Session: Poster Session

Paper Number: 162611

Exploring E-Ring Sealing Performance in Aerospace Duct Systems 

E-rings are critical sealing components in high-temperature pneumatic duct systems within aircraft, particularly in turbine engine bleed air ducting joints. Typically made of resilient metal, these seals have been designed to minimize leakage and contribute to the safety and efficiency of aerospace and industrial applications. The AS1895 standard establishes seal performance and acceptance criteria, including a maximum allowable leak rate of 0.01 SCFM per inch of shaft diameter. This performance requirement underscores the need to evaluate and analyze E-ring performance under various compression levels to better determine when replacement may be required due to joint degradation. Although prior research and product qualification have examined the E-ring’s fatigue resistance, it has not coupled fatigue testing with leak testing and compression variation, leaving the correlation between these factors largely unknown.

This study investigates the sealing performance of AS1895 E-rings, assessing their ability to maintain qualified leak rates under operational conditions. This research aims to deepen the understanding of how compression conditions affect seal functionality and identify key factors influencing their sealing effectiveness. Leak rate testing followed SAE AS1895 testing specifications, systematically measuring seal performance at multiple compression levels. The experiment involved repeatedly compressing the seal using a hydraulic press, with the compression being controlled by four hard stop limiters set at different heights. Once compressed, the seals were internally pressurized with nitrogen to 400 psi, and the resulting leak rate was measured using a nitrogen flow rate meter.

The findings show that all tested Technetics Group designed AS1895 E-ring seals remain within the maximum allowable leak rate requirements, even at lower compression heights. A comparative analysis with alternative seals offers further insight into E-ring seal performance, revealing that slight design variations impact leak rate outcomes. Cross-sectional imaging of the seals provided key insights into why Technetics Group seals met leak rate criteria with less compression, when other available seals failed. Additionally, material fatigue effects became increasingly apparent as cyclic testing progressed, with leak rates demonstrating a consistent correlation with fatigue-related material changes. These findings offer valuable insights into the functional behavior of E-ring seals and the science behind their performance, emphasizing their suitability for aerospace applications requiring high sealing performance and in-application reliability.

Presenting Author: Aaron Cecil Technetics Group

Presenting Author Biography: As an undergraduate Mechanical Engineering student at Clemson University, I am driven by a passion for learning and a desire to contribute to the advancement of the aerospace industry. My current co-op at Technetics Group provides valuable hands-on experience, allowing me to apply my academic knowledge and develop my engineering skills. I plan to pursue a Ph.D. at Clemson to deepen my research and contribute to advancements in aerospace engineering, particularly in droplet combustion.

Authors:

Aaron Cecil Technetics Group
Stefan Roeseler Technetics Group
Ryan Plessinger Technetics Group
Jonathan Kweder Technetics Group