Smart and Cost-Effective Material for Engine Head Cover Gasket

Different types of gaskets are being used in the engine. Each gasket plays a unique role for the application. In general gaskets are used to prevent leakage and fill the space between the mating surfaces under compression loads. Cylinder head cover gasket is being used in all engines. Engine gasket plays a major role in arresting and protecting the leakage of oil and external dust entry into the system. In this study new cost-effective material were identified, tested, and evaluated as per the applicable standards for the gasket application. The existing material is well known grade as VAMAC—ethylene acrylate monomer (AEM) material and the alternate material introduced is high temperature alkyl acrylate copolymer (HT ACM). In general, with AEM material have its own advantages and also challenges. Even though AEM material have some advantages with respect to temperature and mechanical properties the challenges and struggle come into picture on cost volatility and availability of raw material. The above reasons are always risks on the product and reputation. For the proposed material these challenges were taken care and addressed and also the material selected as per engine gasket application requirement. The proposed HT ACM material cost will be 40% lesser than the existing AEM material. Also with respect to supply chain there are multiple RM sources for proposed HT ACM material including M/s Zeon, M/s Unimactec, M/s OSAKA, and so forth. Both AEM and HT ACM materials underwent validation at both the material and assembly levels. This included testing their mechanical, physical, and thermal properties. For application-level testing, samples were assembled at the engine test bed to evaluate durability and endurance cycles. The results indicated that the HT ACM material met all the application requirements with respect to material and part level validation.