In the aerospace industry, failure is not an option – precision is not just necessary, it is vital to maintaining exact requirements and quality control. As a result, aerospace manufacturers and suppliers are continuously seeking components and system solutions that provide proven reliability, performance, and compliance.
Industry standards play a critical role in meeting these high expectations, bringing together global leaders in the mobility sector to create defined, repeatable techniques and consistent manufacturing processes.
Ensuring Safety, Dependability & Quality In Aerospace Systems
AS1895, developed by SAE International, is a critical aerospace standard specification. It addresses the need for highly durable components capable of withstanding extreme conditions while maintaining superior performance - such as resistance to high temperatures, reliable pressure sealing, and extended service life - all achieved through an economical installation process.
Major aerospace companies such as Eaton and Honeywell have long manufactured components that meet this standard. Aviation and space manufacturers continue to collaborate with other businesses that have achieved this trusted compliance.
Omniseal Solutions is one such example, having recently expanded its aerospace offerings with certified AS1895-7 and -23 metal seals. Their metal sealing solutions have already been validated in commercial aircraft and recognized for aerospace safety, reliability, and quality as defined by AS1895.
Stringent Requirements In a “No Failure” Industry
Aviation is one of the most heavily regulated and technically demanding industries worldwide, with stringent requirements for safety, performance, global standardization, and compliance.
Aerospace OEMs and Tier 1 suppliers cannot afford to compromise – particularly when it comes to metal and polymer sealing solutions used in vital systems. An SAE International recognized standard can only be attained if a company's production processes and solutions fulfill the strict criteria for high-performance aviation and space applications:
- Manufacturing Precision: The company must deliver the quality, reliability, and performance levels required by the aerospace industry.
- Material Qualifications: The company must provide production compliance and advanced material processes, such as ISO 9001:2015 and AS9100D.
- Quality Control and Testing: The company must have a comprehensive quality control system that consistently manufactures seals and components that meet rigorous specifications.
AS1895 specifications include:
- Components: A complete joint system connecting a high-pressure, high-temperature grooved clamp coupling, featuring two flanges and a formed metallic seal.
- Harsh Environments: Engineered to operate in harsh conditions, with temperatures ranging from -65 °F to +1200 °F (-54 °C to +649 °C).
- System Applications: These solutions are applied in the bleed-air systems of commercial, military, and business aircraft.
- Dependability: AS1895 joint systems from certain manufacturers have demonstrated proven service life, logging more than 110 billion cumulative flight hours with no reported failures.
By adding the AS1895-7 and AS1895-23 configurations to its metal and polymer solutions portfolio, Omniseal Solutions provides standardized, reliable, and fully verified components that satisfy the increasing demands of today’s airframe and propulsion system designs.
The AS1895 metal seals are built for long-term reliability in environments where temperatures can reach +1200 °F (+650 °C) and pressures are extreme. The aviation industry has placed its trust in these certified seals, especially in bleed air management systems, where performance under pressure is non-negotiable.
Nicolas Schirmer, Metal Seals Product Manager at Omniseal Solutions
Each certified AS1895 metal seal design undergoes extensive and rigorous qualification testing to verify performance under simulated real-world conditions, including temperature cycling and pressure fluctuation - making them a preferred choice for ensuring the integrity of aircraft systems and maintaining flight safety.
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Legend is Certified AS1895 Omniseal® Metal E-Seals
Certified AS1895 Omniseal® Metal E-Seals Image Credit: Omniseal Solutions
Going Beyond In Bleed Air Systems & Additional Applications
Bleed air systems are one of the most critical applications for AS1895 metal seals. These systems operate in high-temperature and high-pressure zones where air extracted from the engine is used for cabin pressurization, anti-icing, and other essential functions. Any leak or failure poses serious safety and operational risks.
Omniseal Solutions’ AS1895 metal seals are engineered to excel under these demanding conditions, with features including:
- Thermal-cycle resistance for applications that involve continuous temperature shifts from cryogenic cold to engine-level high heat
- High-pressure capability to maintain seal integrity throughout system operation
- Long service life, minimizing downtime, and reducing maintenance expenses
- Compliance with SAE AS standards, ensuring compatibility and quality assurance across platforms
With these mechanical characteristics, engineers and OEMs can confidently apply these seals into mission-critical zones, from the engine nacelle to the auxiliary power unit (APU) and beyond.
A Complete Portfolio of Aerospace Solutions
Beyond delivering durable, precise components for bleed-air systems, Omniseal Solutions is a partner in innovation for aerospace sealing in other critical systems, with expertise in a broad range of applications across commercial aircraft industries.
Alongside its AS1895-certified metal seals, the company designs and manufactures customized sealing and wear and friction control solutions:
- Turbine shrouds and combustion chamber seals
- Fuel nozzle and injector seals
- Precision metal boss seals for AS5202 fittings
- Custom-designed sealing components for emerging propulsion systems, including electric and hybrid-electric platforms
To further enhance performance and versatility, Omniseal Solutions offers a comprehensive lineup of sophisticated coatings, including tin, silver, gold, nickel, and its proprietary NCCM coating. These coatings play a critical role in enhancing corrosion resistance, reducing wear, and maintaining seal performance over extended service periods.
In addition to precision solutions and wear and friction control materials, Omniseal Solutions provides clients with a wide range of global engineering services, including testing campaigns that feature leak and load testing, as well as cross-sectional assessment for seal behavior analysis.
By combining these technical capabilities, the company delivers cutting-edge simulation services that enable clients to verify both process reliability and sealing solution durability according to specific application conditions.
Historical Legacy & Future Flight
With over six decades of aerospace experience, Omniseal Solutions has established a reputation for engineering excellence, reliable supply chains, and comprehensive technical expertise. Its sealing solutions have been adopted across hundreds of aircraft platforms and are trusted by leading aerospace OEMs and Tier 1 suppliers around the world.
By expanding its offering with SAE-certified AS1895 metal seals, the company reinforces its commitment to supporting the evolving demands of the aviation sector, from standard jet engines to next-generation propulsion systems.
As the aerospace industry advances to meet sustainability objectives, enhance efficiency, and reduce lifecycle costs, the importance of durable, lightweight, and high-performance sealing solutions will continue to grow.
Certified offerings such as Omniseal Solutions’ AS1895 metal seals serve as the foundation for safe, efficient flight operations, even as systems increase in complexity and operating conditions become more demanding.
By providing standard-compliant, high-dependability solutions, Omniseal Solutions enables its partners to push the boundaries of modern aviation – whether by extending maintenance intervals, enhancing safety margins, or optimizing fuel and thermal management systems.
In the high-stakes world of aerospace, certified components make a significant difference. The integration of AS1895-7 and -23 metal seals into Omniseal Solutions’ aerospace portfolio strengthens its position as a strategic partner to the aviation industry, providing sealing solutions designed for extremes and certified for customer confidence.
More information on aerospace standards is available in Omniseal Solutions’ industry blog: Sealing Solutions & Aerospace Standards Maximize System Performance & Safety
This information has been sourced, reviewed, and adapted from materials provided by Omniseal Solutions.
For more information on this source, please visit Omniseal Solutions.