AS1895 Metal Seals For Bleed Air Systems

Why are bleed air systems one of the most demanding applications? These pneumatic aircraft systems extract high‑temperature and high‑pressure compressed air from the engine to support critical functions: cabin pressurization, wing anti‑icing, and environmental control. Bleed air components are exposed to temperatures from −65°F to +1200°F (−54°C to +650°C), high internal pressures, vibration stresses, and thermal cycling. They also need to adhere to strict regulatory oversight under SAE AS1895 standards.

Bleed air systems are recognized in the aviation industry as part of a “no‑failure”, safety‑critical architecture, using a complex network of ducts, valves and regulators. A minor leakage can result in operational disruptions (system function loss) or safety risks (overheating or fire). OEMs and Tier‑1 suppliers face constant challenges including:

• Maintaining leak‑tight sealing under extreme temperature and pressure cycling
• Managing flange distortion and assembly tolerances over service life
• Ensuring ease of installation and maintenance without specialized tooling
• Meeting stringent AS1895, AS9100, ISO9001, and NADCAP compliance requirements

To successfully solve the above challenges while minimizing aircraft downtime and lifecycle cost at the same time, the aviation industry relies on specialized sealing solutions such as AS1895 metal seals.

Omniseal Solutions’ certified AS1895‑7 and AS1895‑23 metal E‑Seals address many technical requirements for bleed air systems due to their robust, engineered design.

• The metal sealing solutions are manufactured from Inconel 718 and heat‑treated per AMS 5596. They feature a cross-section that yields against mating flanges with a high springback, delivering extreme temperature resilience, high elastic recovery, long service life, and resistance to extreme thermal and mechanical loads.
• Their snap‑fit, low‑load design enables hand installation while maintaining reliable sealing performance.
• Each configuration is fully tested and qualified to AS1895 requirements (SAE International defined specifications for machined flanges and formed metallic seals), with proven field performance across commercial and military aircraft platforms.

• Extreme reliability in critical environments
• Proven safety margin and long service life (provides airtight joint)
• Snap-fit design: ease of installation and maintenance efficiency (no need to re-torque, re-tighten or replace bolts)
• Precision design to handle demanding operating conditions (protects sealing and system integrity).