteners needed but also reduces the overall load on the sealing system. This can lead to cost savings in terms of material usage, assembly time, and maintenance expenses.
  4. Tailored Solutions for Specific Applications: Force testing enables customers to customize replacement seals to meet the specific requirements of their application. By fine-tuning the compression force, customers can address unique operating conditions, such as temperature variations, pressure fluctuations, or dynamic movements, to ensure optimal seal performance and reliability.
  5. Consistent Quality Assurance: Implementing force testing as part of the manufacturing process ensures consistent quality and performance of replacement seals. Customers can have confidence that each seal meets the specified compression force requirements, resulting in reliable and predictable sealing performance across their systems.
  6. Validation of Seal Design and Material Selection: Force testing provides valuable feedback on the effectiveness of seal design and the suitability of materials used in seal manufacturing. Customers can use this data to validate their design choices, identify areas for improvement, and make informed decisions for future seal procurement and development projects.
  7. Enhanced Customer Satisfaction: Ultimately, force testing helps to deliver seals that meet or exceed customer expectations for performance, reliability, and cost-effectiveness. By providing optimized sealing solutions tailored to their specific needs, customers experience fewer issues, reduced downtime, and greater overall satisfaction with their sealing systems.
Bostec Full Metal Seals Force Testing Laboratory
1. PRELIMINARY DESIGN
1. PRELIMINARY DESIGN
2. DEVELOP FORCE TESTING HARDWARE
2. DEVELOP FORCE TESTING HARDWARE
3. UHV TESTING
3. UHV TESTING
4. USABILITY TESTING
4. USABILITY TESTING
5. MODIFY DESIGNS BASED ON TESTING
5. MODIFY DESIGNS BASED ON TESTING
6. RE-TEST TO CONFIRM RESULTS
6. RE-TEST TO CONFIRM RESULTS

Force Testing – Bostec Testing Lab

Force capacity: 80,000# – 1,000,000#