Why do o rings fail?

O ring failure guide

O ring failure often occurs too soon in applications due to inadequate gland design or compound choice.
This article explain why O rings fail by supplying examples of general damage modes. In order to improve
seal execution, it is necessary to correctly and effectively identify the damage mode.
No matter how careful we are during the design phase, O rings can fail in their application for various
reasons. The number of pressures that affect O rings can be very hard to assess which is why it is extremely
important to re-test every material in its original environment and precisely examine them throughout the
installation stages.
The O ring failure guide below provides details of some of the most popular o ring failure modes.

FAILURE 1: EXTRUSION AND NIBBLING

Description and visual indications:

Extrusion is the process where high stresses force material into the clearance gap, then pulses of high
pressure cause the clearance gap to open and close, trapping the O ring between the mating surfaces which
results in physical damage to the seal surface. The edges of the O ring are nibbled, chipped or ragged
(usually on the low pressure side). In severe cases, shaving can occur and the surface may be peeled off.
Contributing factors/failure analysis:
 Excessive gland clearances
  Excessive system pressure
 O ring material too soft
 Degradation of o ring by system fluid
 Irregular clearance gaps caused by eccentricity
 Improper machining of o ring gland (leaving sharp edges)
 O ring size too large for gland

Prevention and suggested solutions

 Increase rigidity of metal components

 Decrease sharp edges of the gland to a minimum
 Reduce back clearance gaps by using backup devices
 Decrease clearance by reducing machining tolerance
 Appropriate gland design
 Compatibility of an O ring material with system fluid
 Installation of adequate O ring size
 Use of the harder seal material

FAILURE 2: COMPRESSION SET

Description and visual indications:

COMPRESSION SET is one of the most common O ring failures. An efficient O ring seal needs a
continuous seal line between the seal surfaces which is a function of gland design and seal cross-section. To
maintain seal integrity without excessive deformation of the seal, the seal line establishes the correct amount
of compression on the O ring. O ring becomes less circular and has flattened surfaces (flat sided oval), it has
taken the shape of the groove and it is unable to recover to its original shape.
Contributing factors/failure analysis:
 Physical and chemical changes appear
  Excessive compression/over tightening
 Improper gland design
 Excessive temperature, which caused the O rings to lose its elastic properties
 Elastomer with high compression set
 O ring volume swell because of system fluid
 Elastomer completely cured during production
 Poor compression set
 Properties of material selected
 Fluid incompatible with O ring material
 O ring losing its elasticity due to cross-link density increase
Prevention and suggested solutions
 Selection of elastomer materials with low compression set
 Confirm material compatibility with intended service conditions
 Confirm the O ring is not over-squeezed
 Check gland design
 Use more flexible polymer structure
 Lower system operating temperature
 Reduce excessive frictional heat build-up at seal interface

FAILURE 3: EXPLOSIVE DECOMPRESSION

Description and visual indications:

After a period of time in service (under high pressure) the pressure is may decrease too quickly. The gas
is then absorbed and expands very fast and blisters and ruptures the elastomer surface. Excessive trapped gas
may result in total destruction of an O ring. Blisters and cracks on the surface due to absorption of gas at high
pressure and the subsequent fast drop in pressure. Surface marked with deep splits. Splits and fissures
revealed after examinations of internal structure. In severe cases, the surface is completely ruptured.
Contributing factors/failure analysis:
 Rapid pressure changes
  Low hardness elastomer
 Absorption of gas by O rings while operating in high pressure conditions
Prevention and suggested solutions
 Slower decompression allows trapped gas to escape from seal material
 Higher hardness elastomer
 Reduce temperature
 Choose ED-resistant material
 Right selection of seal material-explosive decompression resistant
 Consider using metallic O ring or C ring

FAILURE 4: ABRASION

Description and visual indications:

Abrasion is another common type of seal failure. Mostly it’s found in dynamic seals due to rotary
motion, oscillating and reciprocating. Flat area on the side of an O ring where it was touching the dynamic
surface. Grazed lines on the flat surface parallel to the direction of motion. Only one side of the seal will be
worn. Seal surface may have some loose particles and scrapes. Excessive wear – lacerations may be deeper
and there may be breaking in places.
Contributing factors/failure analysis:
 Repetitive friction between O ring surface and the housing
 Dynamic motion
 Improper lubrication
 Improper finish of the surface in dynamic contact with the O ring (the surface may be
abrasive, too smooth or too rough due to inability to hold lubricant)
 Excessive temperature
  Process environment containing abrasive particles
 Poor elastomer surface finish
Prevention and suggested solutions
 Adequate lubrication
 Use O ring sealing materials with improved abrasion resistance
 Eliminate abrasive components
 Use of recommended gland surface finishes
 Eliminate the source of contamination
 Use of wiper or scraper rings will reduce contamination of the seal
 Consider use of internally lubricated O rings – this will reduce friction and wear

FAILURE 5: THERMAL DEGRADATION

Description and visual indications:
Thermal degradation is frequently accompanied by compression set, radial cracking (on
surfaces dealing with highest temperatures), surface becomes shinier in places which is a sign of
softening.
Contributing factors/failure analysis:
 Thermal properties of the elastomer
 Temperature of an application has exceeded maximum temperature ceiling of the seal
material
 Excessive temperature cycling has occurred
 Increase in hardness and modules which makes seal less elastic
Prevention and suggested solutions
 Choose an elastomer with enhanced thermal stability
 Possible cooling sealing surfaces

FAILURE 6: UV DEGRADATION
Description and visual indications:
Discoloration of an exposed surface of an O ring, cracking due to excessive exposure to
prone materials, disintegration (in worst cases).
Contributing factors/failure analysis:
 Ultraviolet light exposure (due to UV having a short wavelength which interacts with
the molecular structure of the exposed part), this usually causes cleavage of the polymer
and results in cracking of the surface, this then leads to leaking premature failure.
Prevention and suggested solutions
 Black and fluorinated materials show higher resistance
FAILURE 7: INSTALLATION DAMAGE

Description and visual indications:

Occurring in both static and dynamic seals, Small cuts, nicks or gashes on the seal
Contributing factors/failure analysis:
 Sharp edge of glands, threads or components, which may damage O ring during
assembly
 Wrong sizing of O ring
 Low hardness elastomer
 Improper lubrication before installation
Prevention and suggested solutions
 Remove all sharp edges
 Proper gland design
 Proper elastomer sizing
 Ensure all components are clean before installation
 Use of lubricant
 Higher hardness elastomer
FAILURE 8: SPIRAL TWISTING FAILURE

Description and visual indications:

Generally found on long stoke, hydraulic piston seals, the surface of the O ring exhibits a
series of deep, spiral 45° angle cuts, spiraling pattern around its exterior with subsequent deep
cutting.
Contributing factors/failure analysis:
 O ring is both sliding and rolling at the same time
 Slow reciprocating speed
 Improper installation
 Irregular seal surface finish
 Excessive gland width
 Low hardness elastomer
 Uneven or rough gland surface finish
 Insufficient lubrication
 Eccentric components
 friction
Prevention and suggested solutions
 Correct installation procedures
 Possible use of polymer backup rings
 Higher hardness elastomer
 Proper gland surface finish
 Adequate gland design
 Internally-lubed elastomers or properly lubricated elastomer
FAILURE 9: OUT-GASSING
Description and visual indications:
Parts of seal formation, decomposition products of the ingredients or other gasses trapped
in the polymer matrix during the molding process can be released under vacuum conditions.
Usually no visible signs, in extreme cases, shrinkage can be seen, decrease in cross-sectional
size.
Contributing factors/failure analysis:
 Inadequately cured seal
 Low hardness/plasticized seal
 High vacuum levels
Prevention and suggested solutions
 Making sure the seals are properly post-cured
 Avoid plasticized elastomers
 Using materials with a pure polymer
 Using materials for the correct temperature

FAILURE 10: CHEMICAL DEGRADATION

Description and visual indications:
Cracks, blisters or even discoloration, in some instances, the degradation is only
observable by measuring of physical properties, change in hardness, loss of original shape and
integrity.
Contributing factors/failure analysis:
 Incompatibility with the chemical and/or thermal environment
 Increase in cross-link density
 Hard and brittle material reduces the ability to provide reaction force
 Chain scission results in a reduced strength
Prevention and suggested solutions
 Selection of more chemically resistant seal
 Correct elastomer material
 Correct temperature

FAILURE 11: PLASMA DEGRADATION

Description and visual indications:
The high energy ionized gasses or radicals that the plasmas consist of, attack the organic
backbone of the material and form small particles or molecules. Discoloration, erosion of seal in
the exposed areas, even material loss on the surface which touches the plasma, powdered residue
on the surface.
Contributing factors/failure analysis:
 Chemical reactivity of the plasma
 Improper gland design
 Ion sputtering
 Incompatible seal material
 Electron heating
Prevention and suggested solutions
 Plasma-compatible elastomer and compound
 Minimize exposed area
 Examine gland design
 Seal damage is unavoidable with long-term exposure to plasma

FAILURE 12: CHEMICAL SWELL

Description and visual indications:
Seal seems larger than its original dimensions, swelling may appear on the whole seal or just
parts exposed to a chemical.
Contributing factors/failure analysis:
 Ingress of media into the seal due to a chemical resemblance of the media and the
compound
 Elevation of seal volume can lead to gland fill
 Loss of sealing or extrusion
 Loss of physical features such as tensile durability
Prevention and suggested solutions
 Check the chemical compatibility of the seal with proven resistance to chemical
environment.

FAILURE 13: THERMAL EXTRUSION

Description and visual indications:
Seal no longer have a round profile, seal takes shape of the groove, a frilly edge will appear on
two opposing sides.
Contributing factors/failure analysis:
 Thermal expansion of a seal is usually much higher than that of adjacent hardware
 The volume of a seal at raised temperatures will have increased much more than that of
the material around it
 At raised temperatures
 A seal can fill the groove and afterward expel into the clearance gaps.
Prevention and suggested solutions
  Advance groove/gland design to let adequate space to place extra seal volume at raised
temperatures

FAILURE 14: FAILURE WITHOUT VISIBLE EVIDENCE ON SEAL

Description and visual indications:
Of the various types of seal failure, this is among the hardest to diagnose because the result of
the problem is not visible on the O ring. There are no visual clues.
Contributing factors/failure analysis:
 Insufficient compression
 Tolerance stack-up
 Eccentric-shaped components
 Parting lines and/or flash left on the O ring from the molding process
 Improper volume relationship between the seal and its gland
Prevention and suggested solutions
 Maintain recommended compression range for the application
 Identify the amount of stretch as it reduces the O ring cross section with increased stretch
 Determine the component tolerance stack-up as it directly affects the seal cross section
 Consider maximum component shift in design to ensure that compression is still
contained within recommended compression range
 Avoid parting lines in O ring grooves as they tend to be areas of flash and mismatch
 Ensure that the O ring gland volume surpasses the O ring volume to allow for seal
expansion without seal detriment.