FUJIFILM LETS YOU SEE THE PRESSURE!

Fel-Pro engineers use many testing procedures when validating gasket designs at the Fel-Pro engineering, manufacturing and distribution center in Skokie, Illinois. One validation test performed includes a pressure-sensitive film made by Fujifilm, which allows us to visualize the distribution and sealing pressure created by gaskets. This impression test is a window inside the internal structure of a cylinder head and block combination, which is critical in the design phase of a gasket.

 

The film is impregnated with microscopic cells filled with red dye. When pressure is applied to the film, these cells burst. The higher the pressure, the more intense the color left behind. The sheets can be placed on the top, bottom, or both sides of a gasket. The imprint left behind on the film after a test is performed allows our engineers to see where the gasket loading is good, and areas that need attention. Using a unique software and scanner setup, the film is scanned, and the data is cataloged for engineering reference. The image created from the ink is computer enhanced to display the variation in color density as a rainbow of colors, with corresponding approximate pressure ranges. Fel-Pro engineers also use the test results to create a colorized 3D version of the pressure image. Tests are run on both OE gaskets and Fel-Pro replacement gaskets during the design process, evaluating both for areas that need enhanced sealing design.

 

fuji blog 1

The evaluation includes checks for proper loading of the combustion seal, oil and coolant passages, and emboss beads on MLS (Multi-Layer Steel) cylinder head gaskets, as well as on the surface of the cylinder head or engine block deck. With every design change made to a Fel-Pro gasket, we test it in many different computer modeling programs, and retest it with the Fuji paper to see the difference. The results allow us to see where we may need to add, remove, or change the shape/height of an emboss bead on a gasket to create even sealing stress across the entire cylinder head.

 

Fujifilm’s pressure sensitive film is not unlike the “telltale needle” on a tachometer – it records the maximum amount of pressure applied to one area, much as the needle records the maximum engine RPM on the tachometer.

 

fuji blog 2

 

You can see the strong primary combustion seal created by the LaserWeld™ Stopper Layer, and the thinner, secondary seal created by the emboss around each cylinder bore opening. You can also see the seal created by the emboss around the oil drainback ports and the block perimeter seal.

 

fuji blog 3

When designing a head gasket, the sealing stress of the gasket is tested before the engine is run. After the engine has run, the sealing stress is tested again. It is the Fel-Pro design engineer’s job to determine how best to use the available bolt load to seal combustion, high pressure oil, oil drain backs and coolant passages.

 

To accurately record the sealing stress after running, head bolts are torqued to “pull-up” torque, which allows us to duplicate the torque value on each bolt sealing the gasket. This is important, because head bolts installedat 75 ft-lbs may only be at 60 ft-lbs after heat cycling.

 

To determine pull-up torque, each bolt and the cylinder head are marked with a witness line. Each bolt is then loosened in proper sequence, one at a time, and “pulled up” with a beam style torque wrench to the witness mark. The torque value required to line each bolt up to the witness line is recorded. The bolts and head are then removed, and the new film is put in place. Each bolt is returned to the same hole it was previously installed in, and retorqued to the pull-up torque values. This allows us to recreate the pressure the gasket would be under once installed on a running engine, and see the loaded created by the gasket at the “relaxed” torque.

 

This Fel-Pro sealing pressure validation is just one of the many tests run to make sure each gasket is worthy of the Fel-Pro name.

 

by .

9 thoughts on “FUJIFILM LETS YOU SEE THE PRESSURE!

  1. Greg

    I just rebuilt a 351 ford with aluminum heads. After 20 minutes running, saw a water leak between the head and block. Pulled the head and gasket off for review. Didn’t see anything on the gasket to know if bad. did see a light void on the block near the bottom edge (not near the water jackets). First Question, can the head gasket be re-used since we have really no run time? Second, what do you recommend on finding where this leak is coming from? Currently used the Peratorque MLS head gaskets. thanks for the help.

    Reply
    1. Fel-Pro Blog TeamFel-Pro Blog Team

      Hi Greg,

      We never recommend reusing a head gasket that has been compressed if the head has been removed. The coating will have conformed to the micro-imperfections in the head and block, and the embossments have been compressed. Reusing the gasket could create leak paths.

      What is the surface finish of the heads and the block? Both need to be 60 Ra or smoother for MLS head gaskets or else they will not be able to seal properly.

      We hope to hear back from you soon!

      Reply
  2. Ralph

    I have been dealing lately with delays on the job I’m trying to finish, a1999 Olds 88/ 3.8L for intake manifold coolant leak that got into every cylinder. The delays have been due to the mail order gaskets that arrived mangled due to the box of head bolts put in the same box loose on top of the gaskets that are only [ shrink wrapped to a slice of cardboard.] The name of the gasket seller/brander is DNJ with a large American Bald Eagle in their logo claiming American quality and design. Please bear with me, the point of this email is coming to FEL PRO.
    My beef was with the shipper that caused this, they apologized and sent me a ticket back and as soon as they saw movement of my return mailing my replacements would begin their perilous journey to me.
    ALL THIS TIME I WAS THINKING WHY DIDN’T I BUY FELPRO BECAUSE ALMOST EVEYTHING THEY SELL COMES IN A BOX………
    Well 3 days later the gaskets arrive by themselves in the box wrapped better and the I find that the right side gasket has been made wrong, has to be forced gingerly over both locating dowels for being too close together. Then I discovered all the bolt holes were off so as to take the impressions of the bolts when I put them all in to get a bigger picture of the misalignment.
    I gave up, made a call, AUTOZONE, $20 for one gasket, oh well live and learn to pay for what you want, the good stuff.
    IF YOU ARE STILL WITH ME HERE IT COMES…….. THIS IS AN EMAIL OF DISAPPOINTMENT NOT ACCOLADES.

    HERE COMES THE CLERK WITH MY GASKET AS I SCAN THE WALLS AND SEE ALL THE FAMILIAR FELPRO BOXES LINED UP IN THE BACK. AND THEN…… THE CLERK HANDS ME. …NOT A BOX BUT WHAT SHOULD BE IN A BOX….A GASKET SHRINK WRAPPED TO A PIECE OF CARD BOARD JUST LIKE WHAT TURNED OUT TO BE THE CHINESE GASKET I AM TRYING TO REPLACE.
    AND THIS GASKET HAS EDGE DAMAGE AS DOES THE CARDBOARD FROM HITTING WHATEVER!!!! THIS IS THE ONLY ONE THEY HAVE BUT HE WROTE ABOUT THE DAMAGE ON THE RECIEPT SO I COULD EXCHANGE AT ANOTHER STORE.

    I WILL USE THE GASKET BECAUSE IT IS EDGE DAMAGE AND NOT BENT WHICH COULD HAPPEN.
    AND NO MORE DELAYS,CAN’T AFFORD THEM, THIS GASKET BETTER WORK,IT HAS TO BE BETTER THAN WHAT I HAVE AT HOME THAT IHOPE I CAN GET A REFUND ON.
    I HAVE A QUESTION NOW. THIS PART DOESN’T DESERVE A BOX? OR DID IT COST TOO MUCH? OR A WAY TO KEEP THE GASKET FROM SLIDING AROUND IN THE PACKAGING? CHEEP CHEEP
    YOUR GASKET ARE WORLD RENOWNED AND I AGREE HANDS DOWN THE BEST BUT THINK WHAT HAPPENS TO THESE TOUGH PRODUCTS ON THEIR JOURNEYS ACROSS THE WORLD!!!!!

    Reply
    1. Fel-Pro Blog TeamFel-Pro Blog Team

      Hi Raplh,

      We are sorry to hear you received a damaged gasket. What is the part number of the gasket you purchased?

      Our sets; head, conversion, full, intake, etc. come packaged in a box because there are multiple parts that need to be packaged. A single individual head gasket comes packaged on a cardboard backing and then shrink wrapped. There are tabs on the cardboard to keep the gasket centered. The way we package our products meets the industry standards, unfortunately we can’t control how they are handled once they leave our hands. Do you have any pictures of the packaging? We would be very interested to see them. You can post a link to them here or email them to us at Support@Felpro-Only.com

      As far as your coolant leak into please look carefully at your upper intake manifold. These plastic intake have been known to burn through at the EGR port. There are coolant passages that lead to the throttle body. Once it burns through it will dump coolant into the lower intake and into all cylinders. Also, you did not state why you were replacing the head gaskets?

      We look forward to hearing back from you!

      Reply
  3. mike

    why can’t your system find your own part numbers?

    MS 96532 and MS 96905 both fail to get hits.

    auto part store is selling me MS 96532 but box contains MS 96905 (suspect to fail).
    I was hoping to get details on these Fel-Pro parts from the Fel-Pro site, but your system cannot find these numbers.

    Reply
    1. Fel-Pro Blog TeamFel-Pro Blog Team

      Hi Mike,

      Where are you searching for those part numbers at? FMe-cat.com is the best place to find any Fel-Pro or Federal Mogul product you might need. You can look parts up with the part number, or if the part number is not known, you can look up the application.

      MS 96532 is an old design that may no longer be available. It is a single layer, embossed stainless steel part.

      MS 96905 is a consolidated design to replace MS 96532. This is our Fel-Ramic material which provides a better seal on used exhaust manifolds.

      We hope this helps, let us know if you have any other questions!

      Reply

Leave a Reply

Your email address will not be published. Required fields are marked *