Experimental investigation of the influence of surface topographic parameters on fluid leakage through static metallic seals

Purpose The purpose of this paper is to monitor leakage in the static sealing interface, using three-dimensional and two-dimensional surface topography parameters as indicators. Design/methodology/approach This study involved developing a test rig for examining fluid leakage in metallic seals. Leakage of water through the interface of the metallic valve and valve seats was measured. The analysis focused on the combined effect of roughness, waviness and form error of metallic seal surfaces on leakage, with a detailed emphasis on the significance of form errors through harmonic analysis. Findings The findings suggest that three-dimensional or areal surface texture parameters have more predictive control over leakage compared to two-dimensional or profile parameters, as they provide information about micro-leak channels in all directions. Moreover, it was observed that average amplitude parameters of surface topography, particularly the form error of metallic valves, are strongly correlated with leakage values compared with the roughness and waviness of the contact surface. In addition, the leakage in metallic seals is profoundly influenced by lower-order harmonics, with a corresponding increase as the average undulation number of the flatness profile rises. Originality/value This research contributes to the understanding of the relationship between surface topography and sealing performance, particularly in metallic seals. By emphasizing the importance of form errors and using advanced surface texture analysis techniques, the study offers insights that can aid in optimizing the design and performance of static seals in industrial applications. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2024-0186/