Optimization of Exhaust Seal Material to Improve Maintenance and Emissions

NCMS Project #: 142065

Problem: Exhaust manifold gaskets and seals are one of the most important parts of an engine since they seal and pressurize the entire exhaust system.  When the exhaust manifold gaskets and seals fail, it can cause other problems with the engine performance, drivability, vehicle safety, and dangerous emissions released into the crew or passenger areas.  

Benefit: Project deliverables will benefit the industrial and commercial vehicle industry by demonstrating how redesigning an exhaust seal can improve vehicle and fleet operational readiness, extend the useful life of the vehicles, and protect the vehicle occupants from danger.

Solution/Approach: In the Army, the exhaust gaskets between the cylinders and the exhaust system of the M88 recovery vehicle systemically fail.  This initiative will use the engine of the M88 recovery vehicle as a surrogate to leverage new commercial materials and optimization processes to design a new engine exhaust seal that is more reliable and less susceptible to the extreme environmental conditions in which they must operate.

Impact on Warfighter:

  • Extend useful life of internal combustion engines 
  • Decrease overall maintenance costs 
  • Reduce toxic exposures, emissions, landfill waste 
  • Improve worker safety 
  • Increase engine performance and warfighter readiness and lethality 

DOD Participation:

  • U.S. Army Tank-automotive and Armaments Command (TACOM) Integrated Logistics Support Center (ILSC)
  • U.S. Army Program Executive Office Ground Combat Systems (PEO GCS)
  • U.S. Army Project Director (PD) Main Battle Tank Systems
  • Anniston Army Depot (ANAD)

Industry Participation:

  • Zatkoff Seals and Packings
  • NCMS

Benefit Area(s):

  • Cost savings
  • Maintenance avoidance and reliability
  • Positive environmental impact
  • Durability
  • Reliability improvement

Focus Area:

  • Reliability improvement