The Advantages of PTFE Piston Rings

Piston rings play a crucial role in the efficient operation of compressors. They provide a seal between the piston and the cylinder wall, preventing gas leakage and ensuring optimal compression efficiency. One type of piston ring that has gained significant popularity is the PTFE (polytetrafluoroethylene) piston ring. This article will explore the advantages of using PTFE piston rings in compressors and how they can improve efficiency and performance.

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What are PTFE Piston Rings?

PTFE piston rings are made from a high-performance polymer called polytetrafluoroethylene. This material is known for its excellent chemical resistance, low friction coefficient, and high-temperature stability. It is commonly used in industries requiring low friction and high wear resistance, such as automotive, aerospace, and industrial applications.

Advantages of Using PTFE Piston Rings

Reduced Friction

One of the key advantages of using PTFE piston rings is their extremely low coefficient of friction. This means they generate minimal frictional forces against the cylinder wall during operation. As a result, there is less energy loss due to friction, leading to improved compressor efficiency.

The piston seal provides low friction performance and long service life. It is low-cost to maintain and practically eliminate stick-slip piston movement.

Improved Wear Resistance

PTFE has exceptional wear resistance properties compared to other materials commonly used for piston rings. The self-lubricating nature of PTFE reduces wear on the ring itself and the cylinder wall it meets during operation. This leads to increased durability and extended service life for the ring and other components with the compressor.

Effective Sealing Capability

Effective sealing between the piston and cylinder wall is crucial for maintaining compression efficiency in a compressor system. The unique properties of PTFE allow it to create a tight seal, preventing gas leakage and ensuring optimal compression performance. This results in improved overall system efficiency and reduced energy consumption.

Chemical Resistance

Compressors often handle various gases, some of which may be chemically aggressive or contain contaminants. PTFE is highly resistant to different chemicals, making it an ideal choice for piston rings in compressors that operate in demanding environments. The chemical resistance of PTFE ensures that the piston rings can withstand exposure to corrosive gases without degradation or loss of performance.

High-Temperature Stability

Compressors can generate significant heat during operation, especially in high-pressure applications. PTFE has excellent thermal stability and can withstand high temperatures without losing physical properties or deforming. This makes PTFE piston rings suitable for compressors operating at elevated temperatures, ensuring reliable performance even under extreme conditions.

PTFE piston rings offer numerous advantages for compressors, including reduced friction, improved wear resistance, effective sealing capabilities, chemical resistance, and high-temperature stability. These benefits contribute to enhanced compressor efficiency and performance. Whether upgrading your existing compressor or selecting piston rings for a new system, PTFE piston rings should be a top consideration. Their unique properties make them an excellent choice for demanding compressor applications.

Frequently Asked Questions

Can I retrofit my existing compressor with PTFE Piston Rings?

In most cases, it is possible to retrofit existing compressors with PTFE piston rings. However, consulting with the manufacturer or an expert technician is recommended to ensure compatibility and proper installation.

Can PTFE piston rings be used in high-pressure applications?

PTFE piston rings are suitable for high-pressure compressor applications due to their high-temperature stability and excellent wear resistance properties.

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Do PTFE Piston rings require special maintenance?

PTFE piston rings are designed for minimal maintenance due to their self-lubricating properties and excellent wear resistance. Regular inspection and cleaning are usually sufficient to maintain optimal performance.

Are PTFE piston rings compatible with all compressor types?

Yes, PTFE piston rings are compatible with several types of compressors, including reciprocating compressors and rotary screw compressors.

How do I know if my compressor would benefit from using PTFE piston rings?

If your compressor experiences issues such as excessive friction, poor sealing efficiency, or premature wear on the current piston rings, switching to PTFE piston rings can be a solution to improve performance and efficiency.

Wear rings can be an integral part of a hydraulic system, as they absorb side loads and eliminate metal-to-metal contact, extending system life.

Contributed by Tom Zozokos, Product Manager, Trelleborg Sealing Solutions Streamwood and Beth Figliulo, Fluid Power Segment Manager, Trelleborg Sealing Solutions Americas

Wear rings, whether metal, thermoplastic, thermoset or PTFE-based, can be an integral part of a hydraulic system. At their most basic, wear rings absorb the side load forces in a piston and/or rod hydraulic cylinder, while eliminating metal-to-metal contact. Generally speaking, wear rings can extend the life of a hydraulic system: it&#;s faster and less expensive to replace a wear ring than an entire cylinder. Although there are applications where metal wear rings are appropriate, there are numerous benefits of non-metallic rings for hydraulic cylinders in fluid power applications such as off-highway, material handling, industrial machines, mobile hydraulics, and agricultural equipment. These are:

• High load-bearing capacity
• Favorable friction behavior
• Damping of mechanical vibrations
• Good wiping effect
• Protection of seal against &#;dieseling&#; (hydraulic fluid flowing too quickly across the cylinder)
• Elimination of local stress concentrations
• Easy installation
• Less downtime, due to less damage to rods or pistons, and longer product life

Non-metallic wear ring materials include polytetrafluoroethylene (PTFE) based compounds, as well as thermoset plastics and thermoset options. Each has its own specific characteristics.

PTFE-based wear rings provide extremely low friction within systems and are particularly well suited in dry-running applications. They can be mated with steel, aluminum and cast iron. The smoothness of PTFE-based wear rings means such little abrasion takes place that, in some cases, less expensive hardware can be used in a system.

Additionally, PTFE-based rings, due to their low friction characteristics, help lower the incidence of stick-slip when starting up the system. Common uses of PTFE-based wear rings include equipment operating at high temperatures and pressures.

Thermoset rings have outstanding wear resistance properties and are designed to offset heavy loads at low speeds. They address application demands for strong, light, durable rings. Although thermoset rings are dense, they are elastic in comparison to metal rings.

Wear rings are available up to 60 in. in diameter, and larger diameters can be manufactured from strip. Most of the rings can be mated with steel, hard chrome plated surfaces and cast iron. Example applications include tensioner cylinders, injection molding hydraulic systems and aerospace landing gear.

Thermoplastic wear rings are the workhorses of hydraulic systems, and in many systems, they are temperature resistant and can provide a high level of performance at a more affordable price than PTFE-based or thermoset wear rings.

Most can be mated with steel, hard chrome plated surfaces and cast iron. Two popular applications for thermoplastic rings are for internal valves and compressor components.

Selection is the name of the game
Choosing the best material for your application is a matter of evaluating the type of application, the size of the load within the system, the installation space, and the mating surface.

Usually, wear rings are supplied as split rings or strip material offered in a roll or precut to size. Chamfered edges are an option that facilitate installation and prevent edge forces from becoming too high in the corner radii of the grooves.

There are several types of split designs:

• Scarf cuts (also called angle cuts) are standard for the hydraulic applications. The angle reduces the edge loading on the ends of the ring and is preferred for linear systems.
• Straight cuts (also called butt cuts) are often seen on strip or net molded rings and are most often used in rotary applications.
• Step cuts provide the best wear ring coverage and can act as a buffer in the system against pressure spikes, but usually at an additional cost.

Maximizing surface contact

Since thermoplastic rings are injection molded, it is not uncommon to see parts shrink unevenly during the cooling process, especially if the tooling design is not optimal. The shrinkage can cause a shape that&#;s thinner in the center than on the ends (often referred to as &#;dogboning&#;).

One way to quickly test a wear ring for dogboning is to lay it against a flat surface and visually assess it for daylight shining through. Of course, dogboned wear rings can be easily discovered during prototype tests. In extreme cases, dogboned rings cannot be installed. In less extreme cases, they cause higher friction than expected and/or act as a wiper, so hydraulic fluid doesn&#;t flow properly.

It is always best to work with a reputable supplier that can avoid dogboning in their design and tool making processes.

Understanding wear rings&#; performance
Some wear rings that are on the market are made for volume commercial applications. This can, in certain circumstances, mean that the tolerance to which they are machined may be wide, typically up to 0.005 in. of the total wall.

Tight machining produces wear rings with tighter clearances and less buildup of tolerances. In terms of total cost of ownership, this expense in some applications can pay dividends; for example, within systems that will be marketed as high performance and judged on their longevity. For systems that are not expected to be used for long periods, cost savings may be achieved by specifying larger-tolerance commercial rings rather than precision ones.

In either case, the quality of the injection molding is an important aspect to consider when choosing a wear ring supplier. Consistency in wear-ring performance means faster installation and increased life between changeovers, something hydraulic cylinder manufacturers strive for. Consider also that selecting the best wear ring for your application can greatly increase its effectiveness. It is always best to work with a supplier that can advise you based on a high degree of expertise in fluid power sealing systems.

Trelleborg Sealing Solutions
tss.trelleborg.com

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