Crush washer truth

I bought a big bag full for every vehicle I own and I change them every time. The copper Nissan ones are unlike any other oil drain washer I've ever seen. It's obvious that they truly crush when installed.

washer - 1.webp
 
Never seen the "golden ones" some type of brass?

I have used (and re-used metal types)

Aluminum (fully annealed) - heat and allow to cool at ambient

Copper (fully annealed) - heat and quench immediately

Fiber, single use composite
 
Are crush washers deformed, and forever changed after one crush?
They can be, some last for many oil changes. I have to assume you are speaking to metal crush washers and not the single-use plastic or fiber types.
Is there any actual design that goes into crush washers?
Yes, crush washers are simply another sealing method.
Is there a difference between the golden ones and the silver ones?
Yes, the difference is in the metallurgy. Silver ones are either aluminum or soft steel and the golden ones are made of copper alloys.
If they are not to be reused, can we account for people who never change them and never have failures? On the same note, has anyone ever heard of a crush washer failure?
I had to replace the crush washer on my transmission drain bolt the other day because the crush washer was too thin and no longer sealing; it was 12 years old. Crush washer material spreads out when torque is applied in order to cover the sealing surfaces.
 
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Never seen the "golden ones" some type of brass?

I have used (and re-used metal types)

Aluminum (fully annealed) - heat and allow to cool at ambient

Copper (fully annealed) - heat and quench immediately

Fiber, single use composite
Nissan is all happy on the copper ones and they almost kinda thread on to the plug.

I've deliberately used those on Toyota and Toyota aluminum-esque on Nissan to test the stability of the space-time continuum. Thus far the world has not ended.....or has it? Is this all a Matrix simulation?? Am I responsible??
 
I've reused them sometimes twice when in a pinch and forgot to replenish my supply. Never had an issue with leaks. But then again, I probably don't ever reuse them more than twice.
 
I've never replaced a drain plug crush washer. The only time I ever needed to buy a crush washer was when I lost the old one in the grass. Otherwise, I would've reused it.
 
I don't replace washers, cars came with alum flat non crush washers, I just take them off, clean, flip to the other side and reuse, never any leaks. I do have a few new ones on hand just in case thou. Copper plain ones work well too.
 
I used to reuse them without any issues on my Toyotas but now I buy them in bags of 20 and change them out each time.
 
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The thin copper metal ones are single use, these flatten to nothing with one tightening of drain bolt. The thick copper or aluminum ones can be re-used with proper annealing. I know the aircraft maintenance group where I work re-use these after batch annealing them. I don't see the aluminum ones being annealed?
 
Crush washers do get thinner with multiple uses. They will get work hardened. Some drain bolts will imprint a pattern onto the crush, for example, the drain bolt may leave a raised edge on the washer.

I use a new one every time but I would not hesitate and reuse a washer two or three times if it still have sufficient thickness and and even and smooth appearance. I prefer copper over aluminum.

Has any super-thrifty BITOGer taken his old crush washer to his friend's house, sanded it flat with that guy's sandpaper and then annealed it in that guy's toaster oven?
 
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