A metal gasket includes embossments that exhibit essentially full functional recovery and full retained internal stress at temperatures up to about 1000° F. which is made from sheet material that is cold rolled and whose embossments are work hardened without any post embossment heat treating that would act to harden the material. This material may also receive a precipitation hardening heat treatment prior to being embossed. The gasket materials include alloys having greater than about 18% Ni, greater than about 14% Cr, from about 0.1 to 10% of at least one of Mo, Ti, V, Al, Co, Nb, Ta or Cu and the balance Fe with incidental impurities, which are cold rolled without any post embossment heat treating that would act to harden the material.
1. A method of making an embossed metal gasket, comprising the steps of:
cold rolling a sheet of an iron-nickel-chromium alloy to develop a deformed microstructure, a tensile strength of at least 1000 MPa at room temperature, and an elongation of at least 5% at room temperature;
the iron-nickel-chromium alloy comprising, by weight: 24-55% Ni; 14-21% Cr; 1-3.3% Mo; 0-0.15% Cu; 0-1% Si; 0-2% Mn; 0.65-2.3% Ti; 0-0.8% Al; 0-0.5% V; 0.001-0.01% B; 0-1.0% Co; 4.75-5.5% of the sum of Nb or Ta; 0-0.08% C; 0-0.015% S; 0-0.015% P; and the balance substantially Fe; and
forming a gasket from the cold rolled sheet, the step of forming the gasket including forming a least one embossed sealing bead.
2. The method of claim 1 , wherein said embossed sealing bead is sealably operable with substantially full retained stress in a fully-clamped, sealed joint at an operating temperature up to about 1000° F.
3. The method of claim 1 , wherein the deformed microstructure formed during the cold rolling step has a degree of deformation that varies as a function of a percentage of cold reduction.
4. The method of claim 3 , wherein said percentage of cold reduction ranges from 10-70%.
5. The method of claim 3 , wherein said percentage of cold reduction ranges from 30-40%.
6. The method of claim 1 , wherein the elongation in a rolling direction of the sheet developed during the cold rolling step is about 6-25%.
7. The method of claim 6 , wherein the elongation in a rolling direction is about 7-10%.
8. The method of claim 1 , wherein said iron-nickel-chromium alloy further comprises at least one element selected from the group consisting of V, Al, Co, Nb, Ta and Cu.
9. The method of claim 1 , further comprising a step of: providing a precipitation hardening heat treatment after the cold rolling step to develop a deformed and precipitation hardened microstructure, wherein said deformed and precipitation hardened microstructure has a hardness which is greater than a hardness of said deformed microstructure formed during the cold rolling step.
10. The method of claim 1 , further comprising a step of: coating said gasket with a heat resistant coating.
11. The method of claim 10 , wherein said heat resistant coating comprises:
chemically exfoliated vermiculite wherein at least 90 weight percent of the vermiculite has a thickness of less than or equal to 30 microns and no dimension is greater than 1 millimeter; a high temperature organic resin that is heat resistant to at least 300 degrees Celsius; a supplementary inorganic resin; and a flaky filler.
12. A method of making an embossed metal gasket, comprising the steps of:
cold rolling a sheet of an iron-nickel-chromium alloy to develop a deformed microstructure, a tensile strength of at least 1000 MPa at room temperature, and an elongation of at least 5% at room temperature;
wherein said alloy comprises, by weight: 50.00-55.00% Ni; 17.00-21.00% Cr; 2.80-3.30% Mo; 0-0.15% Cu; 0-0.35% Si; 0-0.35% Mn; 0.65-1.15% i; 0.35-0.80% Al; 0.001-0.006% B; 0-1.00% Co; 4.75-5.5% of the sum of Nb or Ta; 0-0.08% C; 0-0.015% S; 0-0.015% P; and the balance substantially Fe; and
forming a gasket from the cold rolled sheet, the step of forming the gasket including forming a least one embossed sealing bead.