Component:
Manifold - Stainless Steel
Product:
Cross Hole
Case Number:
1002
Problem:
The SAE J514 plugs have been known to back out in cross hole applications. The resulting leaks could not be tolerated in this aerospace application.
Use Description
The power unit manifolds were used to operate an actuator for a critical aerospace application.
Solution
The aerospace agency reviewed the performance characteristics of Zero-Leak Gold plugs and specified that the -20 socket ZLGP be used in the power unit manifolds.
Results
The ZLGP were tested on the new project and they did not back out or leak.
Post-Script
62631
Component:
Manifold - Hydraulic
Product:
Power Unit
Case Number:
1003
Problem:
A manifold producer to the aerospace industry had discovered that the old-style, O-ring only, ORB plugs were backing out of aluminum manifolds and causing leaks.
Use Description
The aluminum manifold was a component of a power unit used to drive an actuator attached to a launch vehicle.
Solution
The manifold producer specified in their prints that a -20 socket head Zero-Leak Gold plug be used in any future applications for the same unit.
Results
The aerospace facility installed the -20 socket head ZLGP in their manifold. No leaks or backing out of plugs were reported in their application, which had pressures as high as 10,000 psi.
Post-Script
62631
Component:
Manifold
Product:
Case Number:
1004
Problem:
In the nickel-plated manifolds being supplied to NASA, it was determined that the ports containing plugs had to be re-tapped. If the ports were machined in the usual manner, they would have to have a new spot face, which would require nickel plating.
Use Description
Nickel-plated manifolds that were used in a particular NASA application required some degree of modification to existing ports.
Solution
NASA personnel accepted their manifold supplier's advice and specified -06 and -08 Zero-Leak Gold socket head plugs for use in the nickel-plated manifold. The ports were tapped, and no new spot face was required because the ZLG plug does not rely on the spot face for either of its two seals. Both of the ZLGP seals are internal to the port. The first is the metal-to-metal seal formed by the engagement of the complimentary tapers below the head of the plug and the taper at the entrance to the port. The second seal is the elastomeric seal located under the taper of the plug.
Results
The installation of the ZLGP avoided damaging the nickel plating by eliminating the necessity of machining the spot face. The ZLGP provided zero-leak protection for the manifold. Both points resulted in cost savings for all involved.
Post-Script
It is interesting to note that no special certifications were required of EPCO in order for the ZLGP to be used in this application. This may be due to the fact that the standard old-style, O-ring only, straight-thread SAE plugs have some type of certifications, and when their performance characteristics were compared to the documented* performance of ZLGP it became a "no brainer."
*Fluid Power Institute Test conducted at the Milwaukee School of Engineering.
62381
Component:
Filter - Hydraulic
Product:
Filter - Housing
Case Number:
1014
Problem:
The old style, O-ring only, SAE plugs were observed backing out of test stands used on a previous project. Engineering was concerned about using these types of plugs in a new product. They wanted it to be "as perfect as possible."
Use Description
The hydraulic filter is used on mobile fluid carts and fluid power generation. It is extremely important that any potential leakage is eliminated in products that are used in airfield related equipment.
Solution
The -04 hex head Zero-Leak Gold plugs were installed as drain / fill plugs in the filter housings, which in turn were sent to an internationally recognized, independent testing organization for a 1,000,000 cycle test.
Results
The Zero-Leak Gold plugs completed the one-millionth test with no reported leaks. The old style, O-ring only, SAE plugs were also evaluated, and it was reported that they began 'seeping' at 600,000 cycles. The ZLGP were also subjected to burst tests at 15,000 psi with no reported leaks.
Post-Script
The ZLGP became part of the new hydraulic filter design, which was introduced in the market place. Another model filter is planned, and it will utilize ZLGP. 62441