Hydraulic and pneumatic components and systems are often cross-drilled to provide the correct channels for air and gas. Some of these channels have to be drilled from the outside and later need to be closed off (plugged).
The expansions sealing plugs are inserted into a drilled hole and the expander ball is driven into the plug sleeve. The independent grooved sealing rings on the plug ball are driven into the housing material to permanently plug and seal the hole. The ball is retained in place.
No need for tapping or reaming, no machining of O ring grooves or the use of tapes or sealants.
Refer to the data sheet for the correct hole size to drill for the counterbored and drilled holesize and tolerance. Hole concentricity must be held within 0,05mm.
Bore roughness muct be between Rz (RMS) 10-30µ (especially for hard materials).
Avoid spiral or longitudinal grooves as these may affect plug performace. Ensure the holes are clean and dirt free.
Insert the plug into the counterbored hole with the ball facing outwards, seared against the counterbore shoulder.
Press the ball into the sleeve so that the top of the ball is slightly below the top of the sleeve (note approimate values for x and s in table below):
Use the correct installation tool for each plug size. The plugs can be installed using a hammer and the installation tool. An air hammer with the correct air installation tool can also be used.
d1 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 12 | 14 | 16 | 18 | 20 | 22 |
Stoke - S | 1,2 | 1,5 | 2,0 | 2,5 | 3,0 | 3,5 | 4,0 | 4,5 | 5,5 | 6,35 | 7,0 | 8,0 | 9,0 | 10,0 |
Top of ball relative to top of sleeve - x ±0.2 | 0,4 | 0,2 | 0,4 | 0,4 | 0,4 | 0,3 | 0,4 | 0,4 | 0,4 | 0,4 | 0,6 | 0,6 | 0,8 | 0,8 |
Some of the typical applications for our sealing screws include:
"Standard" Expansion sealing plugs - push the ball which expands the sleeve and seals the channel
"Pull" Expansionsealing plugs. Pulling on the mandrel expands the sleeve, sealingthe channel. At a predetermined force the mandrel breaks off.
The radial expansion of the plug causes the housing material around the plug to deform plastically. Therefore a proper minimum wall thickness or distance from an edge is necessary to optimise the strength of the mechanical connection. The operating hydraulic pressure, thermal cycling, plug type and characteristics of the base metal also need to be considered - Please consult our technical department.
The guidelines for minimum wall thickness or distance from the edge (Wmin) are shown below - These minium values produce only a very slight deformation on the exterior profile (less than 20 microns).
Sealing Plug Type | Base MetalSteel (SAE 1144) | Base MetalSteel (SAE 10L15) | Base MetalCast Iron (ASTM A48) | Base MetalDuctile Iron (ASTM A356) | Base MetalAluminium (2024-T4) | Base MetalAluminium (6061-T6) | Base MetalCast Aluminium (356-T6) |
Sealing Plug Type | Factor fminSteel (SAE 1144) | Factor fminSteel (SAE 10L15) | Factor fminCast Iron (ASTM A48) | Factor fminDuctile Iron (ASTM A356) | Factor fminAluminium (2024-T4) | Factor fminAluminium (6061-T6) | Factor fminCast Aluminium (356-T6) |
Steel Body | 0,5 | 0,6 | 1,0 | 0,6 | 0,6 | 1,0 | 1,0 |
Stainless body | 0,6 | 0,8 | 1,0 | 0,8 | 0,8 | 1,0 | 1,0 |
Pull plugs | 0,5 | 0,6 | 1,0 | 0,6 | 0,6 | 1,0 | 1,0 |
The values offered are to be used as a guideline. The base metal chosen for your specific application, the surface treatment, hole size and surface finish all affect the seal performance. Please contact our Technical Department for more information.
Steel (Case-hardened) Plug BodyØ 3-10 | Steel (Case-hardened) Plug BodyØ 12-32 | |
Steel (SAE 1144) | 350 bar working pressure 1,100 bar proof pressure | 380 bar working pressure 900 bar proof pressure |
Steel (SAE 10L15) | 350 bar working pressure 1,100 bar proof pressure | 380 bar working pressure 900 bar proof pressure |
Cast Iron (ASTM A48) | 350 bar working pressure 1,100 bar proof pressure | 380 bar working pressure 900 bar proof pressure |
Ductile Iron (ASTM A356) | 350 bar working pressure 1,100 bar proof pressure | 380 bar working pressure 900 bar proof pressure |
Aluminium (2024-T4) | 350 bar working pressure 1,100 bar proof pressure | 380 bar working pressure 900 bar proof pressure |
Aluminium (6061-T6) | 310 bar working pressure 1,000 bar proof pressure | 240 bar working pressure 800 bar proof pressure |
Cast Aluminium (356-T6) | 310 bar working pressure 1,000 bar proof pressure | 240 bar working pressure 800 bar proof pressure |
Stainless Steel (300 Series) Plug BodyØ 3-10 | Stainless Steel (300 Series) Plug BodyØ 12-32 | |
Steel (SAE 1144) | 450 bar working pressure 1,300 bar proof pressure | 450 bar working pressure 1,100 bar proof pressure |
Steel (SAE 10L15) | 450 bar working pressure 1,300 bar proof pressure | 450 bar working pressure 1,100 bar proof pressure |
Cast Iron (ASTM A48) | 450 bar working pressure 1,300 bar proof pressure | 450 bar working pressure 1,100 bar proof pressure |
Ductile Iron (ASTM A356) | 450 bar working pressure 1,300 bar proof pressure | 450 bar working pressure 1,100 bar proof pressure |
Aluminium (2024-T4) | 450 bar working pressure 1,300 bar proof pressure | 450 bar working pressure 1,100 bar proof pressure |
Aluminium (6061-T6) | 380 bar working pressure 1,200 bar proof pressure | 280 bar working pressure 900 bar proof pressure |
Cast Aluminium (356-T6) | 380 bar working pressure 1,200 bar proof pressure | 280 bar working pressure 900 bar proof pressure |
Aluminium (2024-T4) Plug BodyØ 3-10 | Aluminium (2024-T4) Plug BodyØ 12-32 | |
Steel (SAE 1144) | 450 bar working pressure 1,300 bar proof pressure | 350 bar working pressure 1,100 bar proof pressure |
Steel (SAE 10L15) | 450 bar working pressure 1,300 bar proof pressure | 350 bar working pressure 1,100 bar proof pressure |
Cast Iron (ASTM A48) | 450 bar working pressure 1,300 bar proof pressure | 350 bar working pressure 1,100 bar proof pressure |
Ductile Iron (ASTM A356) | 450 bar working pressure 1,300 bar proof pressure | 350 bar working pressure 1,100 bar proof pressure |
Aluminium (2024-T4) | 450 bar working pressure 1,300 bar proof pressure | 350 bar working pressure 1,100 bar proof pressure |
Aluminium (6061-T6) | 380 bar working pressure 1,200 bar proof pressure | 280 bar working pressure 900 bar proof pressure |
Cast Aluminium (356-T6) | 380 bar working pressure 1,200 bar proof pressure | 280 bar working pressure 900 bar proof pressure |
Alexia House
Glenmore Business Park
Portfield Works
Chichester, PO19 7BJ (UK)
Telephone 0333 207 4498
or + 44 (0) 1483 266 774
Email sales@automotioncomponents.co.uk
Company registration no.2761902
Company VAT number GB 408154022
For other bank details visit our FAQs page.