Large Diameter Aluminum Washers

The processing methods of Large Diameter Aluminum Washers vary according to the ratio of outer diameter to thickness. Thin washers with an outer diameter to thickness ratio greater than 30 usually use the stamping blanking process, while thick washers with a ratio less than 15 are more suitable for CNC turning. According to ISO 4759-1's dimensional tolerance regulations for flat washers, the outer diameter dimensional deviation of an aluminum gasket with an outer diameter of 150 mm should be controlled within plus or minus 0.5 mm, and the thickness deviation should not exceed plus or minus 0.08 mm. Actual measurement data shows that the dimensional consistency of turning processing is about one tolerance level better than that of stamping process, but the material utilization rate of stamping process can reach more than 85%, while turning is only about 65%. There needs to be a trade-off between the two based on batch size and accuracy requirements. The concentricity deviation between the inner hole and the outer circle of the gasket is controlled within 0.2 mm in stamping parts, and can reach less than 0.05 mm in turned parts. For high-pressure flange connections that require uniform load distribution, turning processing is usually preferred to ensure concentricity.

The mechanical behavior of large-diameter aluminum washers in low-temperature environments is different from that at normal temperature. Its tensile strength and yield strength increase as the temperature decreases, but the plasticity and impact toughness decrease accordingly. According to the ASTM E23 Charpy impact test method, the impact absorbed energy of 6061-T6 aluminum alloy at minus 40 degrees Celsius is about 80% of the room temperature value, and the decrease is smaller than that of steel. This makes it suitable for bolted connections in refrigeration equipment and polar structures. It has good low-temperature applicability. At the same time, the surface treatment of the aluminum gasket has a significant impact on the contact corrosion behavior. When the aluminum gasket is matched with a stainless steel bolt, according to the ASTM G71 galvanic corrosion test method, the galvanic current density in a simulated industrial atmospheric environment is about 15 microamps per square centimeter. By anodizing the gasket and controlling the oxide film thickness within the range of ten to fifteen microns, the galvanic current density can be reduced to less than five microamps per square centimeter. In order to match different bolt grades, the Rockwell hardness of large-diameter aluminum washers is usually maintained between HRB 40 and 60 according to ASTM E18. This hardness range can not only ensure that the washers produce sufficient elastic deformation under preload to fit the flange surface, but will not cause serious depression under high surface pressure due to too low hardness, thus achieving a balance between economy and reliability in large flange connections in petrochemical and power equipment.

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