Superior technical guide

For precision moulded seals

 Your guide

Superior technical guide

We believe that this latest edition of the
guide will become an invaluable resource
for anyone involved in the specification
and application of elastomer seals.

We have not designed it to be a catalogue, We like to exceed expectations. Innovation

but a reference to guide you through the and investment are the keys to this.
relevant selection and design processes.
Natural curiosity and the desire to find better
It will become clear as you use the processes and methodologies feed the
guide that we are not in the business Superior promise to innovate.
of commodity production. Superior
Re-investment in state-of-the-art facilities
manufactures precision components
and valued, accountable people increases our
from specialised high performance
ability to convert ideas into production reality.
rubber compounds.
This guide is a part of that investment.
As a result, we actively seek the most
Use it with confidence. It is fully backed by
demanding customers. We relish involvement at
both our Engineering and Technical Service
the earliest point in their product development
teams who are on hand to offer advice and
cycle. It is the customer who benefits most:
support: we strongly recommend using this
more effective application of seals means
service as part of your design development
better product design – everyone wins.
process. You will find the contact number
To this end, we have committed to a culture at the foot of each page.*
of continuous, aggressive improvement in the
design, manufacture and supply of precision
o-rings and special mouldings.

*This service has been developed with you in mind. If you have any issues or comments arising
from it, please contact us in the first instance.

Material Science Department +44 (0)1202 854300 | 1

Superior technical guide Research, development and partnership

01
Research, development and partnership
Contents A relevant approach to design for today’s
Superior technical guide manufacturing.

01 Research, development
and partnership
03 Seal design
05 Quality

Customer Service lies at the heart
of everything we do at Superior.
We will also validate to specific accreditation
standards (e.g. EN681, WRAS, DVGW, ACS,
Consultation 3 Precision o-rings 13 O-ring size range standards 26 KIWA, NSF, EN 549).
Our philosophy is based upon three
Testing O-ring size and compound Quality acceptance criteria ISO 3601-3 27 key constituents:
selection program Optimising
Optimising Quality control: documentation 28
• Material science and technology Through the customer partnership exchange,
Tooling Groove layouts 14 Seal surface inspection levels
• Seal engineering we can assist with optimised seal profile
Staying ahead General housing guidelines 15 Special moulding tolerances design and application.
• State-of-the-art manufacturing
  Housing diametrical tolerances Certification
The combination of these three factors Tooling
02 Specifying compounds
  Lead chamfers Z Environmental compliance
provides the high integrity of our precision Our Tooling Manufacture department designs
  Surface finish or texture
o-rings and seals, and in turn, provides the and machines precision prototype and

06 Assembly
Temperature 4   Coefficient of thermal expansion long term performance and high integrity in production moulds to exceed conventional
Media compatibility rating 5   Coefficient of friction our customers products. Our ‘fast response’ tolerancing. Pilot tooling can be provided
Approvals Static sealing – axial and triangular 16 O-ring stretch during assembly 29 culture is applied to each individual factor to economically and rapidly to further expedite
help reduce our customers’ overall project customer test programs.
Superior elastomer grades 6   Static axial face housing Fitting aids and sharp edges
lead time.
Materials reference guide 7   Static triangular housing Housing chamfers 30 With our extensive tooling expertise, we can
optimise critical surface features to facilitate
Elastomer properties 8 Static/dynamic sealing – radial 17 Traversing cross drilled ports Consultation
reliable function with mating parts.
 Hardness   O-ring stretch in piston sealing Rolling We actively encourage and cultivate early
involvement in customer projects. This helps
  Compression set   Reduction of cross-section due to stretch Cleanliness / cleaning materials Staying ahead
to ensure that the seal element is optimised
  Tensile strength  Guidelines Storage 31 Our continuous capital investment program
within the environment demanded by the
allows us to remain at the leading edge of
  Elongation at break   Gough-Joule effect  Light customer. This ensures that our products are
our field.
  Tear strength Typical compression range 18  Humidity reliable, fit for purpose, correctly specified with
all critical features identified, controlled and We continually implement latest technology
  Gas permeability Typical o-ring housing data for piston  Contaminants
costed at an appropriate and agreed level. systems, ensuring batch-to-batch consistency
and rod sealing applications
 Abrasion 9  Stress throughout the manufacturing process.
Pressure 19
 Colour  Temperature Testing
With such broad customer support facilities,
 Ageing   Oxygen and ozone We work closely with our customers on
Superior will always strive to provide added

04 Custom seal design

all aspects of seal testing and development
  Low temperature flexibility   Shelf life value with our customer programs.
programs. All testing procedures are carried
Media table 10 out to international standards, BS ISO, DIN, Indeed, we find that each new project
Superior engineering 22
Producing an order specification 12 ASTM, or to customer specific requirements. challenges our thinking and creates a
Seal integrity springboard to increasingly enlightened
We offer a diverse range of compounds
Seal performance manufacturing practices.
to satisfy the majority of market needs.
Development of a seal profile
If a customer has a specific need that
Precision mouldings / bespoke seals 23
cannot be met within our existing elastomer
Lip seals / U-seals / V-seals range, we will develop new compound
Symmetrical seals grades at our in-house laboratory.
Quad rings We are able to conduct extensive test
Moulded gaskets programs to fully validate specific
Custom radial seals elastomers to customer parameters
(e.g. temperature/media exposure
Tolerances for moulded parts 24
and mechanical property testing).
A heritage of excellence 25
Our tool room
The service we offer to our customers

2 | www.superiorltd.com Material Science Department +44 (0)1202 854300 | 3

Superior technical guide Specifying compounds

02 Specifying compounds
Important environmental parameters.

Temperature Many factors affect the service temperature Media compatibility rating Approvals
At Superior we are able to develop and of elastomers. All dynamic and shock loads Virtually all elastomers exhibit a physical or We are able to develop and provide
manufacture the majority of elastomer should be avoided at temperatures below the chemical change when exposed to working a comprehensive range of elastomers
compounds used in most market sectors. minus limit of a given compound. However, media, whether gas or fluid. specific for;
elastomers stored in static conditions,
Awareness of specific limitations on each The degree of change depends upon Water Industry:
below the low temperature flexible range,
elastomer is fundamental, in terms of both media composition in combination with WRAS, NSF, DVGW, KTW, ACS,
will recover full physical properties during the
mechanical and chemical characteristics. the elastomer exposed. Aggressive media KIWA, UL
warm-up period. At elevated temperatures,
The most relevant influential working become more active with subsequent Gas Industry:
consideration must be given to the long term
criteria should then be carefully matched increase in temperature. Physical changes EN549, EN682 Compliance
running limit and the short term peak limit of
to elastomer parameters. become apparent in two ways and can
each elastomer. Food and Beverage Industry:
occur simultaneously;
Only then is it possible to achieve accurate FDA, AAA, NSF51
Elastomers exposed to the extreme limit
selection of the most suitable elastomer • the elastomer absorbs the media Pharmaceutical:
can suffer an accelerated loss of flexibility,
for any given environmental condition. – creating a volume increase or swell USP Class VI
resulting in excessive compression set.
Please refer to the materials reference • a base constituent (such as plasticiser)
This can dramatically shorten effective sealing Please consult our Technical Service
guide on page 7. is extracted – creating a volume decrease
life. Also there is an influence in volume swell department for specific accreditations.
Terms and environmental aspects related and age hardening at high temperatures, or shrinkage.
to working with compounds are highlighted dependent on compound type. The degree of volume change is
in the following pages. dependant upon:
The temperature guide below is generic for
Each elastomer type has a specific each elastomer type. We have developed • the media type
working temperature range, however this particular compounds which exhibit improved
• the elastomer chemical structure
will be influenced by many factors: media upper or lower temperature performance.
compatability, dynamic or static operation • the geometric shape of the seal
Please consult our Technical Service (section thickness)
and seal design being several of these.
department on +44 (0)1202 854300
• the stressed condition of the seal
• temperature
• time.
designation

Recommended temperature range: guide only Extended temperature range: guide only
A rubber will swell significantly less when
Superior

°C -100 -80 -60 -40 -20 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300
compressed in the working envelope than
F -148 -112 -76 -40 -4 32 68 104 140 176 212 248 284 320 356 392 428 464 500 536 572
in the free state (up to 50% less).
NBR Nitrile rubber MN/HN
NBR Low temperature Nitrile rubber LN Chemical changes tend to affect the
IIR Butyl rubber BB cross-linking structure of the elastomer
ECO Epichlorohydrin EC (e.g. embrittlement).
ACM Polyacrylate rubber PA
Any application where the media can create
EPDM Ethylene-Propylene-Diene rubber EP
high shrinkage changes to the elastomer
HNBR Hydrogenated Nitrile rubber TH
should be avoided, due to squeeze reduction
AEM Ethylene Acrylate VA
and resultant leakage risk.
FVMQ Fluorosilicone rubber FSIL
FPM Fluorocarbon rubber VF/VP
VMQ Silicone rubber SIL
FFPM Perfluorinated elastomer

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Superior technical guide Specifying compounds

Superior elastomer grades Materials reference guide

Principal properties VMQ: SIL Silicone Material Nitrile Butyl Ethylene Hydrogenated Fluorosilicone Silicone Fluorocarbon
Propylene Nitrile
• excellent low temperature properties,
EPDM: EP Ethylene Propylene
capable to -60°C Designation NBR IIR EPDM HNBR FVMQ VMQ FPM
Terpolymers
• excellent high temperature performance Superior elastomer code MN, LN, HN, WN, BB EP TH FSIL SIL VF, VP
• outstanding resistance to water FN
to 200°C
and steam
• good flexibility, tactile material
• excellent weathering resistance
• can meet FDA, USP expectations Hardness range (IRHD) 40 – 90° 40 – 80° 40 – 90° 50 – 90° 40 – 80° 20 – 80° 55 – 85°
• general temperature use -40°C to +130°C
• poor mechanical properties Colours Limited range Black Limited range Limited range Limited range Limited range Limited range
• can be designed to meet DW Approvals
and food approvals • poor resistance to fuels/oils
Heat resistance °C
• can be designed to give specific • high permeability.
chemical resistance (mineral acids Peak 120 130 160 170 230 230 250
and phosphate esters) FVMQ: FSIL Fluorosilicone
Normal 100 110 130 150 200 200 200
• low compression set in water and air • excellent low temperature
dynamic performance Low temp °C -30 -50 -50 -40 -55 -60 -20
• not suitable for use in mineral oils. -50 low temp version -35 low temp
• increased resistance to fuels, particularly version

NBR: LN, MN, HN, WN, FN useful for aerospace applications Resistances
Acrylonitrile Butadiene (Nitrile) • poor mechanical properties.
Mineral oil (low aromatic) •• x x ••• ••• •• •••
• very good resistance to petroleum
based fluids FKM: VF/VP Fluorocarbon Oxidisation •• ••• ••• ••• ••• ••• •••

• good flexibility at low temps, • excellent resistance to a wide spectrum Ozone x ••• / •• ••• •• ••• ••• •••
-50°C for LN grades of chemicals: fuels, oils, biodiesel etc
Weathering • ••• ••• •• ••• ••• •••
• upper temperature limit of 100°C • chemical resistance can be improved
by use of specific grades Radiation •• / • x ••• •• ••• ••• •••
• can be designed to meet DW
approvals – WN grades • excellent resistance to heat Integrity

• can be designed to meet gas approvals. • can be designed to give high performance Tear strength •• •• •• ••• x x ••
in steam/water
Compression set •• • •• •• ••• ••• ••
HNBR: TH Hydrogenated Nitrile • can be designed to offer excellent
compression set Abrasion resistance •• •• / • •• ••• • • •• / •
• extend the temperature range
of NBR’s to 150°C • low permeability Resilience •• / • • •• •• / • •• •• •

• excellent mechanical properties: • limited use at low temperarure, -20°C Gas permeability •• ••• •• •• x x •••
high strength and wear resistance (special grades are available to extend
Electrical insulation • ••• ••• • ••• ••• Grade dependant
• good dynamic properties and this to -40°C)
weathering resistance • poor resistance to ketones, Inflammability x x x x ••• • •••

• good resistance to many oil additives amines and ethers.

• can be designed to meet gas approvals

• low temp -40°C to -20°C depending Rating
It should be noted that the parameters specified in this table illustrate
on grade. ••• Very Good • Fair the typical working band of commercially available elastomers. Material
•• Good x Unsuitable development is constant and we are able to assist for parameters
Grades can be provided in a hardness range of 30 to 90 IRHD. Grades can be black or coloured outside of the stated values if required.
(mineral filled). The choice of filler will however affect mechanical properties and approvals.
Advice should be sought from the Technical Service department.

6 | www.superiorltd.com Material Science Department +44 (0)1202 854300 | 7

Superior technical guide
Elastomer properties
To fully specify and select a compound, the most relevant
physical characteristics should be known, these are:
Hardness
The term hardness is the measure of a
material’s resistance to a set deforming force
exerted by a given standard indentation
implement over a defined length of time.
Hardness is measured in degree units of IRHD
(International Rubber Hardness Degrees).
It is generally the unit of measure on standard
dimensioned test pieces. It is also the unit
used for measuring the finished component
(e.g. o-ring cross section) by the Micro
Hardness Test.
Standard compounds are nominally 70 IRHD.
Superior can, however, provide compounds
from 20-90 IRHD range, depending upon
material type. Selection of hardness is
dependent upon specific application
requirements. For example:
Softer compounds
• deform more readily under load
(e.g. cover/housing assembly) conform
to surface irregularities
• lower stick/slip effect
• higher running friction.
Harder compounds
• higher extrusion resistance
• lower running friction
• higher stick/slip effect.
The hardness is usually expressed
and controlled as a nominal figure
with ± 5 points tolerance.
original height – recovered height
% Compression Set =
original height – compressed height
8 | www.superiorltd.com
Compression set
This is the measurement of a compound’s
loss of elastic memory. A standard cylindrical
test piece of rubber is subjected to a
defined pre-load at given temperature
and time parameters (e.g. 24hrs/100°C).
The test deformation is usually 25%
of the original height.
The measured recovery of the cross-section
is carried out at ambient temperature.
The end result is recorded as the height not
recovered, expressed as a percentage of the
amount by which the part was compressed.
Usually it can be stated that the better the
elastomeric memory, the lower the compression
set. This is regarded as an important feature
of any compound, as leakage will occur if high
set (and therefore loss of memory) occurs.
Tensile strength
This is the force necessary to rupture a
standard test piece at a given rate of
elongation and expressed as force per
unit area.
In practical terms, this property result does
not assist the end user to select a compound,
because a correctly assembled o-ring does
not rely on its tensile strength to achieve
effective sealing.
Elongation at break
Elongation at break is measured at the
moment of rupture of a test piece under
tensile load, expressed as a percentage.
This is a useful indication of a compound’s
suitability as a large percentage of stretch
may be necessary during assembly
(e.g. piston seal).
x 100
Tear strength
Resistance to tear propagation from
a point of initial damage, sustained
for example, during assembly.
Gas permeability
Elastomers allow gas to enter into
the structure. They will diffuse or
permeate through and escape via
the low pressure side.
The rate of permeation is governed by
temperature, pressure, gas type and
elastomer type. This may be critical
for vacuum and gas containment.
To reduce permeability:
• use larger o-ring sections
• apply more compression
• optimise surface finish
• select high-density elastomers.
Abrasion
Abrasion resistance is a general term
indicating wear resistance.
It can be noted, generally, that HNBR
compounds perform best.
NBR and EPDM have relatively good
abrasion resistance. FPM has a lower
abrasion resistance.
Abrasion resistance improves with hardness
(up to 80 IRHD). However, Silicone and
Fluorosilicone have poor properties
and should only be applied to static
environments.
Colour
Rubbers are usually formulated with the
addition of carbon black fillers. Hence, the
majority of compounds are black in colour.
Rubbers gain much of their strength and
heat resistance from the addition of carbon
black fillers.
However, at Superior we have the expertise
to formulate and produce colour pigmented
compounds for most of the elastomer
range. Colouring is mainly used as
a means of identification, allowing
differentiation of compound grades
in safety-critical applications.
In addition, colour can be used to separate
similar sizes on a customer’s production line.
Please consult our Technical Service
department on +44 (0)1202 854300 for
application and colour range availability.
Specifying compounds
Ageing
Heat ageing tests are widely used to record
changes in property of an elastomer.
Usually hardness, tensile strength and
elongation are measured and compared
to original properties.
Air and relevant fluid ageing over standard
time/temperature durations are meaningful
to compare life expectancies of rubbers.
Standard test conditions are:
NBR 24/70 hrs @ 100°C
EPDM 24/70 hrs @ 120°C
FPM 24/70 hrs @ 200°C
VMQ 24/70 hrs @ 200°C
If elastomers are pushed beyond their
ageing resistance parameters, they will suffer
from cracking, splitting and/or hardening.
Low temperature flexibility
The TR test (low temperature retraction)
provides a measure of the rate of recovery
of an elastomeric material after it has been
subjected to low temperature.
The test, which is described in ISO 2921,
consists of stretching a test piece with an
effective length of 50 or 100mm and placing
it in a bath at -70°C.
The test piece is allowed to retract freely
whilst the temperature is raised at the
rate of 1°C per minute.
The percentage retraction of the test
piece is plotted against temperature.
Retraction values are calculated automatically
with TR10, TR30, TR50 and TR70
values being most commonly recorded.
TR10 and TR70 values are of particular interest.
Material Science Department +44 (0)1202 854300 | 9
Superior technical guide Specifying compounds

Media table
For dynamic applications it is recommended that a swell up to 8% maximum be adhered to (••• rated). For static seals
a volume change up to 25% can be tolerated (••/• rated) as long as the groove volume accommodates any increase.

Recommended Recommended
Superior designation LN/MN HN EP TH FS SIL VF/VP Superior designation LN/MN HN EP TH FS SIL VF/VP
compound compound
Maximum service temperature °C 100 100 150 150 200 200 230/2v00 Fluids resistance (continued)
Low service temperature °C -45/-30 -20 -50 -40 -55 -60 -20/-35 Gases
Water/steam resistance Butane •• ••• x ••• •• x ••• / ••• TH5/03/1, HN75
Water/steam resistance <60°C ••• ••• ••• ••• ••• ••• ••• / ••• WN70/3 Carbon dioxide (dry) ••• ••• •• ••• •• •• ••• / ••• TH5/03/1
Water/steam resistance <80°C •• •• ••• ••• •• •• ••• / ••• EP1/1/5, WN12/7/1 Chlorine (wet) x x • • •• x ••• / ••• VF75B
Water/steam resistance <150°C x x •• •• x x *•• / • EP7/3/7, EP11/7/4 Freon 12 (R12) ••• ••• •• ••• • x •• / ••• HN75
Water/steam resistance >150°C x x • x x x *•• / x VF12/99/3, EP11/7/4 Freon 22 (R22) x x ••• x x x x / x EP7/3/7, EP11/7/4
Fluid resistance Freon 134a (R134a) o o ••• ••• x o x / x EP7/3/7, EP11/7/4
Acids Natural gas •• ••• x ••• • •• ••• / ••• TH5/03/1, HN75
Acetic 10% • • ••• •• x •• • / •••* EP10/00/2 Methane •• ••• x ••• •• x ••• / ••• TH5/03/1, HN75
Formic x x ••• x • •• • / •••* EP10/00/2 Propane •• ••• x ••• •• x ••• / ••• TH5/03/1, HN75
Hydrochloric 20% • • ••• • •• • •• / •••* EP10/00/2 Oils and fuels
Nitric 30% x x ••• x • • •• / ••• VF3/00/10 ASTM No 1 oil ••• ••• x ••• ••• •• ••• / ••• MN70
Phosphoric 20% • • ••• • •• •• ••• / ••• EP10/00/2 ASTM No 2 oil ••• ••• x •• ••• • ••• / ••• HN75
Sulphuric 30% x x •• x • x •• / ••• VF3/00/10, VP5/00/5 ASTM No 3 oil • ••• x • ••• x ••• / ••• HN75
Alkalis ASTM fuel A •• ••• x ••• ••• x ••• / ••• HN75
Baruim hydroxide •• •• ••• ••• •• •• ••• / ••• EP7/3/7, EP11/7/4 ASTM fuel B • •• x x ••• x ••• / ••• VF75B
Calcium hydroxide •• •• ••• ••• •• •• ••• / ••• EP7/3/7, EP11/7/4 ASTM fuel C x • x x •• x ••• / ••• VF75B
Sodium hydroxide •• •• ••• •• • • •• / ••• EP7/3/7, EP11/7/4 Diesel oil •• ••• x ••• •• x ••• / ••• HN75
Alcohols Diesel oil + RME (10%) x x x x • x ••• / ••• VF5/4/4, TH8/5/6
Butyl alcohol (Butanol) ••• ••• •• •• ••• •• ••• / ••• EP70, MN70 Mineral oil (low aromatic) ••• ••• x ••• ••• •• ••• / ••• MN70
Ethyl alcohol (Ethanol) •• •• ••• ••• ••• ••• • / ••• EP70, MN70 Hydraulic oils (petroleum base) ••• ••• x ••• •• • ••• / ••• MN70
Methyl alcohol (Methanol) •• ••• ••• •• •• •• x / ••• EP70, MN70 Lubricating oils ••• ••• x ••• ••• • ••• / ••• MN70
Amines Paraffin ••• ••• x ••• ••• • ••• / ••• MN70
Ethylene diamine •• •• ••• •• x •• x / ••* EP7/3/7, EP11/7/4 Petrol •• ••• x ••• ••• x ••• / ••• VF75B
Ammonia – cold gas ••• ••• ••• ••• x •• x / • EP7/3/7, EP11/7/4 Silicone oil / grease ••• ••• ••• ••• • • ••• / ••• EP7/3/7, EP11/7/4
Ammonia – hot gas x x •• • x •• x / x EP7/3/7, EP11/7/4 Transformer oils ••• ••• x ••• ••• • ••• / ••• MN70
Chlorides Vegetable oils ••• ••• • ••• ••• •• ••• / ••• FN70
Ammonium chloride ••• ••• ••• ••• ••• ••• ••• / ••• EP7/3/7, EP11/7/4 Solvents
Calcium chloride solution ••• ••• ••• ••• ••• ••• ••• / ••• EP7/3/7, MN70, EP11/7/4 Acetone x x ••• x x • x / x EP7/3/7, EP11/7/4
Magnesium chloride ••• ••• ••• ••• ••• ••• ••• / ••• EP7/3/7, MN70, EP11/7/4 Benzene x x x x •• x ••• / ••• VF75B
Zinc chloride ••• ••• ••• ••• ••• ••• ••• / ••• EP7/3/7, MN70, EP11/7/4 Carbon tetrachloride x • x • • x ••• / ••• VF75B
Dimethyl formamide • • •• • x •• x / •• EP7/3/7, EP11/7/4
Ethyl acetate x x •• • x • x / x EP7/3/7, EP11/7/4
Rating The table above refers to room Methyl ethyl ketone x x ••• x x x x / x EP7/3/7, EP11/7/4
temperature tests. Tetrachloroethylene x x x x •• x ••• / ••• VF75B
••• Excellent – recommended (5-8% swell) Toluene x x x x •• x ••• / ••• VF75B
For other conditions and additional
•• Good – minor to moderate effects (8-15% swell) media advice please refer to the Turpentine •• ••• x ••• • x ••• / ••• HN75
Technical Service team for advice. Xylene x x x x • x •• / ••• VF75B
• Fair – moderate to severe effects (1-25% swell) Miscellaneous

x Poor – not recommended (>25% swell)
o Insufficient data available
*Conditions apply Temperature or other limitation affecting polymer choice
Please note that in some conditions a negative swell (shrinkage through extraction) may occur.
Ethylene glycol ••• ••• ••• ••• ••• ••• ••• / ••• EP2/9/10
Detergents ••• ••• ••• ••• ••• ••• ••• / ••• EP7/3/7, EP11/7/4
Dioctyl phthalate x x •• x •• • x / •* EP7/3/7, EP11/7/4
Formaldehyde • • ••• • • •• x / x EP7/3/7, EP11/7/4
Hydrogen peroxide (90%) x x •• x •• •• •• / ••• VF3/00/10, VP5/00/5
Phosphate esters x x ••• • • • • / •• Consult
Potassium nitrate ••• ••• ••• ••• ••• ••• ••• / ••• MN70

10 | www.superiorltd.com Material Science Department +44 (0)1202 854300 | 11

Superior technical guide Seal design

% reduction of cross-section d2
13

12

11

03
10

Seal design 9

This section of the guide is intended to assist 7

Producing an
engineers when consideringUnstretched
sealing criteria.
6
Unstretched
O-ring O-ring
Unstretched
Unstretched
O-ring
O-ring
order specification 5

4
Unstretched O-ring
3

To ease liaison with our Sales department The first part of this section considers It is important to keep in mind that reliability, Sealing types 1

and ensure the correct compound and
size of seal is ordered, we advise that
you apply the following considerations
to your specification:
• Highest peak temperature/duration
• Highest operating temperature
• Lowest temperature at which components
are expected to still function
• Media contact on assembly and
during operation
• Approval for water, gas or other
legislative requirements
• Static or dynamic working condition
(cycle rates/duration)
• Weathering/ozone resistance required
• Likely material being considered: refer
to materials reference guide or provide
compound designation number (e.g. MN70)
• Specific physical property minimums
e.g. Tensile strength, elongation,
compression set
• System pressure
• Colour/hardness requirements
• Quality and documentation requirements
• Lead time plan
• Size of seal (in the case of o-rings,
inside diameter and cross section).
design criteria for o-rings.
Superior is able to select from an extensive
range of standard and non-standard
o-rings (see our Superior size list for
further details or download from our
website www.superiorltd.com).
We can also recommend and manufacture
bespoke sizes. We will then produce
precision moulds which exceed recognised
industrial standard tolerances – quickly and
efficiently, in-house.
d1 d2
TheStretched Stretched
O-ring O-ring 0
standardisation and ease of manufacture various configurations
Stretched
Stretched
O-ring can be
O-ring
around mating parts is achieved through defined according to the type of sealing,
consultation with our Engineering department as describedStretched
below: O-ring
at the earliest possible stage of development.
Practicality demands that this is a concise Radial compression
guide, as each application could present
infinite parameter variables compared with
previous examples. As a result, guidelines and
trends tend to focus in general areas, so we Piston rod Piston
sealingrod sealing
always encourage additional direct contact Type APiston
Piston
rodAsealing
Type rod sealing
TypeType
A A
with our Engineering department to fine Piston rod sealing
tune and elaborate where conditions are Type A
not covered specifically within this guide.
Precision o-rings
Piston sealing
Piston sealing
These are the most versatile and economical Type BPiston sealing
Piston
Type B sealing
TypeType
B B
form of sealing device available. O-rings
will conform most readily to general design Piston sealing
Type B
guideline recommendations, as they have the
most extensive record of service life in diverse Axial compression
conditions. O-rings are mainly used in static
Face sealing
Face sealing
applications, sealing against liquids, gas and FaceFace
sealing
sealing
Type C & DType C & D
TypeType
C&C D&D
general environments.
Face sealing
Our Engineering department is able to Type C & D
assist in specifying for dynamic applications,
with special consideration given to individual A correctly designed housing with the
working conditions. O-rings are generally not appropriate sized seal is important. However,
recommended for dynamic applications. this function is not solely responsible for an
effective seal: the compound used influences
O-ring Size and Compound
the sealing performance.
Selection Program
Superior has created a program to assist the In all applications, where possible the largest
selection process for a specific o-ring. The o-ring cross section diameter d2 should
program allows the user to enter the criteria be specified for the application to overcome
required and media in which it will be used, as tolerances and rolling.
well as the housing information if known, and
the program will select a number of options
available. There is also an option to contact
the sales department for a quotation based
on the information entered. Our O-ring Size
and Compound Selection Program can be
found on our website www.superiorltd.com.

12 | www.superiorltd.com Material Science Department +44 (0)1202 854300 | 13

 b

Pressure direction

B A h
Superior technical guide Seal design
b
r2 No back-up ring

r1
Pressure direction

Groove layouts General housing guidelines b1

To identify each feature of the housing standard One back-up ring

letter symbols can be applied in all cases. Housing diametrical tolerances

Pressure direction

For radial sealing it is important to use tight tolerances as specified for the shaft and bore.
d1 d2
This reduces possible eccentricity and possible loss of compression.
Piston sealing (radial) type A b Letter symbols b b2
r1 rounded, flash-free r For face sealing it is important to use a tight tolerance to reduce the range ofTwo
stretch
back-up rings
The inside diameter (d1) of an o-ring B b Seal housing width2 B
rounded, flash-free orHousing
o-ring outside diameter as applicable.
diametrical tolerances
(b1 and b2 for anti-extrusion devices)
should always be smaller than the housing
A
d1 O-ring t
inside diameter
diameter (d3). The maximum stretch must Bore diameter d4/d10 H8
B g A
be limited to keep the resultant loss in cross d2 O-ring cross-section diameter Shaft diameter d5/d9 f7 These tolerances are as specified in ISO/R286,
ISO System for limits and fits – Part 1, general
sectional diameter to an acceptable level and d9 d3 d4 dd53 Groove diameter d10 d6 Axial – outside diameter d7 H11 tolerances and deviations.
keep the tensile stress to a minimum. d15°
4 Bore
to 20° diameter Axial – inside diameter d8 H11
t
g
d5 Shaft diameter B
Leadininchamfers
Lead chamfers Z (30°
Z (30° – 40°–inclusive)
40° inclusive)
15° to 20° d6 Groove diameter
To enable the o-ring to be fully assembled without undue risk of damage, the appropriate
d7 Outside diameter: d Up to 2mm 2.01 to 3mm 3.01 to 4.5mm 4.51 to 6mm Above 6.01mm
r2 r1 2
lead
0° to 5°
z axial application 0° to 5°
z internal pressure Leadininchamfer needs
chamfers to be
Z (30° applied
– 40° to the housing.
inclusive)
Z minimum 1.1mm 1.5mm 1.8mm 2.7mm 3.6mm
d8 Inside diameter:
Alldedges
2 to be rounded
Up to 2mm 2.01 to 3mm 3.01 to 4.5mm 4.51 to 6mm Above 6.01mm
axial application external pressure
d7 Z minimum 1.1mm 1.5mm 1.8mm 2.7mm 3.6mm
d9 Shaft diameter0 - 5° r1
0° to 5°
(internal pressure)
d10 Bore diameter All edges to be rounded
Rod sealing (radial)
b
type B b b d8
r1
The ideal condition is for the o-ring rounded,
outsideflash-free r2 g Radial clearance r2
B B B (external pressure)
t
Housing Dimensions – static axial (0.2mm
(mm) max)
Surface finish or texture
rounded, flash-free h Seal housing depth: axial sealing
diameter to be equal to, or slightly greater Sealing efficiency can be directly related to surface finish. The application must be considered
than, the housing diameter (d6). Too higher an dr21 Cornerh +0.10
radius bb +0.20 r r2
A t b Housing Dimensions – static axial b (mm) 1 Surface finish of
from a number or aspects
texture to establish the most effective and economic surface finish.
B
interference of the seal outside diameterg A(d6) r1 rounded, flash-free
r2 Edge radiusPressure
(0.2mm)r2
direction
B B
will result in distortion of the seal profile. This d B d A h
rounded, flash-free
Surface roughness
d9 d10 d6 dt2 Seal housing
h +0.10 depth: b radial
+0.20 sealing r1 r2 Surface finish or texture
d3 4 5
is due to its inability to cater for the difference A Letter Surface Application Pressure Ra µm
15° to 20°
z Lead-in chamfer:
t piston and
B g A A Housing sides Static Non pulsating and 1.6
in circumferential length. t rod housing
b Surface roughness
g B and static diameters non alternating
d9 r2 d4 Please
d5 note that
No Ød
10H7 applies to
back-up ring
d10 d6 Letter Surface Application Pressure Ra µm
A maximum outside diameter interference 15° to 20° d3 Pulsating or alternating 0.8
r1 dynamic application. A Housing sides Static Non pulsating and 1.6
of 3% is considered optimum but on small 15° to 20° Pressure direction Dynamic All types 0.8
r2 t r and static diameters non alternating
0° to 5°
diameters this could be up to 8%.z z
0° to 5° 1 g B B Mating surface in Static Non pulsating and 0.8
Pulsating or alternating 0.8
contact with o-ring non alternating
15° to 20° Dynamic All types 0.8
e.g. cylinder bore for Pulsating or alternating 0.4
b1 B Mating surface in Static Non pulsating and 0.8
r2 0° to 5° r1 piston seal Dynamic All types 0.4
d7 0 - 5°
r1 z
One back-up ring 0° to 5°
z contact with o-ring non alternating
0° to 5°
(internal pressure)
Pressure direction The above is for e.g. cylinder
guidance bore
only andfor Pulsating
covers the majority of the sealing or 0.4
alternating However, Superior
applications.
b d8 piston
should be consulted in seal Dynamic
areas of particular concern. All types 0.4
t r2
Face sealing (axial) typeB C
d1 & D
(external pressure)
d2 (0.2mm max) d7 0 - 5°
r1
0° to 5° The above is for guidance only and covers the majority of the sealing applications. However, Superior
This is the simplest use of o-rings, provided the b
(internal pressure)
Coefficient of inthermal
should be consulted expansion
areas of particular concern.
b2
basic rules are remembered. Seal compression is b d8 When an unloaded rubber is heated it will expand inline with the coefficient of thermal expansion
Pressure direction t
Two back-up rings r2
controlled by the depth of the groove and should B
A Housing diametrical tolerances
(external pressure) (0.2mm max) for that particular rubber grade. Rubber compounds have much higher coefficients of thermal
B h
be between 15% to 30%. b expansion than steel or Aluminium (approx. ten times of steel), thermal expansion may cause an
Bore diameter d4/d10 H8 already tight seal to swell and overfill the groove as temperature rises. Housings have been known
For internal pressure, the o-ring should be Pressure direction
These tolerances are as specified in ISO/R286,
Shaft
A
diameter d b 5/d9 f7 to rupture under the force exerted by an expanding seal. A seal design that provides minimal
supported byrthe housing diameter (d7) whilst for B hNo back-up ring ISO System for limits and fits – Part 1, general
2 Axial – outside diameter d7 H11 tolerances and deviations. compression in a low temperature environment cannot rely on thermal effects for help in tightening
external pressurer1the inner diameter (d8) is used. Axial – inside diameter d8
Pressure direction H11
the seal. It is therefore imperative that the seal has the correct compression and groove width
It is possible to remove the internal spigot, where b
to allow for these situations.
r2 No back-up ring
there is internal pressure, provided there is no
r1
Pressure direction Coefficient of friction
risk of cavitation. b1
One back-up ring The coefficient of friction for a rubber seal is influenced by many factors. These include compound
hardness, surface finish of mating components, speed of movement and lubrication. Breakout
Pressure direction
friction is generally higher than running friction. To lower breakout and running friction, coatings
b1
One back-up ring or lubrication can be applied.

Pressure direction Superior offer a wide range of solutions to help alleviate frictional forces. Superior dry coatings can also
b2
Two back-up rings aid assembly and increase efficiency on automatic assembly lines while reducing assembly efforts,
Housing diametrical tolerances d1 d2 reduce risk of rolling during installation, and eliminate sticking of components after long storage.
b2
Bore diameter d4/d10 H8 Two back-up rings
Shaft diameter d5/d9 f7 These tolerances are as specified in ISO/R286,
Housing
ISO System for limitsdiametrical tolerances
and fits – Part 1, general
Axial – outside diameter d7 H11 tolerances and deviations.
14 | www.superiorltd.com Material Science Department +44 (0)1202 854300 | 15
Axial – inside diameter d8 H11 Bore diameter d4/d10 H8
 1.78 1.30 2.40 0.2 - 0.4 0.2 - 0.4
A
2.00 1.50 2.60 0.2 - 0.4 0.2 - 0.4
2.50 2.00 3.20 0.2 - 0.4 0.2 - 0.4
B h
2.62 2.10 3.60 0.2 - 0.4 0.2 - 0.4
Superior technical guide pressure
from inside
3.00 2.30 3.90 0.4 - 0.8 0.2 - 0.4
Seal design
3.53 2.80 4.80 0.4 - 0.8 0.2 - 0.4
r2 4.00 3.25 5.20 0.4 - 0.8 0.2 - 0.4
5.00 4.00 6.50 0.4 - 0.8 0.2 - 0.4
r1
5.33 4.35 7.20 0.4 - 0.8 0.2 - 0.4
6.00 5.00 7.80 0.4 - 0.8 0.2 - 0.4
6.99 5.75 9.60 0.8 - 1.2 0.2 - 0.4
8.00 6.80 10.40 0.8 - 1.2 0.2 - 0.4
Static sealing – axial and triangular 9.00 7.70 11.70 0.8 - 1.2 0.2 - 0.4 Static/dynamic sealing – radial
10.00 8.70 13.00 0.8 - 1.2 0.2 - 0.4
12.00 10.60 15.60 0.8 - 1.2 0.2 - 0.4

% reduction of cross-section d2
13
0° to 5° d7 Housing
0° to 5°Dimensions – staticd8axial (mm)
Static axial face housing O-ring stretch in piston sealing 12

The o-ring is compressed in the axial direction. b d2 h+0.10 b b+0.20pressure r1 r2 When an o-ring’s internal diameter is less than 50mm, the maximum stretch should be less than 11
B from outside
When the o-ring
Use of a is subjected to a pressure 1.50 1.10 1.90 0.2 - 0.4 0.2 - 0.4 8%. When an o-ring’s internal diameter is greater than 50mm, the maximum stretch should be less 10
fitting aid
the o-ring will undergo a relative displacement. 1.78 1.30 2.40 0.2 - 0.4 0.2 - 0.4 than 6%. The maximum stretch is derived from the largest groove diameter and smallest o-ring 9

% reduction of cross-section d2
A A
Therefore it is important to correctly size the 2.00 1.50 2.60 0.2 - 0.4 0.2 - 0.4 internal diameter. 13 8

2.50 2.00 3.20 0.2 - 0.4 0.2 - 0.4 7

o-ring to limit the movement when pressure h h
12
B B 2.62 2.10 3.60 0.2 - 0.4 0.2 - 0.4 11 6
is applied. If the pressure is internal, then Unstretched O-ring
pressure 3.00 2.30 3.90 0.4 - 0.8 0.2 - 0.4 10 5
the o-ring’s outside diameter should be in from inside
3.53 2.80 4.80 r2 0.4 - 0.8 0.2 - 0.4
0° 9 4
contact with the housing outside diameter. 4.00 3.25 5.20 0.4 - 0.8 0.2 - 0.4
r2 8 3
B
The circumferential interference should be 5.00 4.00 6.50 r1 0.4 - 0.8 0.2 - 0.4
r1 7 2
no more than 1%. 5.33 4.35 7.20 0.4 - 0.8 0.2 - 0.4
6 1
6.00 5.00 7.80 0.4 - 0.8 0.2 - 0.4 Unstretched O-ring
If the pressure is external then the o-ring’s Recommended axial compression Stretched5 O-ring 0
6.99 5.75 9.60 0.8 - 1.2 0.2 - 0.4 2 4
O-ring cross section d2 in mm
inside diameter should be in contact with 8.00 6.80 10.40 0.8 - 1.2 0.2 - 0.4 4

the housing. In this case the o-ring should Axial compression or face seal
9.00 7.70 11.70 0.8 - 1.2 0.2 - 0.4 3

10.00 8.70 13.00 0.8 - 1.2 0.2 - 0.4

Reduction of cross-section due to stretch
be stretched up to a maximum of 4%. 35 2

12.00 10.60 15.60 0.8 - 1.2 0.2 - 0.4 When an o-ring is stretched, the cross-section distorts to 1assume an oval form. The o-ring cross-
30
0° to 5° d8
section reducesO-ring
Stretched when subject to stretch. As rule of thumb, 0 approximately half of the stretch
25
Squeeze %

2 4 6 8 10 12 14 16 18 20 22 24 26
20
max. e.g. 5% stretch equals 2.5% reduction in cross-section.
b % stretch of inside diameter d1
15 pressure min.
from outside This reduction in cross-section lowers the compression and thus the sealing stress.
10

A5
Piston rod sealing
Guidelines Type A
0
1 2 3 4 5 6 7 8 • Static o-rings are squeezed to higher percentages than dynamic, as friction
h
B d2 (mm) concerns are reduced.
static-axial
Piston sealing (radial)
r2 • Surface finish requirements can be relaxed in comparison to dynamic
b b
r1 rounded, flash-free applications (except
r
where pulsating
Piston pressure is present).
rod sealing
2
B B BType A
r1 rounded, flash-free
• Dynamic o-rings are exposed to lower squeeze percentages compared to static
Piston sealing
Static triangular housing O-ring housing data for axial and triangular sealing applications to reduce
A t friction and wear. Type B
B g A
Location grooves with a triangular shape are • Surface finish requirements are critical to reduce friction, seal wear and damage.
d2 h b t s Axial Triangular
sometimes used for screwed flanges and caps. d9 d3 d4 d5 d10 d6
d2
minimum r1 r1 • T15°
heto groove width will need to be increased for one/two back up rings, if system
However, manufacturing these to accurate sizes maximum maximum 20°

Lead in chamfers z1 and z2 (30˚ – t40˚ inclusive) pressures g

are exceeded beyond normal o-ring capability.
is difficult. Since the sealing function of the o-ring 1.50 1.00/1.05 2.25/2.55 2.08/2.20 3.80 0.2 0.75 B
Piston sealing
depends on the exact shape of the locating 1.60 1.20/1.25 2.36/2.66 2.20/2.32 4.00 0.2 0.80 15° to 20° • Oscillating and rotating conditions are regarded as dynamic.
d2 Up to 2mm 2.01 to 3mm 3.01 to 4.5mm 4.51 to 6mmType BAbove 6.01mm Face sealing
1.78 1.24/1.37 2.54/2.84 2.41/2.54 4.80 0.5 0.76 • Although suitable
groove, the dimensions and tolerances given r2
Z minimum 1.1mm
0° to 5° 1.5mm 1.8mm 2.7mmfor 0°
dynamic
to 5°
work, ro-rings
3.6mm 1
are best applied to short
Typestroke/small
C&D
2.00 1.35/1.45 2.89/3.19 2.76/2.88 4.60 0.5 1.10 z z
in the following table are to be strictly observed. diameter applications.
2.40 1.70/1.80 3.45/3.75 3.30/3.42 5.00 0.5 1.30 All edges to be rounded.
Installation in rectangular grooves is preferable. • The Housing
preferredDimensions – static
is 60axial
to 80(mm)
0° to 5 ° Ø d7
2.50 1.78/1.88 3.38/3.68 3.44/3.56 5.25 0.5 1.40 o-ring hardness IRHD.
d7 0 - 5°
r1
r2 2.62 1.90/2.03 3.60/3.90 3.68/3.81 6.35 0.9 1.02 • Media compatibility and temperature are critical,
0° to 5° b d2 h +0.10 b +0.20 r 1 as swell or
r 2 shrinkage should
3.00 2.20/2.30 4.00/4.30 4.20/4.32 6.00 1.0 2.00 Rod sealing (radial) B
(internal pressure)
Face sealing
b d8 be minimised for reliable function.
t 3.50 2.60/2.70 4.50/4.80 4.81/4.93 6.80 1.0 1.90 t Type C &r2 D
B
3.53 2.54/2.80 4.80/5.10 4.95/5.08 8.00 0.9 1.52 A (external pressure)
• Compounds with the highest wear
(0.2mm max) resistance should be selected.

b b b
4.00 3.00/3.10 5.10/5.40 5.51/5.63 7.40 1.0 2.20 r1 • Pneumatic and hydraulic applications can be accommodated.
B
rounded, flash-free
Surface
h
finish orrtexture
2
B
5.00 3.80/3.90 6.23/6.53 6.86/6.98 8.90 1.0 2.70 B flash-free
rounded, Pressure direction

5.34 4.19/4.45 7.10/7.40 7.50/7.63 11.00 0.9 2.20 B A h pressure

s Letter Surface Application Pressure Surface roughness
A t from inside Superior does not generally recommend the use of o-rings as rotary seals.
45° 5.70 4.40/4.50 7.00/7.30 7.80/7.92 10.00 1.0 B3.00 g A Ra µm
6.99 5.60/5.85 8.90/9.20 10.03/10.16 15.00 0.9 2.54 A r2 Housing Sides Static Non pulsating and 1.6
d9 d4 d5 d10 d6 b
8.40 6.60/6.70 10.00/10.30 11.50/11.62 14.00 1.0 d3
4.00
15° to 20°
r1 r2 and static diameters Gough-Joule
non effect
alternating No back-up ring

Ø h8 r1 Pulsating
t
g When a or alternating
freely suspended,
Pressure 0.8 rubber is stretched and heated, the rubber will contract,
direction loaded
B
Dynamic All types 0.8
Installation in a 15° to 20°
attempting to regain a less stressful state. This occurs becauseStatic axial face
of the rubber’s housing
stressed structure.
triangular groove B Mating surface in Static Non pulsating and 0.8
The ‘O’ ring is
This phenomenon is of particular importance in rotary applications, where the combination compressed in of
the axial
r2 0° to 5° contact with ‘O’ Ring r1 non alternating
0° to 5°
installedorstretch b
and system heat direction. When the ‘O’ ring is subjected
0.4 can cause the o-ring to retract and seize the rotating shaft.
z z 1
e.g. cylinder bore for Pulsating alternating
One back-up ring

piston seal Dynamic All types 0.4 to a pressure the ‘O’ ring will be subject
Pressure direction
to a relative displacement. Therefore it is
d7 0 - 5°
r1 and covers
0° to 5°
The above is0for
° to guidance
5° only Ø dthe
8 majority of the sealing applications. However, Superior Seals important to correctly size the ‘O’ ring to
d1 d2
(internal pressure)
should be consulted in areas of particular concern.
limit the movement when pressure is applied.
b d8 b pressure
t r2 b2 If the pressure is internal, then the ‘O’ ring’s
B (external pressure) from outside
(0.2mm max) Two back-up rings
outside diameter should be in contact with the
Housing diametrical tolerances
b
16 | www.superiorltd.com A housing outside
Material Science Department +44diameter.
(0)1202 The circumferential
854300 | 17
Pressure direction
Bore diameter d4/d10 H8 interference should be no more than 1%.
A
 Superior technical guide Seal design

Whilst the adjacent table is a Typical o-ring housing data for piston and rod sealing applications
Pressure
guideline
30
for o-ring compression,
Hydraulics, dynamic
O-Ring Rousing data for piston and piston rod sealing applications
the following graphs display a more Elastomers tend to act as a viscous fluid when under pressure, resulting in migration into the
25
d2 b b1 b2 Corner radii ‘extrusion gap’.
accurate representation. b b1 b2 Zero pressure
Squeeze %

20 max.

15 d2 t t t r. maximum
Therefore, under certain conditions, a supporting back-up ring is used in conjunction with
10 an o-ring to reduce the risk of extrusion. The back-up ring effectively bridges any gap due
Typical compression range min.
(100 bar maximum)
pressure alternating pressure Without With
to the clearance between the shaft and bore.
5 anti- anti-
(100 bar +) (100 bar +)
extrusion extrusion
0 Hydraulics, dynamic
1.8 2.65 3.55 5.3 7 Mode d2 t b t b1 t b2 rings rings For axial face-sealing applications, extrusion gaps should be eliminated, ensuring that pulsating
30
O-ring cross section d2 in mm
Hydraulics, dynamic Static 1.50 1.17/1.09 2.30/2.50 - - - - 0.50 0.25 pressures do not create ‘panting’ between mating faces.
25 Pressure
30 *Static 1.60 1.18/1.25 2.30/2.50 - - - - 0.50 0.25 Zero pressure
20 Pneumatics, dynamic
%

25 max. Static and

30 1.46/1.52 2.40/2.60 1.47/1.52 4.10/4.23 1.47/1.52 6.10/6.23
Squeeze

dynamic 1.78 0.50 0.25

15
%

20
25 max.
Pneumatic 1.55/1.60 2.40/2.60 - - - -
Squeeze

10
%

15
20 min. Static and
2.00 1.64/1.72 2.70/2.90 1.68/1.72 4.10/4.30 1.68/1.72 5.50/5.70 0.50 0.25
Squeeze

5
10 max. dynamic
15 min.
0 *Dynamic 1.97/2.09 3.20/3.40 2.01/2.09 4.60/4.80 2.01/2.09 6.00/6.20
105 1.8 2.65 3.55 5.3 7 Pneumatic 2.40 2.13/2.20 3.20/3.40 - - - - 0.50 0.25
50 O-ring cross section d2 in mm min. *Static 1.84/1.97 3.10/3.30 - - - - Zero pressure Pressure Extrusion
1.8 2.65 3.55 5.3 7
0 Static and
Pneumatics,
1.8 O-ring
2.65 cross 3.55
dynamic section d2 in5.3
mm 7 2.06/2.19 3.40/3.60 2.12/2.19 4.80/5.00 2.12/2.19 6.20/6.40
dynamic 2.50 0.80 0.25
30
O-ring cross section d2 in mm Pneumatic 2.24/2.31 3.40/3.60 - When exceeding the recommended gap size (in accordance with the graph below)
Pneumatics, dynamic - - -
25
30 Static and an anti-extrusion device is required.
Axial compression or face seal 2.20/2.30 3.17/3.37 2.26/2.31 4.60/4.73 2.26/2.30 6.50/6.63
%

20
35
dynamic 2.62 0.80 0.25
25
Squeeze

15 max. Pneumatic 2.34/2.41 3.17/3.37 - - - - • Recommended extrusion gap is based upon radial clearance if eccentricity is zero,
%

30
20
*Dynamic 2.50/2.65 4.00/4.20 2.57/2.65 5.40/5.60 2.57/2.65 6.80/7.00
Squeeze

25 or diametral clearance if concentricity of mating diameters cannot be assured.

%

10 max.
15 max. Pneumatic 3.00 2.70/2.77 4.00/4.20 - - - - 1.00 0.25 Pressure Extrusion
Squeeze

20
5 min. *Static 2.35/2.50 3.70/3.90 - - - -
10
15 min. 600 • It should be noted that Silicone and Fluorosilicone (due to low tensile strength) should
working pressure: bar

0 Static and
5
10 1.8 2.65 3.55 5.3 7 min. dynamic
3.50 2.94/3.11 4.70/4.90 3.01/3.11 6.10/6.30 3.01/3.11 7.50/7.70 1.00 0.25 only be applied in grooves with extrusion gaps at half the recommended radial clearance
5
0
1.8
O-ring cross section d2 in mm
2.65 3.55 5.3 7 Static and for other compounds.
3.02/3.12 4.30/4.50 3.10/3.15 5.50/5.63 3.10/3.15 7.40/7.53
0 dynamic 3.53 0.90 0.25
1 2 O-ring
Axial compression 3orcross section
face4 seal 5 d2 in6 mm 7 8
3.18/3.25 4.30/4.50 - - - -
• If a selected radial clearance will not achieve a given pressure, then the next
35 Pneumatic
d2 (mm)
30 Axial compression or face seal
static-axial Static and A good quality 70 IRHD compound will resist hardness range should be considered.
4.00 3.40/3.57 5.30/5.50 3.47/3.57 6.70/6.90 3.47/3.57 8.10/8.30 1.00 0.25
35 dynamic
25
500 extrusion at room temperature up to 100 Bar. • If a 90 IRHD rubber compound does not satisfy the given parameters, then a PTFE
Extrusion
%

30 Hydraulics, pneumatics, static max. Static and

However, extrusion resistance is influenced by:
% Squeeze

20 4.30/4.52 6.60/6.80 4.42/4.52 8.40/8.60 4.42/4.52 10.20/10.40

30
25 dynamic 5.00 1.00 0.40 or Thermoplastic back-up ring should be selected.
%

15 min.
max. 4.57/4.67 6.60/6.80
Squeeze

25
20 Pneumatic - - - -
10 max. • temperature
15
20 min. Static and
5 4.66/4.77 6.35/6.55 4.71/4.49 7.60/7.73 4.71/4.79 10.20/10.33
Squeeze

10 dynamic 5.34 0.90 0.40 • pulsating pressure spikes mm

15
0 Pneumatic 4.83/4.93 6.35/6.55 - - - -
5 1 2 3 4 5 6 7 8
10 min. *Dynamic 4.95/5.18 400
7.50/7.70 5.08/5.18 9.30/9.50 5.08/5.18 11.10/11.30 • seal cross section 0,30
0 d2 (mm)
1 2 3 4 5 6 7 8 Pneumatic 5.70 5.22/5.38 7.50/7.70 - - - - 1.00 0.40 70 80 90 rubber hardness (IRHD)
5 static-axial • housing design (radii, draft angles).
d2 (mm) *Static 4.70/4.95 6.40/6.60 - - - -
0 0,25
Hydraulics,
1.8 pneumatics,
2.65 static-axial
static
3.55 5.3 7 Static and
30 6.00/6.12 8.65/8.85 6.07/6.14 10.05/10.18 6.07/6.14 13.50/13.63 Please consult our Engineering department
O-ring cross section d2 in mm dynamic 6.99 0.90 0.40
25
Hydraulics, pneumatics, static
Pneumatic 6.12/6.32 8.65/8.85 - - - - for detailed information regarding particular

Clearance (radial)
30 max. 0,20
*Dynamic 7.50/7.75 11.00/11.20 7.63/7.75 13.20/13.40 7.63/7.75 15.40/15.60 working conditions.
%

20
25 300
Squeeze

max. Pneumatic 8.40 7.75/7.96 11.00/11.20 - - - - 1.00 0.40

15
%

20 *Static 7.20/7.50 7.00/9.20 - - - - 0,15

Squeeze

10 min.
15
5
10 min.
0
*BS 4518 recommendations 0,10
5 1.8 2.65 3.55 5.3 7 NOTE: All dimensions in mm
0 O-ring cross section d2 in mm
1.8 2.65 3.55 5.3 7 200
0,05
O-ring cross section d2 in mm
n
ios
t ru
ex

150 0
0 70 140 210 280 350 410 bar
Pressure
100
90
80 • Anti extrusion rings are required when • For temperatures above 100°C use
n
sio

70
ru

60 considering conditions to the right of the curve for the next hardness rubber.
t
ex
no

50
40 the hardness curve.
30
20 degrees of hardness 70 80 90 IRHD
10
0
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
diametrical play (mm)

18 | www.superiorltd.com Material Science Department +44 (0)1202 854300 | 19

Our state of the art toolroom
designs and manufactures
precision prototype and production
moulds to meet the engineering
challenges of our customers.
Superior technical guide Custom seal design

04
Custom seal design and manufacture
Using Superior custom designed seals can
mean fast service and quality assurance to you.

Moulded Seals are homogenous rubber parts Precision mouldings / Symmetrical seals
which are components that operate within custom seals • Lower assembly force than the
static and dynamic applications. Where a specific moulding profile is required, equivalent o-ring
we apply our extensive experience to guide
• Greatly reduces the chance of spiralling
Superior engineering the design evolution to achieve the most
Superior’s core strength is providing our reliable and cost effective solution. • Symmetrical design enables seal to be
customers with optimal design and robust assembled both ways
sealing solutions. Superior has the ability to Our broad design capabilities at Superior • Less volume than the equivalent o-ring
assist in the design of sealing solutions which enable us to supply unique profiles for
applications where traditional o-rings • Can cope with pressure from both sides.
exceed customer expectations. Support
and Technical Service are always on hand are not suitable.
Quad rings
to provide advice on component design, Our portfolio includes generic profiles • Two sealing beads in contact with both
compound selection and analysis. such as: the groove and bore
When an o-ring is desired we can calculate • diaphragms • Greatly reduces the chance of spiralling
the ideal housing geometry and o-ring size • precision flat washers • Symmetrical design enables seal to be
for given parameters. Where an o-ring cannot • spherical balls. assembled both ways
be used, Superior can offer help and advice
to find a solution for you. Although there is an infinite number of different • Lower friction for dynamic applications.
seal profiles which can be used to suit
Seal integrity individual applications, there are a number
Moulded gaskets
We are focused on the fact that our precision • Low assembly force
of more commonly used custom seal profiles.
o-rings and special mouldings are a crucial Listed below are just a small number and their • Tailored profile
part ‘of the bigger picture’. The integrity and advantages. • Able to cope with larger tolerances
quality of Superior products are fundamental
Seal performance Seal design assistance • Able to cope without flatness
to the integrity of each end product, helping Lip seals / U-seals / V-seals
to achieve outstanding product performance The performance of the seal is dependant Getting involved at the earliest possible stage of • Plastic housings
• Self energising when pressure acts
and enhance our customers’ hard-won on 5 factors: development, our engineering department aims • Retention
against the lips
reputations. The unique integrity of our to become an integral part of our customer’s
• system media • Lower assembly force than the • Axial (face) sealing
products is achieved through a combination team, providing services such as:
• hardware equivalent o-ring • Multiple sealing ports
of 3 Key Elements; Compound, Design and • seal design
• service conditions • Lower dynamic running force than • Customer information
Manufacturing process.
• housing recommendations the equivalent o-ring
• seal design • Location tags
• design for manufacture and assembly • Require less space than the
• seal compound. • Stabilising features.
(DFMA) equivalent o-ring
• CAD • Less creep in housing Custom radial seals
• problem solving • Able to cope with larger tolerances • Low dynamic force
• advice. • Able to cope with eccentric conditions • Eccentric conditions

• Able to cope without flatness • Tolerances

All these services combined assist in reducing
(axial sealing). • Special conditions
Design Compound project lead times.
Seal • Profile.
Integrity

Manufacturing
Process

22 | www.superiorltd.com Material Science Department +44 (0)1202 854300 | 23

Superior technical guide Custom seal design

Tolerances for moulded parts
Moulded seals are subject to changes
in their geometry during vulcanization.
These changes should be allowed for when
designing. The greater the degree of accuracy
demanded, the closer the control which must
be exercised during manufacture. When
particular physical properties are required
in the product, we advise consultation with
Superior’s Engineering department.
All rubber shows some shrinkage when
cooled after moulding, and allowance for this
is made in the mould design. The amount of
shrinkage is dependent on rubber type.
Moulds are made in various ways depending on
the type of product and accuracy demanded.
Superior recommend the use of ISO 3302-1
Class M2 tolerance for high-quality precision
mouldings (see table below).
In compression moulding more rubber is
used than is required to fill the cavity, and
the excess is flashed. This flash can prevent
the mould sections from fully closing and
thus affects the finished part dimensions.
However, for injection and transfer moulding
all dimensions can be considered as fixed.

moulded part

upper half of mould

C F
flash

C
F

lower half of mould

Nominal dimension Class M2
Up to and F C
Above
including ± ±
0 4.0 0.10 0.15
4.0 6.3 0.15 0.20
6.3 10 0.20 0.20
10 16 0.20 0.25
16 25 0.25 0.35
25 40 0.35 0.40
40 63 0.40 0.50
63 100 0.50 0.70
100 160 0.70 0.80
Two types of tolerances, F and C are used.
Fixed dimension (F): Dimensions which are
not affected by influences like flash or lateral
movement of different mould parts.
Closure dimension (C): Dimensions which
can be altered by flash thickness or lateral
movement of different mould parts.
A heritage of excellence
Since 1972 Superior has built a reputation
for engineering excellence. Our tool-making
expertise and capabilities ensure we
consistently meet the tightest tolerances,
not to mention budgets and deadlines,
every single time.
Our tool room
As a full service facility we are able to manage
projects from prototyping right through to
production. We focus on providing engineers
and product designers with physical samples
in the shortest possible lead time.
The marketplace and our customers’ needs
are constantly changing. We are flexible
enough to react to changing demands
quickly, and can use off-line programming
to take new designs to machine as quickly
as possible.
The service we offer
to our customers
Our success is based on our clients’ success.
That’s why we do everything we can to make
working with Superior benefit their business.
Our clients can expect to have samples
perfectly bagged, delivered on their desk
ready for practical trials. We are here to help
our customers win business and launch new
products in the most compressed time scales
and above all with confidence.

160 - 0.50% 0.70% We have complete control of the tool making

Dimensions in mm process, and are committed to expanding
our facility in line with client needs. In fact we
constantly invest in the latest, state-of-the-art
technology to ensure all tooling and products
are manufactured with 100% accuracy and
meet our customers’ tightest deadlines.

24 | www.superiorltd.com Material Science Department +44 (0)1202 854300 | 25

Superior technical guide Quality

05 Quality
Standards compliance
Quality acceptance
criteria ISO 3601-3

O-ring size range standards Limits of size for surface imperfections for Grade N o-rings
At Superior, we pride ourselves on our
precision o-ring range which exceeds the
Surface Limiting Size limit
cross-sectional tolerances for the following imperfection dimension

dimensional standards; Grade N

b +0.2 O-ring section diameter d2

ISO 3601-1 B
rounded, flash-free <2.25 >2.25 >3.15 >4.50 >6.30
<3.15 <4.50 <6.30 <8.00
DIN 3771 Part 1
e e e

BS 4518 g Off-register e 0.08 0.10 0.13 0.15 0.15

B r1 A mismatch
(offset)
The benefit of close tolerances on an o-ring Ø d9 Ø d3 Ø d4

cross section (d2), is the ability to reduce our

r2 t
customer’s tolerance chain and improve the
overall performance of the customer’s product. 15 ° to 20 °
Combined f 0.10 0.12 0.14 0.16 0.18 f

flash
f

0° to 5 °
In the Superior o-ring size list, the internal z
diameters conform to ISO 3601-1 tolerances
and the cross section diameter has a reduced
h
tolerance. These precision o-ring tolerances Backrind g 0.18 0.27 0.36 0.53 0.70
g
apply to NBR 70 compounds. O-rings
manufactured in other compounds and h 0.08 0.08 0.10 0.10 0.13
hardness’ are produced to conform
ISO 3601-1 tolerances, however n
Excessive n Not less than o-ring section diameter
dimensions for the internal diameter trimming on lower tolerance
may be towards the lower end.

Flow marks j 1.50 * 1.50 * 6.50 * 6.50 * 6.50 * k

k 0.08 0.08 0.08 0.08 0.08 j

l
Foreign l 0.60 0.80 1.00 1.30 1.70 m
material,
non-fills and
indentations
(including m 0.08 0.08 0.10 0.10 0.13 l
parting-line
d1 d2 indentations)
High shrinkage compounds may Quality is an integral part of the Superior customer service philosophy
* or 0.05 x o-ring internal diameter, whichever is greater but not exceeding 50 mm
require dedicated tooling to comply with
Total control of all aspects of seal This section is designed to give guidance
ISO 3601-1 dimensions and tolerances,
manufacture ensures that we always to quality and design engineers.
but will still allow for the principle of a more
comply with recognised standards
accurate cross-section. Superior can also
applied by the industry. We thoroughly recommend that all quality
supply o-rings to customer’s specifications.
and specification issues are addressed at
With our expertise we can closely define the earliest point in the development stage
A continually updated version of the Superior
and control seal tolerances and surface of any new project. This ensures that all
o-ring size list can be downloaded from our
characteristics. Our continual investment customer-critical features and commercial
website www.superiorltd.com
programs enable us to apply the latest issues are identified from the outset.
control and inspection techniques.

26 | www.superiorltd.com Material Science Department +44 (0)1202 854300 | 27

Superior technical guide
Quality control: documentation
All documentation for despatch to the
customer conforms to the ISO 9001 standard.
The documentation issues and details are
continually being revised and updated
according to demands from individual
customers and the industry in general.
Please consult our Quality department
for specific requirements.
Seal surface inspection levels
All our o-rings are inspected to ISO 3601-3
DIN 3771 part 4. The standard level is Grade N.
For more information on inspection levels
please consult our Quality department.
28 | www.superiorltd.com
Special moulding tolerances
Dimensional tolerances on special
mouldings will relate to ISO 3302-1
or customer specification.
Certification
Certification can be provided with the product,
but must be stated at point of order.
Environmental compliance
Superior is able to provide materials compliant
to current European and Worldwide legislative
requirements e.g. ROHS, REACH and IMDS.
Assembly
06
Assembly
This section of the guide is intended to assist engineers
when considering sealing criteria.
An o-ring is a precision component requiring Piston sealing assembly aid
care during installation and handling. Many
failures of o-rings can be directly related to
improper installation. Long-term, leak-free
o-rings can only be achieved when the
correct size for the housing is chosen.
O-ring stretch during assembly
During assembly an o-ring inside diameter
can be stretched up to 50% for most
compounds, however it is advisable to keep
below this value where possible to prevent
damage to the o-ring. Sometimes this value Use of a Fitting Aid
may be unachievable, this is particularly
true with o-rings of small inside diameter
and large section.
Rod sealing assembly aids
It is essential to give the o-ring time to
recover, this is especially important during
automatic assembly.
Fitting aids and sharp edges
O-rings should not be drawn over sharp
edges, threads, slits, bores and splines
during fitting. The use of fitting aids during
assembly ensures the avoidance of sharp
edges and features.
Suitable assembly tools, as detailed,
aid location and avoid contact with sharp
edges. The aid should be manufactured
from materials which will not damage sealing
locations and surfaces (e.g. plastic or brass).
For manual assembly or removal of an
o-ring from a groove, a spatula-type tool
can be manufactured from a soft material.
All edges should be smooth, rounded
and free from burrs.
Material Science Department +44 (0)1202 854300 | 29
 Superior technical guide Storage

15° to 20°
Housing chamfers
To prevent damaging the o-ring section
Traversing cross drilled ports
An o-ring can be sheared when a
Rolling
O-rings are at risk from rolling when fitted
Storage
15° to 20° during assembly, chamfers are necessary spool or a rod moves in a bore broken over a diameter. This risk can be accentuated
y
on all leading edges, all other edges must be by cross-drilled ports. The deformed on large inside-diameter/ small section
y Recommended storage conditions Stress
free from burrs. Dimension X should always o-ring returns to its original round cross o-rings. This can result in spiral failure and
for products based on Superior Always store o-rings in their unstressed,
be greater than dimension Y to ensure section as it enters the port and is sheared leakage. To reduce the risk of rolling we
rubber compounds. free state, avoiding distortion and the risk
trouble free assembly. as it leaves the drilled area. To avoid this, recommend that suitable lubrication be
of ozone attack. Large rings should never
connection holes should be repositioned. applied to the o-ring prior to assembly.
Optimum service is the primary objective be hung on pegs.
If repositioning is not feasible, an internal
in the development of any compound
chamfer is recommended. Cleanliness / cleaning materials
at Superior. Temperature
At Superior we rigorously control cleanliness
Finished components should be stored
at all process stages, particularly during the We give careful consideration to minimising below 30°C and preferably below 25°C.
final post-deflashing cleaning cycle. the compound factors that may adversely
Use of a
15° to 20° fitting aid affect seal performance. It is in the nature Extended exposure to higher temperatures in
Use of a All seals are supplied to the customer free
15° to 20°
Piston assembly fitting aid of rubbers that changes can occur during air can accelerate ageing effects and cause
from surface silicone film and surface particle
Piston assembly
extended component storage and become distortion, hardening, elongation loss and
contamination (e.g. flash particles).
exacerbated by inappropriate conditions impairment of low temperature flexibility.
Foreign particle contamination on seals and practices. Recommended conditions
15° to 20°
should always be followed. If inadvertent freezing has occurred, the
can cause leakage after assembly.
15° to 20° apparent hardening effect can be reversed by
If applying lubricants, the seal should be Light warming to normal ambient temperatures.
assembled immediately into the housing, Sunlight and intense artificial light can cause
Rod assembly Oxygen and ozone
mference, allowing or protected if placed in storage or transition. surface deterioration of rubber components.
re re-compression Rod assembly Superior o-rings are supplied in sealed
mference, allowing In extreme cases, this is manifested as
re re-compression
All cleaning media must be compatible shallow crazing. polythene bags which prevent exposure to
Shelf life
with the elastomer. circulating air and atmospheric impurities.
It is practically impossible to define a specific
X We recommend that storage of such parts
We recommend that o-rings are kept in these maximum shelf life for finished elastomeric
15° should take place in dark or very low-intensity
to 20°
bags until required – it is the combined effect products. To achieve the best results, always
Y artificial light conditions.
of atmospheric oxygen and temperature that rotate stock and store as recommended.

Humidity promotes the problems encountered above.

Fitted ‘O’ ring,
Leading edge chamfer rolled
Fitted ‘O’ ring, You should avoid conditions where
X>Y
rolled
condensation may occur prior to
assembly/installation.
Contaminants
Airborne contaminants deposited on the
surface of o-rings prior to installation can
promote surface attack. Examples include
cutting oil mists, powders and active
chemicals used in production processes.
In the case of particulates, such
contamination can create a leakage
path when in service.
As far as is possible, o-rings should be
kept in their sealed delivery bags until
required for installation.
The following table of suggested
Ozone is present in low concentrations shelf life is for guidance only.
in the atmosphere and at much higher levels
near some electrical equipment. It will attack 3 years 7 years
rubber components based upon particular Superior FN Superior EP
elastomers when they are stretched or Superior WN Superior SIL
distorted. This appears as cracks at right Superior PA
5 years
angles to the direction of distortion. Superior TH
Superior LN
Superior VF/VP
Of all common o-ring elastomers, Superior MN
only nitrile (NBR) is significantly prone Superior HN
to ozone attack.
These storage times are more
Once again, storage in the original
conservative than those proposed in
sealed polythene bags in dark or very
BS ISO 2230:2002, ‘Controlled storage
low-intensity artificial light conditions
and packaging of vulcanised rubber
offers full protection.
and rubber products’.

30 | www.superiorltd.com Material Science Department +44 (0)1202 854300 | 31

Superior technical guide

We are fiercely proud of our

place in the world of engineering.
We are also constantly aware of the continuous challenges that
face us in order to maintain our position and ensure we continue
to fulfil obligations to our customers.
By continually monitoring our performance, sharpening our technical expertise and tightening
response times, we are able to reinforce our added value. If you would like to learn more about
how Superior can contribute to your business’ success we would be pleased to answer your
questions and welcome you to meet our people, see our facility and discuss your requirements.

A warm welcome awaits you at Superior.

 www.superiorltd.com

Superior Seals Limited Superior Specials Limited

Nimrod Way Nimrod Way
Ferndown Industrial Estate Ferndown Industrial Estate
Wimborne, Dorset BH21 7SH, UK Wimborne, Dorset BH21 7SH, UK

Tel: +44 (0)1202 854300 Tel: +44 (0)1202 891180

Fax: +44 (0)1202 854313 Fax: +44 (0)1202 894468
Email: sales@superiorltd.com Email: specials@superiorltd.com

All technical information included in this document is provided free of charge for guideline purposes only and is based on
01.13.02

technical data which Superior believes to be reliable. This information is intended for use by suitably skilled and qualified
persons entirely at their own discretion and risk. As the end use of our product is beyond our control, we make no warranties
express or implied and no liability can be accepted in connection with the use of this information, which is subject to revision
without prior notice as additional knowledge and experience are gained. COPYRIGHT © 2013 Superior GROUP LIMITED