Compression-Induced Deformation and Gas Permeability of Graphite Foil Under Stress Relaxation: Experimental Study and Modeling

Graphite foil is widely used as a sealing material in flange joints in the form of gaskets or gasket components. Predicting gasket permeability during stress relaxation remains challenging because both the compression state and the gas pressure affect leakage. No unified semi-empirical model based on the Darcy–Klinkenberg framework with compression pressure as a direct input has been available for use in flange-joint numerical simulations. Graphite foil gaskets with a density of about 1.0 g/cm3 and a thickness of ~1.5 mm were tested under compression pressures from 5 to 100 MPa. Helium leakage was measured at helium pressures from 0.5 to 8 MPa. Leakage and deformation during loading and unloading were recorded using EN 13555-based procedures. The results were analyzed using a Darcy–Klinkenberg formulation and equivalent slit- and capillary-based representations of the leakage channels. The second-order model reproduced the pressure-dependent leakage more accurately than the first-order Darcy approximation (R2 ≥ 0.9985 vs. 0.916–0.992), particularly where slip-flow effects were significant. Exponential dependences of the intrinsic permeability and the Klinkenberg coefficient on deformation and power-law relations with compression pressure are proposed to model leakage during unloading. The proposed semi-empirical model allows estimation of graphite-foil permeability under stress relaxation with the use of EN 13555 test procedures and its subsequent implementation in numerical simulations of flange joints. Limits of the model’s applicability, including loading regime, ranges of compression pressure, gas pressure and anisotropic nature of permeability, are discussed.