EXPERTISE

At Kastaş, we research the future of sealing and develop innovative sealing technologies,
as R&D is the main driver of our growth and at the center of our main strategic goals.

Our R&D team, specialized multidisciplinary, carries out the activities with the aim of
developing advanced sealing technologies and efficient solutions.

Our R&D activities consist of design development, material development, process
and production technologies,and tests and simulations, all of which are run by an experienced team.
As our aim is to continue developing products based on innovative designs and high-performance materials,
we are committed to investing in advanced production technologies which will boost our quality and efficiency.

DESIGN DEVELOPMENT

Design Development is one of two main pillars of high-performance product development,
and is carried out by the Kastaş R&D team according to the market and customer expectations using
the advanced software available in our test center. As a result, we are able to offer
new and unique designs, customer- or project-specific solutions, as well as improvements in standard product lines.

PRODUCT AND MOLD DESIGN

Whether working on a standard product or customer-specific project, we design sealing elements and molds using most advanced 3D design, mold flow and software tools, according to the technical requirements of the application, product design and production plan.

FINITE ELEMENT ANALYSIS (FEA)

Simulating the newly developed design alternatives in different working conditions before prototype production reduces the development costs while increasing R&D efficiency and productivity. The staff at the R&D center perform FEA on new designs, during product design optimization, and as a means of verification of customer-specific demands before physical tests.

COMPUTATIONAL FLUID DYNAMICS

Material flow, fiber orientation, and directions are simulated in the injection mold using Moldex3D and Digimat programs. The analysis results are used to prevent errors in production processes and achieve productivity enhancements, thus resulting in a superior performance of our sealing and guiding elements.

PRODUCT TESTING

Both standard and special designed products are tested at the Kastaş Test Center using software simulations and also advanced test-benches for various applications, while using precise application parameters in order to validate the design and material developed.

MATERIAL DEVELOPMENT

Kastaş R&D aims to develop advanced elastomer, polymer and composite materials for use in its future sealing technology designs.

ELASTOMER MATERIAL DEVELOPMENT

With its experience and state-of-the art R&D infrastructure, Kastaş develops elastomer materials that set new standards in sealing technology. High-performance elastomer compounds for increasing requirements in fluid power and special materials for specific applications are developed and tested in-house and are certified by accredited laboratories.

POLYMERIC MATERIAL DEVELOPMENT

Combining in-house laboratory research with co-engineering studies with international suppliers, Kastaş is committed to the material science R&D, with the aim of developing new high-performance polymer materials.

TEST CENTER

Established in 2006, Kastaş Test Center relies on various test benches and equipment for performing lifecycle and performance tests, such as hydraulic-pneumatic piston and rod tests, wiper and guide ring tests, high pressure, and low- and high-temperature tests.

Product tests, especially as a part of new product development, existing design optimization, new raw material performance analysis, customer-specific working conditions verification, and competitor benchmark tests, are conducted at the Kastaş R&D center.

As Kastaş, we are continuously investing into advancing the capabilities of our Test Center.

HYDRAULIC ROD SEAL TEST RIG

Technical Data:
  • Number of Seals: 6 seals
  • Velocity: 0.01 – 0.5 m/s
  • Stroke: 20 – 500 mm
  • Pressure: 10 - 450 bar
  • Temperature: 10 °C – 150°C
Testing Criteria:
  • Leakage rate
  • Frictional forces
  • Wear
  • Extrusion
  • Stick-slip effect

Hydraulic Piston Seal Test Rig

Technical Data:
  • Number of Seals:
    1 Double Acting Seal, 2 Single Acting Seal
  • Speed: 0.05 – 0.5 m/s
  • Stroke: 20 – 500 mm
  • Pressure: 10 - 450 bar
  • Temperature: 10 °C - 150°C
Testing Criteria:
  • Leakage rate (Dynamic and Static)
  • Frictional forces
  • Wear
  • Extrusion
  • Stick-slip effect

Wiper Test Rig

Wiper test rig offers the opportunity to measure the working performance of wipers against different environmental pollutants.

Technical Data:
  • • 0 – 0.3 m/s linear test speed
  • Possibility of testing with various hydraulic fluids
  • Possibility of testing with various environmental pollutants
Testing Criteria:
  • The amount of contaminants pass through test product into the system

Guiding Element Test Rig

Guiding element test rig offers the opportunity to measure the load carrying capacity performances of guiding elements under dynamic and static loads at different temperatures.

Technical Data:
  • Force capacity: 0 – 400 kN
  • Temperature: 10 - 150 °C
Testing Criteria:
  • Dynamic and static testing
  • Compression
  • Wear

Low Temperature Test Rig

Technical Data:
  • Number of Seals:
    2 Rod Seals, 1 Piston Seal
  • Speed: 0.05 – 0.5 m/s
  • Stroke: 20 – 250 mm /li>
  • Pressure: 5 - 200 bar
  • Temperature: Down to -40°C
Testing Criteria:
  • Leakage rate
  • Wear
  • Extrusion
  • Low Temperature Sealing Capacity

Hydraulic High Pressure Test Rig

Thecnical Data:
  • Number of Seals: 1
  • Speed: 0 m/s
  • Stroke: 0 mm
  • Pressure: 5 - 1000 bar
  • Temperature: 10 °C - 100°C
Test Criteria:
  • Extrusion
  • Gap Clearance

Pneumatic Test Rig

Thecnical Data:
  • Number of Cylinders: 8 Cylinders
  • Frequency: Up to 1 Hz
  • Stroke: 20 – 400 mm
  • Dimensions: Up to 100 mm
  • Pressure: 0 - 10 bar
Test Criteria:
  • Leakage rate
  • Wear
  • Minimum Working Pressure
  • Maximum Cycle Time

Ultra Low Temperature Test Rig

Ultra low temperature test rig offers the opportunity to measure the sealing performance of materials at very low temperatures.

Technical Data:
  • -80 +150 °C
Testing Criteria:
  • Leakage Rate

Testing Capacity

Leakage
Measurement

1Speed up to
m/s

Stick-Slip
Analysis

Leakage Measurement
During Test

0 Pressure up to
Bar

Radial load bearing
capacity

-0 °C +0°CTemperature

Friction
Force Test

Wear and
Extrusion Test

Low
Temperature Test

Dust Particle
Detection

PROCESS DEVELOPMENT

At Kastaş, we regularly develop and optimize all our production processes by giving importance to quality and continuous improvement. Kastaş develop the machinery, installations, and systems required for the new procedures and improvement of the existing process.

High-performance products can only be produced with efficient, highly repeatable, and stable processes. High-tech process machines needed in production processes are designed and developed within Kastaş.

ADVANCED TECHNOLOGIES

Today where production methods are developing rapidly, traditional manufacturing methods are being replaced by advanced technology methods. At Kastaş, we closely follow the development of manufacturing technology and enrich our production capabilities with new technologies that will meet the sealing element needs of the future. We apply these technologies in international cooperation with the world's leading companies in the sector.

Developing technologies bring both opportunities and risks. Kastaş follows advanced technologies closely and applies them to sealing solutions with innovative approaches.

Kastaş is a member of the European Sealing Association (ESA) and represents Turkey in the Executive Committee.

Within ESA, joint projects are developed with industry stakeholders, and up-to-date developments in the sector are monitored.

Kastaş involves in the standards and legislation in the field of sealing elements in the European Union and globally. Kastaş follows the development of new technologies and creates its R&D strategies accordingly in the medium and long term.

Kastaş ;

As a technical expert, Kastaş takes part in ISO TC 131 Fluid Power Technical Committees
and takes an active role in the development of ISO standards related to sealing elements.

 

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