In the present paper, a theoretical model for leakage analysis of bolted flange joints without gaskets, which can take the surface roughness into consideration, is proposed based on percolation theory. In this model, Persson’s rough contact theory is employed to predict the height of the critical constriction along the percolating path. Based on this model, a criterion of maximum allowable bolt spacing is also suggested to guarantee a low leakage rate. The reasonable agreement between the theoretical predictions and detailed three-dimensional finite element analysis results verifies the validity and usefulness of the proposed theoretical model.
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