Fluid Power Institute Report

MILD STEEL (12L14) ZERO-LEAK GOLD® BURST PRESSURE EVALUATION

The Zero-Leak Gold product line of EPCO Products, Inc., a Fort Wayne, IN based company, is a revolutionary line of plugs and fittings. The fittings developed a zero leak seal at lower assembly torque values than their SAE counterparts. EPCO wanted to determine more accurately the burst pressures of the larger and smaller plug sizes that were not originally included in the earlier Zero-Leak Gold Plug tests conducted by the Fluid Power Institute. EPCO wanted confirmation of these values under accepted industry practices and established measuring methods.

EPCO contacted the Fluid Power Institute (FPI) located at the Milwaukee School of Engineering (MSOE) to perform a burst test at two installation torque values on Zero-Leak Gold Plugs (ZLGP) per ISO 1436-1:2001 standard for hydrostatic pressure testing to failure. Supplied specimens were installed in two different strength manifolds of Ductile Iron material [D654512 & D805506] provided by Daman Products Company and (6 each) ZLGP of the following SAE dash sizes:

ZLGP Plug Sizes Tested: -00, -01, -02, -04, -06, -10, -12, -16, -24, -32

Burst Pressure Evaluation Summary PDF

The average burst pressure shown in the table below is based on all samples of the given size which was calculated using six ZLGPs (3 from both manifolds because the difference was minimal in burst pressure between the two.

Results - 70% Torque Value

Table 1 - ZLGP Burst Summary
ZLGP Size Torque ZLGP Burst
[psig (MPa)]
SAE Burst*
[psig (MPa)]
ZLGP Woking**
[psig (MPa)]
SAE Working***
[psig (MPa)]
-00 5 in. - lbs. 28,359 (195.6) -- 7,090 (48.9) --
-01 20 in. - lbs. 33,128 (228.5) -- 8,282 (57.1) --
-02 43 in. - lbs. 44,072 (303.9) 24,360 (168.0) 11,018 (76.0) 6,090 (42.0)
-04 124 in. - lbs. 47,257 (325.9) 24,360 (168.0) 11,814 (81.5) 6,090 (42.0)
-06 23 ft. - lbs. 43,449 (299.6) 37,120 (256.0) 10,862 (74.9) 9,280 (64.0)
-10 57ft. - lbs. 39,702 (273.8) 37,120 (256.0) 9,926 (68.5) 9,280 (64.0)
-12 90 ft. - lbs. 35,574 (245.3) 24,360 (168.0) 8,894 (61.3) 6,090 (42.0)
-16 160ft. - lbs. 33,288 (229.6) 24,360 (168.0) 8,322 (57.4) 6,090 (42.0)
-24 215 ft. - lbs. 25,689 (177.2) 14,500 (100.0) 6,422 (44.3) 3,625 (25.0)
-32 265 ft. - lbs. 18,458 (127.3) 12,006 (82.8) 4,615 (31.8) 3,002 (20.7)

*   J1926-4 Revised Augest 2010 Table 3 Internal Hex: Test Pressure-Burst

**  ZLGP Working = Average Burst/4 (Using 4:1 Safety Factor)

*** J1926-4 Revised Augest 2010 Table 3 Internal Hex: Working Pressure