Sylvie Willis
Diesel fuel is a difficult fluid to seal, and gasket selection is critical to prevent leaks. Gaskets and sealants must be chemically compatible with diesel to avoid leaks caused by chemical reactions, dissolution, or absorption of the fuel into the gasket material. While some materials like EPDM rubber, silicone, and neoprene are not recommended for diesel applications, others like nitrile rubber (NBR or Buna-N), FKM/Viton®, and PTFE offer better fuel resistance and are suitable alternatives. Choosing the right gasket material and sealant is essential to ensure a reliable seal and prevent flammable liquid leaks in diesel fuel systems.
Characteristics and Values
| Characteristics | Values |
|---|---|
| Fuel-resistant gasket materials | Nitrile rubber (NBR or Buna-N), FKM/Viton, PTFE |
| Gaskets to avoid | EPDM, Silicon, Neoprene |
| Sealant | Spray copper, Gasgacinch, Permatex, "The Right Stuff", Ultra Black, Hi-Tack, RTV |
| Fuel types | Gasoline, diesel, kerosene |
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What You'll Learn
Gaskets and sealants for diesel fuel tanks
Diesel is a difficult fluid to seal, and choosing the wrong material can lead to leaks of flammable liquid. Gaskets and sealants for diesel fuel tanks must be carefully selected to ensure compatibility with diesel fuel and resistance to leaks.
When selecting a gasket material for a diesel fuel tank, it is important to consider the chemical compatibility of the material with diesel fuel. Some common materials, such as EPDM, silicon, and neoprene, are not recommended for use with diesel fuel as they may not be chemically compatible and can break down over time.
Instead, materials such as nitrile rubber (also known as NBR or Buna-N), FKM/Viton®, and PTFE are better suited for use with diesel fuel. These materials offer superior fuel resistance and can withstand the challenges posed by hydrocarbons present in diesel fuel.
In terms of specific gasket and sealant products for diesel fuel tanks, Permatex offers a range of options that are suitable for this application. Their PermaShield® Fuel Resistant Gasket Dressing & Flange Sealant is a polyester urethane-based compound that provides superior fluid resistance and can withstand extreme temperature changes without hardening. It is designed to seal axle assemblies, hydraulic parts, oil pans, water pumps, and various gasket applications. Another product by Permatex that has been used successfully in diesel fuel tank applications is their Aviation Form A Gasket, which is specifically designed for use with fuels and oils.
In addition to selecting the right gasket material and sealant, it is crucial to ensure that the surfaces to be sealed are clean and free of any diesel residue. Sanding and cleaning with a suitable product, such as Brakeclean, can help achieve the required level of cleanliness. Proper surface preparation and the selection of compatible gasket materials and sealants will help ensure the effectiveness and longevity of the seal in diesel fuel tank applications.
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Nitrile rubber, FKM/Viton, and PTFE as fuel-resistant gasket materials
Nitrile rubber, FKM/Viton, and PTFE are gasket materials that offer excellent fuel resistance, durability, and sealing performance in gasoline environments.
NBR (Nitrile Rubber) is a popular choice for low-cost fuel gaskets and seals as it offers excellent resistance to gasoline, diesel, and petroleum oils. Nitrile rubber is often used in sectors such as oil and gas, and the automotive industry. It has excellent resistance to fuel and oil, although when the percentages of additives in the fuel change, such as an increase in naphtha, its sealing performance decreases. Nitrile rubber also has excellent resistance to heat.
FKM, commonly known as Viton, is a top-tier choice for harsh fuel environments. FKM rubber gaskets offer outstanding resistance to gasoline, ethanol blends, biodiesel, and aggressive chemicals at high temperatures. Viton is a branded synthetic rubber used in extreme chemical environments and has excellent resistance to both nitrile and naphtha. It is very expensive but should be used consistently where guarding against failure is critical.
PTFE, or Polytetrafluoroethylene, also known as Teflon, is inert to gasoline and other aggressive fuels, providing exceptional sealing performance and durability. It is an excellent choice when chemical compatibility and non-reactivity are critical. PTFE lacks the compressibility and elastic recovery of nitrile or Viton but conforms readily to uneven surfaces and has a very wide working temperature range. A cost-effective way to use PTFE is to add an envelope to the bore of a gasket to give extra chemical protection without compromising the sealing capability.
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Gaskets and sealants for fuel pumps
Gaskets and sealants are essential components of fuel pumps, ensuring that flammable liquids like diesel, gasoline, and kerosene are securely contained. The wrong choice of material can lead to leaks, making the selection of fuel-resistant gasket materials critical.
Nitrile rubber, also known as NBR or Buna-N, is widely recommended as the first choice for fuel applications. It offers excellent fuel resistance and flexibility, even at high temperatures. Another option is FKM/Viton®, which is more expensive but remains flexible up to 400°F, making it suitable for applications with high-temperature requirements. PTFE is another fuel-resistant material to consider, although it lacks the compressibility and elastic recovery of nitrile or Viton.
When it comes to sealants, a thin layer is generally recommended to avoid plugging passages or interfering with the compression of the gasket. Permatex offers a range of products, including the Permatex 80019 Aviation Form-A-Gasket No. 3 Sealant and the Permatex 85420 Permashield Fuel Resistant Gasket Dressing & Sealant, which are both popular choices among car enthusiasts. Other sealants mentioned include spray copper, ultra black, and right stuff, with users emphasizing the importance of finding a sealant that suits one's specific needs and applications.
In addition to gasket materials and sealants, proper installation techniques are crucial. Some recommend installing gaskets dry without any sealant, while others suggest using a thin film of sealant to hold the gasket in place during installation. It is important to follow manufacturer guidelines and seek advice from specialists to ensure safe and effective fuel pump gasket installation and maintenance.
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Spray sealants like spray copper and RTV
Gaskets play a crucial role in preventing leaks of flammable liquids such as gasoline, diesel, and kerosene. Choosing the wrong material for a gasket can lead to leaks, as these hydrocarbons can cause a range of issues, from swelling to dissolving gasket materials.
When it comes to gasket sealants, it is essential to consider their compatibility with diesel fuel. Some materials, like EPDM rubber, silicon, and neoprene, are not chemically compatible with diesel. For instance, EPDM rubber roofing mats, often used as a gasket material, may not be suitable for direct contact with diesel fuel.
In contrast, spray sealants like spray copper and RTV (Room Temperature Vulcanizing) silicone offer advantages in terms of flexibility, adhesion, and temperature resistance. RTV silicone sealants, for instance, can form a flexible bond between various materials, including wood, metal, glass, and plastic, providing a seal against water, dust, and air leakage. They are also effective against chemicals, oils, and greases. However, it is important to note that RTV silicone sealants are not recommended for direct contact with gasoline, kerosene, or other liquid solvents.
One example of a spray copper sealant is the Permatex Ultra Copper RTV Silicone High-Temperature Gasket Maker. This product is designed for high-temperature applications, offering superior adhesion, sensor safety, and low odor. It is also non-corrosive and highly resistant to auto fluids and vibration. With a temperature range of -65°F to 700°F (-54°C to 371°C), it is suitable for high-performance engines.
For applications requiring an even higher temperature limit, FKM/Viton® can be considered, although it is more expensive than alternatives. Another option is PTFE, which has a wide working temperature range and readily conforms to uneven surfaces, although it lacks the compressibility and elastic recovery of other materials.
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Gaskets and sealants for fiberglass fuel tanks
When selecting gaskets and sealants for fuel tanks, it is important to consider the compatibility of the materials with the type of fuel being used. Diesel, gasoline, and kerosene are challenging fluids to seal, and using the wrong material can lead to leaks of flammable liquids. Hydrocarbons, present in most liquid fuels, can cause certain materials to swell, leading to gasket failure. Therefore, it is crucial to choose fuel-resistant materials specifically designed for use with diesel fuel.
For fiberglass fuel tanks, proper preparation is essential before applying any sealant. Sanding and thoroughly cleaning the surface with a suitable product, such as Brakeclean, is necessary to remove any diesel residue, grease, or oily residue, which can compromise the effectiveness of the sealant.
Several products on the market are recommended for sealing diesel fuel tanks. One option is the Permatex Aviation Form A Gasket, which resists gasoline, oil, and grease. While diesel is not specifically mentioned, some users have found success using this product in diesel applications. Permatex also offers the Aviation Sealant and the Permashield Fuel Resistant sealant. Additionally, the KBS Tank Sealer System is advertised as forming a tough, fuel-impervious coating and is suitable for use with diesel and fiberglass tanks.
When selecting a gasket material for diesel fuel tanks, nitrile rubber (NBR or Buna-N) is often recommended as the first choice for fuel applications. It offers excellent fuel resistance and elasticity. Other options include FKM/Viton®, which is more costly but remains flexible at higher temperatures, and PTFE, which has a wide working temperature range but lacks the compressibility of nitrile or Viton®. For gasket creation, products such as Permatex's fuel-resistant sealant or Leak-Lock by Highside Chemical are available.
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Frequently asked questions
Gaskets made of nitrile rubber, also called NBR or Buna-N, are the first choice for most fuel applications. Other options include FKM/Viton® and PTFE.
Some gasket sealant products for diesel fuel include Permatex, Gasgacinch, and Indian Head Aviation Gasket Sealant #3.
Diesel fuel can be difficult to seal due to its chemical composition. It can cause materials to swell and become less elastic, leading to gasket failure. Therefore, it is important to choose a gasket sealant that is compatible with diesel fuel.
