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Sealing Plugs
KOENIG-EXPANDER® - Sealing Plugs for operating pressure up to 450 bar

MB 600-090

Bore Roughness Requirements

When installing KOENIG Expander® in hard base material no positive anchoring is possible. So, to attain suitable working pressures and anchorage, it is necessary to have a bore roughness of Rz = 10-30 µm. At a roughness greater than Rz = 30 µm leakage might occur.

Roughness profile

Required roughness profile



The ideal bore roughness for anchorage is attained by drilling with a twist drill or core drill.		Undesirable roughness profile



By reaming, a one-sided, smooth roughness profile is created. This is not desirable.

Base Material / Conditions

Unbenanntes DokumentThe working pressure specifications on the preceding page are obtainable under the following conditions:

Base Material
of the Installation
Tensile
Strength
(avg.) [N/mm²]
Elongation (min.)
[%]
Ultimate Strength
(avg.) Rp 0.2
[N/mm²]
Hardness
(min.) HB
High Strength St.
ETG-100
AISI 1144
1000
6
865
280
Free Machining Case
Hard. Stl. C15Pb
Din 1.0403
560
6
300
180
Cast Iron
GG-25
DIN 1691
250
-
-
160
Ductile Cast Iron
GGG-50
DIN 1693
500
7
320
170
Aluminium-Alloy
Al CU Mg 2
DIN 3.1354 / AA2024
480
8
380
120
Aluminium-Alloy
Al Mg Si Pb
DIN 3.0615 / ~AA6262
340
8
300
90
Cast Al Alloy
G-Al Si 7 Mg
DIN 3.2371 / AA356-T6
300
4
250
80
  • Equivalent working pressure capability can be obtained when using base materials with similar mechanical characteristics. However, the appropriate installation instructions must be followed.

  • Applications for cast aluminium, magnesium alloy, other non-ferrous metals and non-metallic materials upon request

  • Factors which may lower the working pressure capability are:
    - anchorage principle
    - bore roughness requirements
    - design guidlines
  • Anchorage between sleeve and base material is achieved when the sleeve is a minimum of HB = 30 greater than the base material. If the hardness difference is less, hole roughness of 10 - 30 µm is needed to achieve indicated working pressures
Security Range

The security range (the difference between working pressure and Test (B) pressure) allows for uncontrollable variations. For instance, dynamic loading at 1 million cycles and a frequency of 3 - 4 Hz has shown that burst pressure Test (A) and Test (B) pressure are reduced about 20% after this point.  

Design Guidelines

Wall thickness/distances from edge

As the radial expansion of the KOENIG Expander® sleeve occurs, the base material in which it will be anchored plastically deforms. The resultant strength, as well as the hydraulic pressure and temperature service conditions depending on the Expander type and characteristics of the base material, require minimum wall thickness, or distance from edge.

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Distance to external wall
Distance to exterior wall
Wall thicknesse between bores
The guideline values for minimum wall thickness and distance from edge (Wmin.) express these influencing factors. At these minimum values, only slight deformation on the exterior profile of the base material of less than 20 µm is likely. This does not affect the function of the KOENIG Expander®. Below the guideline values (Wmin.) the possibility of overloading the base material exists, which can adversely influence the function of the KOENIG Expander®. In such cases tests must be conducted.

Guideline values Wmin. for wall thickness and distance from edge

For KOENIG Expander® diametersd1 ≥ 4 mm: Wmin. = fmin. ⋅ d1
d1 < 4 mm: Wmin. = fmin. ⋅ d1 + 0.5 mm

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Base material Description
1
2
3
4
5
6
7
ETG 100
C15Pb
GG-25
GGG-50
AICuMg2
AIMgSiPb
G-AISi7Mg

Avg. tensile strength [N/mm²]
1000
560
250
500
480
340
300
Min. elongation
A5 [%]
6
6
-
7
8
8
4
Avg. ultimate strength
Rp 0,2 [N/mm²]
865
300
-
320
380
300
250
KOENIG Expander® series
Factor fmin.
MB 600
0.6
0.8
1.0
0.8
0.8
1.0
1.0
MB 700
0.6
0.8
1.0
0.8
0.8
1.0
1.0
MB 850
0.5
0.6
1.0
0.6
0.6
1.0
1.0
SK
0.5
0.6
1.0
0.6
0.6
1.0
1.0
HK 55
0.4
0.5
0.8
0.5
0.5
0.8
0.8
LP 900
0.3
0.3
0.5
0.3
0.4
0.5
0.5
LK 600
0.3
0.3
0.6
0.5
0.4
0.5
0.5
LK 950
0.3
0.3
0.6
0.5
0.4
0.5
0.5

Roundness tolerance

To assure reliable functioning of the KOENIG Expander® with regard to pressure performance and to assure leak tight sealing, a roundness tolerance of t = 0.05 mm must be held.

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By using a double lipped twist drill, the called out hole and roundness tolerances are reached. Better tolerances, particularly for larger diameter holes, can be held by using a triple lipped twist drill

Conicity of the bore

Within the effective sealing area of the KOENIG Expander®, the bore must be according to the data sheets. The bore lead in can be beveled up to a depth of 0.25 x d1 (LK: 0.15 x d1) because this area has no significant effect on the sealing function.

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MB series
SK series
HK series
 LP series LK series

Required Installation Lengths

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dN
MB series
SK series
HK series
LP series
LK series
Threaded Plugs DIN 908
d1
l3 min
l4 min*
d1
l4 max
d1
l4 max
d1
l2 min
d1
l4 max
d1
l4 max
2.0
3.0
3.4
5.0
.
.
.
.
       
.
.
3.0
4.0
3.8
5.5
.
.
3.0
7.0
3.25
5.80
   
.
.
4.0
5.0
5.3
7.0
4.0
6.5
4.0
8.0
4.40
7.00
4.0
 4.0
.
.
5.0
6.0
6.3
8.5
5.0
7.5
5.0
9.5
5.40
8.00
5.0
 4.8
M 8x1
11.5
6.0
7.0
7.3
9.5
6.0
8.0
6.0
10.0
6.40
8.50
6.0
 5.3
M 8x1
11.5
7.0
8.0
8.3
11.0
7.0
9.0
7.0
11.0
7.40
8.50
7.0
 5.8
M 10x1
12.0
8.0
9.0
9.8
12.5
8.0
10.5
8.0
11.5
8.45
9.50
8.0
 6.8
M 10x1
12.0
9.0
10.0
10.8
13.5
9.0
11.0
9.0
13.0
9.60
10.00
9.0
 6.8
M 12x1.5
16.0
10.0
12.0
12.8
16.0
10.0
12.5
10.0
13.5
10.65
11.00
10.0
 6.8
M 12x1.5
16.0
12.0
14.0
14.5
18.0
.
.
.
.
12.75
12.00
12.0
 7.8
M 14x1.5
16.5
14.0
16.0
16.5
20.0
.
.
.
.
   
14.0
 8.7
M 16x1.5
16.5
16.0
18.0
18.5
22.5
.
.
.
.
   
16.0
11.5
M 18x1.5
17.5
18.0
20.0
21.5
25.5
.
.
       
.
.
M 20x1.5
19.5
20.0
22.0
24.5
28.5
.
.
       
.
.
M 22x1.5
19.5

dN = given nominal bore/system bore size
*Installation lengths MB series
The required installation length (I4) min. for MB plugs is for base materials with hardness greater than HB=90. For softer materials, deeper installation is required.  

Contact Corrosion

Unbenanntes DokumentIn choosing a KOENIG Expander® you must consider that the material of the sealing plug and the material of the production piece can show different electrical potentials. In the presence of an electrolyte (e.g. 5% Water-NaCi solution), this potential difference causes electrochemical attack on the least noble of the metals in contract - galvanic corrosion. In this case, either the base material or its surface protection will become the anode and will be transferred to the pure metal of the cathode. The corrosion speed or the current density will be determined by the relative surface area or volume of the anode and cathode as illustrated below.

  Cathode
     
  Anode
Large Anode Area → Low Current Density at the Anode → Slow CorrosionSmall Anode Area → High Current Density at the Anode → Fast Corrosion

Effect of Galvanic Corrosion

The following table shows the expected galvanic corrosion behavior of KOENIG Expander®s in common base materials allowing for the relative surface areas of both metals, which influences the speed of corrosion.

  KOENIG Expander® series
Base Material MB 600 MB 700 MB 850 SK HK 55 LP 900 LK 600 LK 950
Steel, carbon/low alloy, plain
2
2
2
2
2
2
2
2
Steel, carbon/low alloy, Zn plated, chromate
2
2
1
2
2
2
2
2
Steel, carbon/low alloy, phosphatized
2
2
2
2
2
2
2
2
Nitrided or case hardening steel
behavior depends on the method used
Stainless steel, DIN 1.4305, AISI 303
1
1
3
3
3
2
1
3
Stainless steel, DIN 1.4005, AISI 416
1
1
3
3
3
2
1
3
Cast iron, GG DIN 1691, plain
2
2
2
2
2
2
2
2
Cast iron, GG DIN 1691, Zn plated, chromate
2
2
1
2
2
2
2
2
Cast iron, GG DIN 1691, phosphatized
2
2
2
2
2
2
2
2
Ductile cast iron, GGG DIN 1693, plain
2
2
2
2
2
2
2
2
Ductile cast iron, GGG DIN 1693, Zn plated, chromate
2
2
1
2
2
2
2
2
Dual cast iron, GGG DIN 1693 phosphatized
2
2
2
2
2
2
2
2
Aluminium alloy,          Ws-Nr. 3.3211, AA 6061
2
2
2
2
2
2
2
2
Aluminium alloy,          Ws-Nr. 3.0615, ~AA 6262
2
2
2
2
2
2
2
2
Aluminium alloy,          WS-Nr. 3.1354, AA 2024
2
2
2
2
2
2
2
2
Aluminium alloy,          WS-Nr. 3.4365, AA 7075
2
2
2
2
2
2
2
2
Cast aluminium alloy, WS-Nr. 3.2371, AA 356-T6
2
2
2
2
2
2
2
2
Cast aluminium alloy, Ws-Nr. 3.2373
2
2
2
2
2
2
2
2
Cast aluminium alloy, Ws-Nr. 3.2381
2
2
2
2
2
2
2
2

Key to the galvanic corrosion behavior of KOENIG Expander®s in the presence of an electrolytic medium installed in base materials per the above table:

1. Not accelerated
2. Lightly accelerated
3. Accelerated

Suggestions to prevent galvanic corrosion

  • Chose materials with no or low potential difference.
  • Use corrosion reducing designs, i.e. if possible prevent the accumulation of fluids on the outer surface of the workpiece.
  • By using suitable surface coatings, corrosion attack can be considerably reduced..

Salt spray testing per DIN 50021 can be done in our lab.

Pressure Performance Tests KOENIG Expander®

Test (A) Pressure Test To Failure

In test (A) the KOENIG Expander® is subject to increasing static pressure until plug blowout occurs. These tests are done by Koenig Verbindungstechnik for functional testing during manufacturing runs. Each production lot (Batch No.) undergoes these tests.



Test (B) Temperature/Pressure Cycling

In test (B) the KOENIG Expander® is subject to a long term test simulating practical conditions. This determines the pressure which can be applied (lower limit) without plug blowout, with intermittent pressure and varying temperature.

Conditions

Temperature:2 hours at +100 °C, 2 hours at -40 °C
series LK and LP partially 2 hours at +150 °C, 2 hours at -40 °C
Temperature change:between 30 and 45 minutes
Pressure:intermittent 2 minutes at 0 bar, 3 minutes at test pressure
Duration:170 h (long-term test)
Drill Hole: tolerance, roundness and roughness per data sheets, plain surface distance from edge per data sheets



We emphasize the fact that the use of our sealing plugs has been tested in the above listed temperature range. Please contact us in case of deviating temperature conditions.

Quality Management

KOENIG Expander®

The first priority at Koenig Verbindungstechnik is to maintain the highest standards regarding our products, systems and service in the areas of suitability, performance, reliance, security and the environment. Koenig Verbindungstechnik has implemented an efficient and integrated quality and environmental management system, certified to ISO/TS 16949:2002 and ISO 14001. Total quality management (TQM) serves our customers via:

Clear specifications
in cooperation with our suppliers.

Precise instructions and operational sequences
for all employees.

Instructions
for test procedures.

Process control
in production and assembly.

Quality monitoring
using statistical techniques like SPC, control charts etc.

Design control
in development, project engineering and the document amendment system.

Employee training
via regular internal auditing and implementation of a quality circle.

Important:

All KOENIG Expander®s can be identified by the batch numbers on the packing label (production serial number). This batch number guarantees traceability of all quality-relevant features of production and procurement.



Anchorage Principle

The required bore roughness is directly related to the hardness and the mechanical characteristics of the base material. Depending on the combination of sealing plug and base material, anchorage takes place either by the groove profile of the expander sleeve biting into the base material or on anchorage to the surface roughness of the bore.

Note:
When selecting a KOENIG Expander® the bore roughness must always be adjusted according to the hardness of the base material.

Anchorage principle related to the base material



Hard base material: to achieve the allowable working pressure, anchorage to the bore roughness or the base material is required. Roughness Rz = 10 to 30 µm.
Soft base material: anchorage to the bore of the base material occurs automatically due to the serrations on the sleeve of the KOENIG Expander®.
Soft base material: anchorage is not possible with the HK series. Such combinations are not allowed for high pressure applications.
Transition zone: to achieve the allowable working pressure, anchorage to the bore roughness of the base material is required. Roughness Rz = 10 to 30 µm.

Anchorage due to plug sleeve serrations
KOENIG Expander® series MB 850 in aluminium alloy HB = 90
Anchorage due to plug sleeve serrations
KOENIG Expander® series SK in aluminium alloy HB = 90
Anchorage due to bore roughness
KOENIG Expander® series HK 55 gray cast iron HB = 160
Sufficient anchorage due to plug sleeve serrations
KOENIG Expander® series LK 950 in aluminium alloy HB = 90
Anchorage due to plug sleeve serrations
KOENIG Expander® series LP 900 in aluminium alloy HB = 90

Pressure Performance

series MB 600
 d1
mm 		Base material of the installation
ETG-100
AISI 1144		 C15Pb
1.0403 		GG-25
     DIN 1691     		 GGG-50
DIN 1693		 AICuMg2
3.1354 		AIMgSiPb
3.0615 		G-AISi7Mg
3.2371
   
Proof pressure test (B)*
[bar] 		PB**
[bar] 		(B)*
[bar] 		PB**
[bar]
3-10 1400 450 1200 380
12-14 1000 350 900 280
  * Proof pressure ** Max. allowable working pressure = nominal pressure

Installation Instructions

Series MB

Drilled hole

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  • The drilled hole must be within the tolerances shown on the preceding dimensional sheets.
  • The counterbored hole (d2) must be properly sized for the through hole (d3) according to the dimensional sheets.
  • Holes must be round within 0.05 mm.
  • With hard materials the bore roughness should be from Rz = 10-30 µm for best results.
  • Longitudinal rifles and spiral grooves should be avoided. These influence the sealing effectiveness.
  • The bore must be free of oil, grease and chips.

Setting procedure

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  1. With  the ball facing out the KOENIG Expander® is inserted in the counterbored  hole. The top sleeve should not be above the surface of the base  material.
  2. With only a slight or no counterbore, the base of the sleeve must be adequately supported during installation.
  3. The  ball can now be pressed in until the top of the ball is below the edge  of the sleeve. Corresponding approximate values for stroke S as well as the dimensions X are from the table below.

Important:

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  • Use the proper size setting tool for the KOENIG Expander® according to the data sheet.
  • Cleaning/degreasing of plugs before installation, only spray cleaning with air drying allowed. (No dipping and vacuum drying).

Press

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Assembly lines with limited travel are preferred as insertion force is difficult  to control. KOENIG Expander®s are also ideal for automated installation  since they offer optimal orientation capability. Small quantities or  single parts can be installed with a hammer and setting tool.  Installation can also be done with an arbor press.

Installation dimensions

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MB 600 / MB 700 / MB 850 series
d1 (mm)
3
4
5
6
7
8
9
10
12
14
16
18
20
22
S (mm)
Stroke
(standard value)
1.2
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.5
6.35
7.0
8.0
9.0
10.0
X (mm)
± 0,2
Position of top of ball relative to top of sleeve
0.4
0.2
0.4
0.4
0.4
0.3
0.4
0.4
0.4
0.4
0.6
0.6
0.8
0.8

Setting forces

Untitled Document a) Force with minimum bore tolerance
b) Force with maximum bore tolerance

Measured in steel with a tensile strength of Rm = 1000N/mm².
Base materials with lower tensile strengths show lower values

Plug removal

Untitled DocumentWith KOENIG Expander® MB series removal of the plug is possible. The plug can be drilled out  with a carbide tipped drill or with a high speed steel drill.

MB 600-030 to 140 Ball HB ~200: High Speed Steel Drill
MB 700-030 to 220 Ball HRC   ~45: Carbide Tipped Drill
MB 850-030 to 220 Ball HRC   ~45: Carbide Tipped Drill


Procedure

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  • Expander diameter 6 mm or .250 inch:
    Drill out, in one process, to the next larger diameter according to the data sheet.

  • Expander diameter over  6 mm or .250 inch:
    Drill out in several steps with last step to the next larger diameter according to the data sheet.

  • Clear chips, remnants of the sleeve, and oil and grease from the bore.

  • Install a new KOENIG Expander®.

  • Note: After plug removal always use the next larger size plug.

Subject to technical alterations.
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