Tribol Lett (2010) 38:187–194

DOI 10.1007/s11249-010-9589-1

ORIGINAL PAPER

A Hydrodynamic Laser Surface-Textured Gas Mechanical

Face Seal
Shaoxian Bai • Xudong Peng • Yefeng Li •

Songen Sheng

Received: 26 October 2009 / Accepted: 8 March 2010 / Published online: 23 March 2010
 Springer Science+Business Media, LLC 2010

Abstract A new type of hydrodynamic laser surface nr, nh Dimple numbers respectively in radial and
texturing gas seal with orientation ellipse dimples is rotating directions
introduced to improve hydrodynamic effect. Theoretical p, po Pressure in lubrication regime, Pa
model is developed to study the hydrodynamic effect of P Dimensionless pressure
this new gas seal. Then, a parametric investigation of the Po Dimensionless seal pressure
texturing parameters such as slender ratio, dimple incli- pa Standard atmospheric pressure, 1.01325 9
nation angle, dimple depth, and dimple area rate is pre- 105 Pa
sented for the presented gas seal under different operating q Leakage rate, m3/s
parameters of rotation speed, seal pressure, and clearance. Q Dimensionless leakage rate
Results show that the orientation dimples can greatly r Radial coordinate, m
improve hydrodynamic effect of laser surface texturing gas R Dimensionless radial coordinate
seals. Open force may be improved more than 20% greater ri,j Radial coordinate of dimple center, m
by hydrodynamic effect in the analysis. Rw , RQ Increase ratio respectively of open force and
leakage
Keywords Mechanical seals  Gas lubrication  Sp Dimple area density
Surface texturing  Hydrodynamic effect w Open force, N
W Dimensionless open force
g Bulk viscosity with pressure free, Pa.s
List of Symbols
h Coordinate of rotating direction, 
a, b Respectively long and short axis of ellipse
hi,j rotating direction coordinate of dimple center, 
dimple, m
h0 Degree of the numerical analysis regime, 
c, h Sealing clearance, m
x Rotation speed, rpm
do, di, dp Diameters respectively of outside, inside,
a Inclination angle of ellipse dimple long axis, 
textured and dimple, m
c Slender ratio
hp Dimple depth, m
l Distance parameter, m2

S. Bai (&)  X. Peng  Y. Li  S. Sheng
College of Mechanical Engineering, Zhejiang University
of Technology, Hangzhou 310032, China
e-mail: bshaoxian@163.net
S. Bai  X. Peng  S. Sheng
Key Laboratory of Special Purpose Equipment and Advanced
Processing Technology, Ministry of Education, Zhejiang
University of Technology, Hangzhou 310032, China
1 Introduction
The surface texture generated by laser surface texturing
(LST) on the contact surfaces has some advantages in
reducing friction and wear of mechanical seals. Etsion and
Burshtein [1] developed the first model for LST mechani-
cal seals based on circle micro dimples. Since then a large
volume of theoretical and experimental work was

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188 Tribol Lett (2010) 38:187–194

published on various aspects of LST liquid and gas seals by influence of dimple orientation on hydrodynamic gas seals.
Etsion’s group [2–8]. Etsion et al. [2] investigated the Hydrodynamic effect on open force and leakage has been
performance of textured faces experimentally on a water numerically analyzed. Additionally, the mechanism of the
pump. The water pumps seal showed improved perfor- presented hydrodynamic LST gas seal is illustrated.
mance with textured faces as compared to original un-
textured ones. Kligerman and Etsion [3] investigated the
LST effect in a circumferential gas seal. It was found that 2 The Model
the presence of the micro-pores on one of the seal mating
faces generates substantial hydrodynamic effect that A schematic description of a partial LST mechanical seal
maintains a small clearance between the rotating shaft and with ellipse dimples is presented in Figs. 1 and 2. The
the stationary seal ring. Etsion and Halperin [4] success- textured face portion adjacent to the high-pressure bound-
fully employed partial LST to enhance hydrostatic effects ary at do extends from dp to do. Hence, this allows treating
in high-pressure seals. McNikel and Etsion’s experimental the LST face as a collection of radial dimples columns as
results [5] show the potential benefits of the new concept in shown in Fig. 2a.
terms of smother running, low friction torque, and lower The micro dimples are distributed uniformly with an area
face temperature. Then, theoretical model to study the density Sp, representing the percentage of the seal face area
effect of partial LST on a hydrostatic gas seal was devel- between dp and do (see Fig. 2a) that is occupied by the dimples
oped, and optimized the LST gas seal performance in terms 4nh nr ab
of maximum film stiffness, combined with minimum gas Sp ¼ : ð1Þ
do2  dp2
leakage [6–8]. All these studies show that LST seal pro-
vides better sealing. A spherical segment with a long axial radius a, short
There are some other recent works concerning perfor- axial radius b, depth hp, and inclination angle a (see
mance of the LST face seal. Peng et al. [9] numerically Figs. 1, 2b) models each one of the micro ellipse dimples.
analyzed the effect of face asperity geometry on perfor- When the ratio of long to short axis of the ellipse dimple is
mance of a liquid-lubricated face seal, such as face opening greater than 1, the dimple presents obvious orientation. In
force, fluid film stiffness, and face frictional torque. Results order to consider the influence of micro-dimple orientation
show that a LST seal with the rectangle section profile properties, slender ratio c is defined as follows:
micro-pores or the column micro-pores exhibits the best a
performance. Furthermore, static performance of a gas- c¼ : ð2Þ
b
lubricated face seal with rectangle micro-pores is numeri-
Here, the direction of the dimple in the seal face is
cally analyzed by Qin et al. [10].
decided by the inclination angle a and the slender ratio c
However, in the above studies, the hydrodynamic effect
together.
generated by LST micro-pores, especially the circle dim-
According to the basic assumptions adopted in this
ples, is much smaller in gas-lubricated face seals than in
work, the seal faces are separated by a uniform gas film
liquid application. The micro-pores do not provide obvious
thickness, c, (see Fig. 1). The sealed gas is compressible
hydrodynamic open force especially when the seal pressure
and viscous (Newtonian) with a constant viscosity g. The
is high [11]. As pointed out by McNikel [5], the micro-
dimples generated by LST provide a weak hydrodynamic
effect compared to conventional lift devices that act as
effective thrust bearings. This will lead to that the mating
sealing faces can not separate open quickly during starting
operation in non-contacting mechanical face seals, and
friction and wear from face contact is easy to happen. As
pointed out by Feldman [7], the circle dimple LST seal has
higher risk of friction and wear from face contact although
it provides better sealing. Therefore, the LST seal based on
circle dimples is actually a type of hydrostatic gas seal
discussed in the above studies. In order to minimize the
risks from face contact, enough hydrodynamic open force
is necessary especially for low pressure starting operation.
In this article, a new type of hydrodynamic LST gas seal
with ellipse dimples is introduced to improve of hydrody-
namic effect. Theoretical model is developed to study the Fig. 1 Schematic of a partial LST mechanical seal

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Tribol Lett (2010) 38:187–194 189

Equation 3 can be solved for the pressure distribution. In

the analysis, pressure-periodic boundary condition is
po applied as following:
do

pa pðr ¼ 0:5do ; hÞ ¼ po ; pðr ¼ 0:5di ; hÞ ¼ pa ;

pðr; h ¼ 0:5h0 Þ ¼ pðr; h ¼ 0:5h0 Þ: ð5Þ
dp

di For the mechanical face seal shown in Fig. 1, the

leakage rate, actually, is the flow rate in the radial
direction. According to the flow continuity principle, the
leakage rate should keep consistent at any radial, and its
expression is as follows.
Z2p
h3 r op
qðrÞ ¼ pdh ð6Þ
0.5do 12gpa or
0
pθ =0.5θ 0 = pθ = −0.5θ 0
The open force is expressed as following equation.
0.5dp
Z2p Zro
0.5di w¼ prdrdh ð7Þ
0 ri
0

p = pa p = po
In order to study the seal performance, following
dimensionless parameters are defined: dimensionless
r
radial coordinate R ¼ 0:5d i
, dimensionless pressure P ¼ ppa ,
dimensionless seal pressure Po ¼ ppoa , dimensionless open
r 12qg
force W ¼ d4w
2 p and dimensionless leakageQ ¼ c3 p .
a i a

2a 2b

3 Results and Discussion

The shape and main calculation data of the ellipse dimple-

Fig. 2 Geometry of a LST seal micro surface structure: a radial
ellipse dimples column and boundary conditions; b individual cell
with a single ellipse dimple
textured face mechanical seals used for the analysis are
shown in Fig. 1 and Table 1. And the values of the ring
dimensions refer to Gabriel’s experimental work [12].

generalized gas lubrication equation for mechanical seal 3.1 Pressure Distribution
shown as in Fig. 1 is express as
    Figure 3 presents pressure distributions along the center
o h3 op2 o h3 op2 oðphÞ
þ ¼ 12x : ð3Þ line of a dimples column is represented by the dotted
roh g roh or g or oh
curves at rotation speed x = 0 and is given by the solid
For the ellipse dimple surface, the local film thickness, curves at rotation speed x = 3,000 rpm. When slender
h(r, h), is given by:

c þ hp ; l  1 Table 1 Specification of ellipse dimple-textured seal face
hðr; hÞ ¼ ;
c; l[1 Item Symbol Dimensions
    2 and data
r cosh  ri;j coshi;j sina  r sinh  ri;j sinhi;j cosa
l¼ Outside diameter do 156 mm
a
    2 Inside diameter di 116 mm
r cosh  ri;j coshi;j cosa þ r sinh  ri;j sinhi;j sina Textured diameter dp 130 mm
þ ;
b Dimple depth hp 5 lm
ð4Þ Calculation region angle h0 2
Dimple number in rotating directions nh 180
where, ri,j, hi,j are coordinates of dimple center (i = 1,…,
Dimple number in radial directions nr 8
nh; j = 1,…, nr).

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10
8 Pressure flow
Dimensionless pressure P
γ =1
6
γ =2
γ =3
4 γ =4
2
1.00 1.05 1.10 1.15 1.20
Dimensionless radial R
Fig. 3 Pressure distribution along the center line of a dimples column
(Sp = 0.3, hd = 5 lm, a = 55, c = 2 lm, Po = 9)
ratio c = 1, the dimple is circle with no obvious orienta-
tion. The dimple is ellipse with significant orientation when
slender ratio c [ 1. Clearly, hydrodynamic effect is very
weak for circle dimple seal. When the dimples have sig-
nificant orientation, however, pressure increases with
increase of slender ratio. It means that the hydrodynamic
effect increases greatly for this inclination micro-dimple
gas seals.
This may be explained by the fact that, as shown in
Fig. 4, for the directional dimple, the fluid from outside to
inside driven by outside higher pressure, will flow in the
long axial direction of the dimple under the shear action of
rotation speed. It means that the direction of the dimple
increase the flow distance in the dimple and produce fluid
cumulative effect in the dimple length direction, the
resistance force is decreased by shear action of rotation
speed. Hence, the pressure in the dimple increases under
the influence of dimples’ orientation.
3.2 Influence of Operation Parameters
3.2.1 Rotation Speed
Figure 5 shows the effect of the rotation speed on the open
force and the leakage. As can be seen the open force
increases slightly with the increase of rotation speed when
the slender ratio c = 1, but does significantly when the
slender ratio c [ 1. Meanwhile, with the increase of slen-
der ratio, the open force increases obviously, about 80%
under the condition of x = 10,000 rpm and c = 4. This
means that the seal faces will separate quickly with
increase of rotation speed during of the seal start.
On the other hand, the leakage presents the similar trend
as the open force. Rotation speed has no obvious influence
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Tribol Lett (2010) 38:187–194
Rotating direction
High pressure
(seal outside)
Shear flow
ω=0
ω = 3000 rpm Low pressure
Dimple
(seal inside)
1.25 1.30 1.35
Fig. 4 Influence mechanism of dimple direction on gas flow in seal
clearance
on the leakage when the slender ratio is c = 1. However,
increasing rotation speed leads to significant increase of the
leakage when the slender ratio is c [ 1.
Hence, the directional dimple with certain inclination
angle may produce obvious hydrodynamic effect. This is a
type of hydrodynamic seal.
3.2.2 Seal Pressure
Figure 6 presents the influence of seal pressure on the open
force and the leakage for rotation speed x = 0 and
x = 3,000 rpm. It can be seen that both the open force and
the leakage have the same trend with the increase of seal
pressure. When the rotation peed x = 0, the hydrostatic
open force and the leakage increase greatly with the
increase of sealing pressure as obtained by Feldman [7].
Additionally, the slender ratio c has no obvious effect on
either open force or leakage.
While the rotation speed x = 3,000 rpm, increase of the
slender ratio c results in significant increase of both open
force and leakage as expected when the seal pressure
Po \ 10. However, increasing seal pressure leads to the
decrease of the hydrodynamic effect induced by the
directional dimple. It can be observed that the hydrody-
namic open force is about 100% higher than the hydrostatic
open force at the case of Po = 1.1 and c = 4, and only
about 7% greater at the case of Po = 20 and c = 4. At the
same time, the increase of hydrodynamic effect produces
the increase of the leakage as shown in Fig. 6.
Another important result shown in Fig. 6 is that the
hydrodynamic effect is very weak when the slender ratio
c = 1. As can be observed that the rotation speed has no
obvious influence on open force even at low seal pressure
Po = 1.1.
Tribol Lett (2010) 38:187–194 191

32 100

γ = 4

Dimensionless open force W

Dimensionless open force W

28

γ = 3
γ = 1, ω = 0
10 γ = 2, ω = 0
24
γ = 3, ω = 0
γ = 2 γ = 4, ω = 0
γ = 1, ω = 3000 rpm
20 γ = 2, ω = 3000 rpm
γ = 1 γ = 3, ω = 3000 rpm
γ = 4, ω = 3000 rpm

1
16 1 10 100
0 2000 4000 6000 8000 10000 Seal pressure Po
Rotation speed ω / rpm
100000
7000

10000

Dimensionless leakage Q
6000 γ = 4
Dimensionless leakage Q

1000
5000 γ = 1, ω = 0
γ = 3 γ = 2, ω = 0
γ = 3, ω = 0
4000 100
γ = 4, ω = 0
γ = 1, ω = 3000 rpm
γ = 2 γ = 2, ω = 3000 rpm
3000 10 γ = 3, ω = 3000 rpm
γ = 4, ω = 3000 rpm
2000
γ = 1 1
1 10 100
1000 Seal pressure Po
0 2000 4000 6000 8000 10000
Rotation speed ω / rpm Fig. 6 Influence of sealing pressure on open force and leakage
(Sp = 0.3, hd = 5 lm, a = 55, c = 2 lm)
Fig. 5 Influence of rotation speed on open force and leakage
(Sp = 0.3, hd = 5 lm, a = 55, c = 2 lm, Po = 9)

clearance have significant influence on hydrodynamic open

3.2.3 Seal Clearance
Figure 7 demonstrates the influence of the seal clearance
on the open force and leakage. When the slender ratio
c = 1, the open force decreases greatly with the increase of
the seal clearance as presented by Feldman [7]. However,
the hydrodynamic effect is very weak. The hydrodynamic
open force has a slight increase only at low seal clearance,
about 3% higher than the hydrostatic open force for
c = 1 lm.
On the contrary, when the dimple has obvious orienta-
tion, the hydrodynamic open force increases obviously
with the increase of the slender ratio c. The hydrodynamic
open force is about 50% greater than the hydrostatic open
force in the case of c = 4 and c = 1 lm, which is far more
than that of c = 1.
According to the discussion above in this section, con-
clusions can be obtained that the directional dimple face
seal is a type of hydrodynamic seal, and the operation
parameters of rotation speed, seal pressure and seal
force and leakage. The general trend is that open force
increase with increase of rotation, and decrease with that of
seal pressure and seal clearance. Meanwhile, the increasing
open force is always companied with increase of the
leakage.
3.3 Influence of Dimple Parameters
In order to analyze the influence of dimple parameters on
the hydrodynamic performance, two ratio parameters are
defined here. One is increase ratio of hydrodynamic open
force, Rw, which reflects the increase of open force under
the shear action of shear speed. The expression is as
follows
W  Wx¼0
Rw ¼ : ð8Þ
Wx¼0
The other is increase ratio of leakage, RQ, which reflects
the shear action of rotation speed on leakage. Its expression
is as follows

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192 Tribol Lett (2010) 38:187–194

28 24
γ = 2, ω = 3000 rpm
23 γ = 3, ω = 3000 rpm

Dimensionless open force W

26
γ = 1, ω=0 γ = 4, ω = 3000 rpm
Dimensionless open force W

γ = 2, ω=0 22
24 γ = 3, ω=0
γ = 4, ω=0 21
γ = 1, ω = 3000 rpm
22 γ = 2, ω = 3000 rpm 20
γ = 3, ω = 3000 rpm
γ = 4, ω = 3000 rpm 19
20

18
18 γ = 2, ω = 0
17 γ = 3, ω = 0
γ = 4, ω = 0
16 16
1 10 100 0 10 20 30 40 50 60 70 80 90
Seal clearance c / μm Inclination angle α / °
5000 2800
γ = 2, ω = 3000 rpm
4500 2600 γ = 3, ω = 3000 rpm
γ = 1, ω = 0 γ = 4, ω = 3000 rpm
Dimensionless leakage Q

4000 γ = 2, ω = 0 2400

Dimensionless leakage Q
γ = 3, ω = 0
3500 γ = 4, ω = 0 2200
γ = 1, ω = 3000 rpm
3000 2000
γ = 2, ω = 3000 rpm
γ = 3, ω = 3000 rpm
2500 1800
γ = 4, ω = 3000 rpm
2000 1600

1500 1400
γ = 2, ω = 0
1000 1200 γ = 3, ω = 0
γ = 4, ω = 0
500 1000
1 10 100 0 10 20 30 40 50 60 70 80 90
Seal cleaerance c / μm Inclination angle α / °
Fig. 7 Influence of clearance on open force and leakage (Sp = 0.3, Fig. 8 Influence of dimple inclination angle on leakage (Sp = 0.3,
hd = 5 lm, a = 55, Po = 9) hd = 5 lm, c = 2 lm, Po = 9)

Q  Qx¼0
RQ ¼ : ð9Þ
Qx¼0
3.3.1 Influence of Dimple Inclination Angle
Figure 8 shows the relationship curves between the load
and the dimple inclination angle. It can be seen that the
dimple inclination angle has significant effect on the load.
When the dimple inclination angle h = 0 and h = 908, the
rotation speed has no obvious influence on the open force,
that is hydrodynamic effect is very weak. However, the
dimple inclination angle h = 20–808, the hydrodynamic
effect is very significant, the load increase very large with
the rotation speed and the slender ratio.
It can be seen that the dimple inclination angle has
significant effect on the open force. As same as the influ-
ence on the open force, when the dimple inclination angle
h = 0 and h = 908, the rotation speed has no obvious
influence on the leakage, that is hydrodynamic effect is
very weak. However, while the dimple inclination angle
h = 20–808, the hydrodynamic effect is very significant,
the leakage increase very large with the rotation speed and
the slender ratio.
3.3.2 Influence of Dimple Area Rate
Figure 9 shows the increase of hydrodynamic open force
and leakage under three different dimple area rate cases at
rotation speed x = 3,000 rpm. As same as analyzed in
Sect. 3.3, the increase of open force and leakage is the most
significant at the inclination zone of a = 30–508 under the
influence of hydrodynamic effect. It can be seen that, area
rate has also significant effect on open force and leakage.
With the increase of area rate, the hydrodynamic open
force increase greatly. The hydrodynamic open force is
22% greater that the hydrostatic open force in the case of
area rate Sp = 0.3 and dimple inclination angle a = 50.
The leakage presents the similar change trend with the
open force under different dimple area rates. The larger the
dimple area rate, the greater the leakage. The rotation
speed makes the leakage increase about 90% for the sealing

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Tribol Lett (2010) 38:187–194 193

25 20
Sp = 0.12

Increae ratio of hydrodynamic open force

c = 2 μm, Po = 9, ω = 3000 rpm
Sp = 0.2
Increase ratio of hydrodynamic open force

c = 5 μm, Po = 9, ω = 10000 rpm

20
Sp = 0.3 15 c = 3 μm, Po = 9, ω = 3000 rpm
c = 3 μm, Po = 20, ω = 10000 rpm
15
10

Rw / %
Rw / %

10

5
5

0
0
0 10 20 30 40 50 60 70 80 90
Inclination angle α / °
-5 -5
0 5 10 15 20 25
100 Dimple depth hd / μm
90 Sp = 0.12
100
Sp = 0.2
80 c = 2 μm, Po = 9, ω = 3000 rpm
Sp = 0.3
c = 5 μm, Po = 9, ω = 10000 rpm
Increase ratio of leakage

70 80
60
c = 3 μm, Po = 9, ω = 3000 rpm

Increase ratio of leakage

c = 3 μm, Po = 20, ω = 10000 rpm
RQ / %

50 60

40

RQ / %
40
30

20
20
10

0
0 10 20 30 40 50 60 70 80 90 0
-10
Inclination angle α / °
-20
Fig. 9 Influence of dimple area rate on seal performance (c = 4, 0 5 10 15 20 25
hd = 5 lm, c = 2 lm, Po = 9) Dimple depth hd / μm

face with area rate Sp = 0.3 and dimple inclination angle Fig. 10 Influence of dimple depth on open force and leakage (c = 3,
a = 60. a = 55)

3.3.3 Influence of Dimple Depth

LST gas seal. A parametric investigation and a numerical
example for a typical LST gas seal are presented. Fol-
The influence of the dimple depth on the increase ratios of
lowing conclusions can be obtained.
the hydrodynamic open force and the leakage can be
obtained in Fig. 10 under four different operation condi- • Dimple orientation can greatly improve hydrodynamic
tions. An important result is the existence of an optimum effect of micro-pores in gas-lubricated mechanical face
value of the dimple depth at a given operation condition for seal, which leads both open force and leakage to
both increase ratio of hydrodynamic open force and that of increase. The open force can be increased about 20%
leakage. However, when the dimple depth is larger than greater in the case of rotation speed x = 3,000 rpm in
25 lm, the hydrodynamic effect will be very low. the analysis of this article.
Meanwhile, results shown in Fig. 10 demonstrate that a • The hydrodynamic effect of the orientation dimples is
significant increase ratio of hydrodynamic open force, about decided by the texturing parameters such as slender
10%, can be acquired by increase rotation speed from 3,000 ratio, dimple inclination angle, and dimple area rate.
to 10,000 rpm, for the case of a larger seal clearance Hydrodynamic open force of LST gas seal can be
c = 5 mm or that of a higher seal pressure Po = 20. improved significantly by proper design of these
texturing parameters.

4 Conclusions
This article introduced a new type of gas face seal with
ellipse dimples to improve hydrodynamic open force of the
Acknowledgments The research is financially supported by
National Nature Science Foundation of China (Contract Nos.
50805130 and 50775206), Tribology Science Fund of State Key
Laboratory of Tribology of China (Contract No. SKLTKF08B01) and

123
194
Zhejiang Nature Science Foundation of China (Contract Nos.
Y1090620 and R1090833).
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