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: 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 6: 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 7: 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.
FAILURE 8: HEAT HARDENING AND OXIDATION

Description and visual indications:

Seen in both static and dynamic seals, the surface of O-ring appears pitted and/or
cracked, often accompanied by the flatness of high compression set.
Contributing factors/failure analysis:
 Excessive temperature causing elastomer hardening
 Evaporation of plasticizers
 Cracking from oxidation
Prevention and suggested solutions:
 Specify high temperature O-ring materials with antioxidants
 Lower operating temperature of hydraulic system
FAILURE 9: EXCESSIVE SWELL

Description and visual indications:

Easily identified by a marked increase in seal dimensions; can occur in both static and
dynamic applications. Results in reduction of physical properties and can result in improper
sizing between seal and gland. Dynamic applications are especially prone to this problem
because friction accelerates seal failure.
Contributing factors/failure analysis:
 Like a sponge, the seal absorbs the surrounding fluids and swells to the point of
malfunction because of incompatibility between seal compound and system environment
(i.e. chemical incompatibility, high humidity, etc.)
Prevention and suggested solutions:
 Select an O – ring material that is chemically compatible with the fluid it will contact.
FAILURE 10: WEATHER OR OZONE CRACKING

Description and visual indications:

Occurring in both static and dynamic seals exposed to atmospheres containing ozone and
other air pollutants, this failure mode is marked by the appearance of many small surfaces cracks
perpendicular to the direction of stress.
Contributing factors/failure analysis:
 Ozone attacks the polymer chains
 Causing O – ring material to crack
Prevention and suggested solutions:
 Substitute O – ring elastomers that are resistant to ozone attack