Sealants Explained: How They Work and Top Uses

In numerous settings, maintaining structural integrity and preventing leaks or contamination points is vital for safety and proper equipment operation. Sealants are essential in achieving these goals, offering protection against environmental factors, mechanical stress, and chemical exposure. After reading this blog, you will have a comprehensive understanding of sealants, including their applications, compositions, and significance in various industries.

What Are Sealants?

Sealants are specialized substances used to fill gaps, joints, or seams between surfaces to prevent the passage of liquids, gases, or various other contaminants. Unlike adhesives, which primarily bond surfaces together, sealants provide flexibility and resistance to temperature variations, movement, and vibrations. Used across aerospace, automotive, construction, and marine sectors, sealants are formulated for specific environments and compatibility with materials like metal, glass, plastic, or composites. Moreover, they can be applied using various techniques, including extrusion, spraying, and brushing, depending on their formulation and the surface they are being applied to.

Standard Sealant Types

Silicone Sealants

Silicone sealants are among the most versatile types, finding their use everywhere from households to industrial environments. Notably, their high thermal resistance and flexibility make them ideal for sealing joints that are regularly exposed to high temperatures. They are most commonly applied using caulking guns or automated dispensing systems to achieve precise seals in high-temperature environments like engine compartments, aircraft assemblies, and glass facades.

Polyurethane Sealants

Polyurethane sealants provide exceptional bonding strength, making them suitable for construction and heavy-duty industrial use. These sealants exhibit strong adhesion to various surfaces, including wood, concrete, and metals, while also being highly resistant to abrasion and mechanical stress. Typically applied with a trowel, brush, or extrusion gun, polyurethane sealants are favored for expansion joints in bridges, airframe sealing, and sealing structural panels in buildings.

Acrylic Sealants

Acrylic sealants are frequently chosen for interior settings due to their ease of use and ability to be seamlessly painted over. They offer moderate flexibility and good adhesion to porous materials, regularly being used for sealing gaps in walls, ceilings, and windows. While not as durable as silicone or polyurethane, they are still effective in environments with minimal exposure to extreme conditions. These sealants are usually applied using a cartridge gun or manually spread with a putty knife to create a smooth and aesthetically pleasing finish.

Hybrid Polymer Sealants

Hybrid polymer sealants combine the benefits of silicone and polyurethane for superior flexibility and strength. These advanced formulations are often used in high-performance applications where both durability and adaptability are required, their resistance to chemicals and environmental factors making them a preferred choice for sealing fuel tanks, hydraulic systems, and aircraft fuselage joints. Application methods vary, ranging from manual administration in small-scale repairs to precision-controlled dispensing in aerospace manufacturing.

Specialty Sealants

Beyond general-purpose sealants, various specialized formulations exist to meet the stringent demands of certain industries.

Aerospace Sealants

Aerospace sealants are largely used in fuel tanks, engine components, and structural assemblies, which must withstand high-altitude pressures, fuel exposure, and temperature fluctuations. Often composed of polysulfide, fluorosilicone, or silicone-based formulations, these sealants offer excellent resistance to jet fuel, hydraulic fluids, and environmental stressors. Given their critical role in aircraft construction and maintenance, specialized sealant dispensing tools and robotics tend to be used to seamlessly create airtight seals that can endure flight operations.

Marine Sealants

Marine sealants protect vessels and offshore structures from constant water exposure and harsh environmental conditions. As such, they are formulated with polyurethane, polysulfide, or silicone-based materials that resist saltwater corrosion, UV radiation, and biological growth. They are carefully applied to ensure watertight seals on hull seams, deck fittings, and underwater components, the most common method being heavy-duty caulking guns or trowels.

Electronic Sealants

Electronic devices utilize specialized sealants to safeguard delicate circuits from moisture, dust, and other environmental contaminants. Unlike soldering or mechanical bonding, electronic sealants provide a non-conductive, flexible barrier that prevents short circuits while maintaining long-term reliability. Silicone-based and epoxy options are particularly valued for their ability to encapsulate components without adding stress to fragile connections, typically being applied using automated machinery for the most uniform coverage.

Access High-Quality Sealants Through Keep You Flying

For industries that depend on premium or industrial sealants, sourcing the right products from trusted entities is essential. Keep You Flying, an ASAP Semiconductor website, provides access to a vast sealant catalog and many other components that are compliant with rigorous industry standards. More than that, we offer competitive pricing, rapid fulfillment, and a seamless procurement experience, making us a preferred choice for professionals to acquire all the parts they need for their operations.