In the world of sealing technology, one of the critical factors determining the performance and reliability of a gasket is its compression set. When gaskets are installed between two mating surfaces, they are subjected to compressive forces that create a tight seal to prevent fluid or gas leakage.

However, over time, these forces can cause the gasket material to undergo permanent deformation, known as compression set. This deformation affects the gasket's ability to "rebound" or return to its original thickness and shape once the compressive load is removed.

Impact of Compression Set on Sealing Efficiency and Gasket Longevity

If a gasket suffers from a high compression set, it may no longer apply adequate pressure against the flange surfaces, leading to potential leaks and system failures. Conversely, materials with a low compression set can maintain their resilience and sealing force, thereby extending the lifespan of the gasket.

This concept is vital to understand when selecting materials for critical applications where maintaining a consistent seal over long periods is essential. This is especially important for industries relying on tight, leak-proof seals, such as automotive, aerospace, chemical processing, and oil and gas.

Best Installation Practices to Minimise Compression Set

Proper Torque Application

Over-tightening can increase the compression set by excessively flattening the gasket. Using a torque wrench ensures even pressure and prevents damage. Utilise torque control systems to maintain the recommended compression, which helps reduce deformation.

Material Selection

Choose gasket materials that are designed for the specific operational environment. For example, fluoroelastomers (like Viton) have a low compression set and excellent resistance to chemicals and high temperatures, making them ideal for chemical processing applications.

Avoid Excessive Heat

High temperatures accelerate material ageing, increasing the compression set. Selecting gaskets rated for higher temperatures or using heat-resistant coatings can help mitigate this issue.

Use of Compression Limiters

These are unthreaded bushings that prevent the gasket from being over-compressed, thus minimising the risk of permanent deformation. They are often moulded into the gasket during manufacture or bonded in after.

Regular Inspection and Maintenance

Regular checks on gaskets in critical applications to monitor signs of compression set, such as visible flattening or hardness, can anticipate sealing failure and prevent costly downtime.

Factors like temperature, chemical exposure, and the duration of applied load all influence the extent of the compression set. By understanding how this property affects sealing efficiency and gasket longevity, manufacturers and engineers can make informed decisions about material selection, design, and installation practices to ensure optimal performance and reliability.

At Dobson Gaskets, our highly skilled team will be able to advise on the right material choice for your application, and best practices for installation to ensure optimal gasket performance and extend the life of your sealing solutions.