The Critical Impact Of SAE Aerospace Standards: Certified AS1895-7 and -23 Metal Seals

By Nicolas Schirmer (November 2025) 

In an industry where failure is not an option and precision is paramount, aerospace manufacturers and suppliers are constantly seeking components and system solutions that deliver trusted reliability, performance, and compliance. Industry standards are a key part of achieving these high expectations, bringing together global leaders in the mobility industries to create defined, repeatable methods and consistent processes.

One of these aerospace standards is AS1895 developed by SAE International - a critical standard due to the need for durable components that can withstand extreme conditions and offer high performance: high-temperature resistance, pressure sealing, and long service life with a cost-effective installation method. Leading aerospace companies such as Eaton and Honeywell have been manufacturing components that meet this standard for a long period of time. 

Aviation and space manufacturers continue to partner with other businesses who have attained this trusted compliance such as Omniseal Solutions who recently expanded its aerospace offering with certified AS1895-7 and -23 metal seals. Already proven in commercial and military aircraft, their metal sealing solutions are considered the benchmark in aerospace safety, reliability, and quality as defined by AS1895.

Aviation remains one of the most heavily regulated and technically demanding industries in the world. With stringent requirements for safety, performance, global standardization, and compliance, aerospace OEMs and Tier 1 suppliers cannot afford to compromise — especially when it comes to metal and polymer sealing solutions for critical systems. A SAE International recognized standard can only be achieved if a company's manufacturing processes and solutions can meet the rigorous requirements for aviation and space high-performance applications:

1. Manufacturing Precision: The company must provide quality, reliability, and performance levels demanded by the aerospace sector.

2. Material Qualifications: The company must provide manufacturing compliance and advanced material processes such as ISO 9001:2015 and AS9100D. 

3. Quality Control & Testing: The company must have a meticulous quality control system that consistently produces seals and components that conform to stringent specifications.

AS1895 specifications include:

• Components: A complete joint system that connects high-pressure and high-temperature grooved clamp coupling, with two flanges and a formed metallic seal.

• Extreme Conditions: Designed to function in extreme operating environments, with temperatures ranging from -65°F to +1200°F (-54°C to +649°C).

• System Applications: These solutions are used in the bleed-air systems of commercial, military, and business aircraft.

• Reliability: Some manufacturers' AS1895 joint systems have been proven service life, logging over 110 billion cumulative flight hours without a reported failure.

Omniseal Solutions’ addition of the AS1895-7 and AS1895-23 configurations to its metal and polymer solutions portfolio allows the company to offer standardized, trusted, and fully validated components to meet the growing demands of modern 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,” explains Nicolas Schirmer, Metal Seals Product Manager at Omniseal Solutions. “The aviation industry has placed its trust in these certified seals — especially in bleed air management systems — where performance under pressure is non-negotiable.”

The certified AS1895 metal seals are rigorously tested. Each seal design undergoes extensive qualification testing to validate performance under simulated real-world conditions, including temperature cycling and pressure fluctuation.

This combination of engineering excellence, precision manufacturing, and robust validation make AS1895-certified seals a preferred choice for aircraft designers seeking to ensure system integrity and flight safety.

One of the most critical applications for AS1895 metal seals is in bleed air systems — high-temperature, high-pressure zones where air extracted from the engine is used for cabin pressurization, anti-icing, and other essential functions. Any leak or failure in this system can pose serious safety risks and operational challenges.

Omniseal Solutions’ AS1895 metal seals are tailored to excel in these harsh environments, with features that include:

• Thermal cycle resistance for applications involving continuous temperature shifts from cryogenic cold to engine level high heat

• High-pressure capability for maintaining seal integrity during system operation

• Extended lifespan to reduce downtime and maintenance costs

• Compliance with SAE AS standards, ensuring compatibility and quality assurance across platforms

These mechanical properties allow engineers and OEMs to confidently integrate these seals into mission-critical zones, from the engine nacelle to the auxiliary power unit (APU) and beyond.

Omniseal Solutions has not only provided precision and durable components for the bleed air systems; it is partner in innovation for aerospace sealing in other critical systems, with expertise in a wide range of applications across commercial aviation and defense sectors. In addition to its AS1895-certified metal seals, they engineer and manufacture custom 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-engineered sealing components for emerging propulsion systems, including electric and hybrid-electric platforms

To further enhance performance and adaptability, Omniseal Solutions offers an extensive lineup of advanced coatings, including tin, silver, gold, and nickel, as well as proprietary NCCM coating. These coatings are critical for improving corrosion resistance, minimizing wear, and maintaining seal performance over extended service periods.

Along with precision solutions and wear and friction control materials, they offer customers a broad range of global engineering services such as testing campaigns, which include leak and load tests and cross-sectional assessment to analyze seal behavior. Combining these technical capabilities allow the business to provide advanced simulation services to customers, in order to validate the reliability of processes as well as the durability of sealing solutions according to specific application conditions.

With over 60 years of aerospace experience, Omniseal Solutions has cultivated a reputation for engineering excellence, supply chain dependability, and deep technical expertise. Its sealing solutions have been used in hundreds of aircraft platforms, earning the trust of major aerospace OEMs and Tier 1 suppliers globally.

By expanding its offering with SAE-certified AS1895 metal seals, the company reaffirms its commitment to supporting the evolving needs of the aviation industry — from traditional jet engines to next-generation propulsion systems.

As the aerospace sector evolves to meet sustainability goals, enhance efficiency, and reduce lifecycle costs, the importance of durable, lightweight, and high-performance sealing solutions will only grow. Certified products like Omniseal Solutions’ AS1895 metal seals provide the foundation for safe and efficient flight operations, even as systems become more complex and operating conditions more demanding.

By delivering standard-compliant, high-reliability solutions, Omniseal is enabling its partners to push the boundaries of what is possible in modern aviation — whether that’s achieving longer maintenance intervals, improving safety margins, or optimizing fuel and thermal management systems.

In the high-stakes world of aerospace, certified components make all the difference. Omniseal Solutions’ integration of AS1895-7 and -23 metal seals into its aerospace portfolio strengthens its role as a strategic partner to the aviation industry, delivering sealing solutions that are engineered for extremes and certified for confidence.

As aircraft systems continue to demand higher performance under more challenging conditions, Omniseal Solutions’ continued innovation and commitment to quality will be a key enabler of safer, more efficient flight.

Want to know more about aerospace standards? Read our industry blog: Sealing Solutions & Aerospace Standards Maximize System Performance & Safety