Effect of Surface Characteristics on Contact and Leakage in Sealed Joints with Metal Gaskets: A Review

Abstract

Highlights Surface characteristics strongly affect the sealing performance of joints with metal gaskets. Reliable prediction of leakage at sealing interfaces requires coupled contact and microgap flow descriptions. Surface engineering and manufacturing-process optimization can improve sealing performance. Abstract The article presents a review of the current state of knowledge on the effect of surface characteristics on contact conditions and leakage in sealed joints with metal gaskets. The sealing mechanism is discussed, in which joint tightness is governed primarily by the deformation of microscale surface irregularities, the increase in the real contact area, and the disruption of the continuity of microgaps forming flow channels. Particular attention is given to the influence of contact geometry and surface topography on the leakage rate. The paper summarizes selected experimental studies on metal gaskets and discusses approaches to modeling the contact of rough surfaces and leakage at their interface. Taken together, the reviewed evidence indicates that reliable prediction of tightness requires simultaneous consideration of contact mechanics, material properties, loading conditions, and the surface geometric structure. The review identifies promising directions for the further development of contact and leakage models. The importance of modeling and the deliberate design of sealing and mating surfaces for improving joint tightness and reducing fluid losses and fugitive emissions is also highlighted.