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Enhancement of seal life through carbon composite back-up rings under

shock loading conditions in defence applications

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DOI: 10.1016/j.dt.2015.08.003

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Defence Technology ■■ (2015) ■■–■■
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Enhancement of seal life through carbon composite back-up rings under

shock loading conditions in defence applications
Shankar BHAUMIK a, A. KUMARASWAMY b,*, S. GURUPRASAD a
a
R&DE (Engrs.), Pune 411015, Maharashtra, India
b
Defence Institute of Advanced Technology (DU), Pune 411025, Maharashtra, India
Received 8 March 2015; revised 30 July 2015; accepted 7 August 2015
Available online

Abstract
The life of Nitrile Butadiene Rubber (NBR) O-ring seal having shore hardness of A70 and A90 under shock loading conditions was investigated
by a specially designed pneumo-hydraulic shock test rig. Shock tests have been carried out on bare seals, seal with conventional
polytetrafluoroethylene (PTFE) back-up rings and seal with newly developed carbon composite back-up rings to study its behaviour under different
operating conditions until failure. Experiments were conducted by varying annular gap ranging from 0.3 to 0.5 mm, oil temperature from 30 °C
to 70 °C and rate of pressure rise from 600 to 2400 MPa/s. Significant enhancement in seal life was observed with carbon composite back-up ring
at reduced annular clearances compared to seal life with conventional PTFE back-up ring and without back-up rings.
© 2015 China Ordnance Society. Production and hosting by Elsevier B.V. All rights reserved.
Keywords: Hydraulic seal; O-rings; Shock load; Seal extrusion; Pneumo-hydraulic shock absorber; Back-up rings

1. Introduction structures in general and aerospace structures in particular

experience shock loads of different magnitudes throughout
Hydraulic seals are used in a variety of critical applications
their service life. Shock is generally measured through time
involving machinery and are several times more expensive
histories expressed in seconds and amplitude expressed in g’s
compared to seals. The critical importance of the seal can be
of the shock event. Shock can also be measured in terms of
quantified by the failure of a static O-ring due to cold tempera-
velocity, displacement, force, pressure, etc. Shock testing is
ture freezing, causing catastrophe of NASA space shuttle
commonly performed by imparting kinetic energy to the system
“Challenger1986”. Therefore, the precise design and evaluation
by drop hammering, impact, shaker, pyro-shock, etc. The fail-
of reciprocating hydraulic seals are of supreme importance to
ures caused by shock include crack or deformation of structural
avoid such costly mistakes.
elements, failure of weld joints, hydraulic seal failure, etc.
O-rings are the simplest and most versatile seals among
High pressure hydraulic seals are the common and most
various types and cross sections of hydraulic seals having wide
critical elements of any hydraulic system. Many of the defence
applications involving static and dynamic loading conditions.
equipment experiences shock/blast loads during deployed con-
O-rings are employed in reciprocating hydraulic actuators
ditions. These blast/shock loads create short duration peak pres-
involving long stroke and large diameter seals. The most impor-
sures, which are several times higher than the system operating
tant application includes the use of O-rings in reciprocating
pressure that will affect the seal life and in turn affect the
hydraulic rod and piston seals. The life of reciprocating
reliability of the system. Shock isolators/dampers are generally
dynamic O-ring seals is influenced by extrusion, spiraling,
used to isolate the shock loads and safeguard the delicate com-
finish of sliding surface and hardness of the seal.
ponents of the system. One such pneumo-hydraulic shock
Shock is defined as a non-periodic excitation of a system
absorber is shown in Fig. 1, in which the dynamic seals expe-
characterized by sudden relative displacement in a system. All
rience a short duration pressure surge of 1000 bar during shock
load isolation.
* Corresponding author. Tel.: +912024304191.
Experimental research on hydraulic seals has been in
E-mail address: akswamy@diat.ac.in, adepu_kswamy@yahoo.com progress for several decades. Over the years, theoretical and
(A. KUMARASWAMY). experimental investigation of tribological characteristics of
http://dx.doi.org/10.1016/j.dt.2015.08.003
2214-9147/© 2015 China Ordnance Society. Production and hosting by Elsevier B.V. All rights reserved.

Please cite this article in press as: Shankar Bhaumik, A. Kumaraswamy, S. Guruprasad, Enhancement of seal life through carbon composite back-up rings under shock loading
conditions in defence applications, Defence Technology (2015), doi: 10.1016/j.dt.2015.08.003
 ARTICLE IN PRESS
2 S. BHAUMIK et al. / Defence Technology ■■ (2015) ■■–■■
Fig. 1. Effect of shock load on pneumo-hydraulic shock absorber.
reciprocating hydraulic seals such as leakage, friction, wear and
extrusion has been carried out by numerous researchers.
Numbers of test rigs have been built and various methods were
employed for determination of tribological characteristics.
Nikas, Müller, Field and Nau investigated the leakage and fric-
tion of reciprocating hydraulic seals [1–4]. Hirano and Kaneta
investigated the friction characteristics of flexible seals for
reciprocating motion [5]. Nau determined the friction of oil
lubricated sliding seals by conducting a number of experiments
[6]. Iwanami and Tikamori experimentally determined leakage
from O-ring packing [7]. Kawahara et al. [8] and Kaneta [9]
also contributed to the experimental investigation of tribologi-
cal characteristics of reciprocating hydraulic seals. Nikas for-
mulated algebraic equations to describe the shape and contact
pressure of the extruded part of the seal with the rod [10].
Significant theoretical work was carried out by Salant [11–13],
Nikas [14–17], Fatu and Hajjam [18] to determine the tribol-
ogical characteristics of reciprocating hydraulic seals. Bhaumik
et al. investigated the contact mechanics in reciprocating
hydraulic U-seals for defence applications [19]. Thatte and
Salant developed a transient numerical model for reciprocating
hydraulic seals to take account of the varying rod speeds [20].
However, no theoretical or experimental data to assess the influ-
ence of shock/blast load on hydraulic seals were found in the
literature. Therefore, in order to quantify the performance of
hydraulic seals under severe operating conditions, it is neces-
sary to design a test rig capable of generating shock pressure
peaks to test the sealing elements of the hydraulic system.
In view of the above, in the present investigation, a special
test rig has been developed and seal life as a function of param-
eters such as annular gap, rate of pressure rise, seal hardness, oil
temperature, etc., was investigated with and without the use of
back-up rings. It was observed that the seal life was enhanced
Please cite this article in press as: Shankar Bhaumik, A. Kumaraswamy, S. Guruprasad, Enhancement of seal life through carbon composite back-up rings under shock loading
conditions in defence applications, Defence Technology (2015), doi: 10.1016/j.dt.2015.08.003
significantly with carbon composite back-up ring at reduced
annular clearances compared to seal life with conventional
PTFE back-up ring and without back-up rings.
2. Pneumo-hydraulic test rig for hydraulic seals subjected
to shock loading
The test rig [21] capable of generating various types of
shocks pulses by variation of parameters such as peak pressure,
pulse duration, pulse shape, etc., shown in Fig. 2 has been
developed to simulate the performance of static and dynamic
hydraulic seals. The test rig is integrated with a data acquisition
system for capturing test data for further analysis. The shock
test rig will generate controlled hydraulic pressure pulse in a
test chamber. The test chamber having bore diameter of 63 mm,
rod diameter of 36 mm and stroke length of 300 mm is similar
to a hydraulic cylinder integrated with rod/piston seal to be
tested under dynamic conditions. The schematic of hydraulic
system for the test rig consisting of hydraulic power pack,
hydro-pneumatic accumulator, controlled valves, impact cylin-
der, test chamber, transducers and data recorder is shown in
Fig. 3. The hydraulic power source consists of 2 cc/rev, 30 MPa,
fixed displacement radial piston pump driven by an electric
drive unit. The accumulator of 50 L capacity is charged by a
hydraulic power source to the desired pressure depending on the
peak test pressure. After charging the accumulator to relief
pressure setting, the pump flow is by-passed to the reservoir of
60 L capacity through the maximum pressure set relief valve
and a return line filter. The pump pressure is also available to the
DC valve for operation of pilot operated check valves provided
in the circuit for forward and reverse motion of impact cylinder
of bore diameter of 125 mm, rod diameter of 90 mm and stroke
length of 500 mm. The DC valve solenoids are energized by a
power supply through a timer to control the pressure pulse
 ARTICLE IN PRESS
S. BHAUMIK et al. / Defence Technology ■■ (2015) ■■–■■ 3

Fig. 2. Pneumo-hydraulic shock test rig.

duration. The rate of pressure rise and pressure drop is con-
trolled by hydraulic flow control valves. A set of parallel flow
control valves of 600 L/min has been provided to cater for high
flow rate to the piston side of impact cylinder; the low oil
volume from annular side is drained into the reservoir through
a smaller pilot operated check valve. The pressure profile and
peak pressure in the chamber may be controlled by hydraulic
control valves and accumulator charge pressure. The accumu-
lator sizing is done to meet the impulse pressure profile
requirements.
All of the test parameters can be controlled by hydraulic
system accumulator, control valves and timer based switching
of the DC valve. The peak-test pressure up to 120 MPa can be
maintained, which is three times the working pressure of a
mobile hydraulic high-pressure system with an extra load factor
of 20%.
With a rate of pressure rise of 1200 MPa/s, i.e., 120 MPa
pressure rise in 100 ms, a total impulse cycle duration of
1800 ms can be achieved. The impulse data generated using the
test rig are given in Table 1. Cyclic impulse test may be carried
out by controlling hydraulic valves using a timer. The test
chamber is fitted with pressure and temperature transducers,
which are connected to a data recorder. Test at elevated tem-
perature is controlled by wrapping a heating strip around the
test chamber and a controller to maintain the test temperature.
The test chamber is fitted with pressure sensor (160 MPa) and

Fig. 3. Schematic of hydraulic system.

Please cite this article in press as: Shankar Bhaumik, A. Kumaraswamy, S. Guruprasad, Enhancement of seal life through carbon composite back-up rings under shock loading
conditions in defence applications, Defence Technology (2015), doi: 10.1016/j.dt.2015.08.003
 ARTICLE IN PRESS
4 S. BHAUMIK et al. / Defence Technology ■■ (2015) ■■–■■

Table 1 Fig. 4. Tests were carried out by varying annular gap/clearance,

Impulse data generated on shock test rig. temperature and rate of pressure rise.
S. No. Time Pressure test chamber Pressure impact cylinder The stroke length of rod during shock test was kept at
(/ms) (/MPa) (/MPa) 100 mm. A hydraulic mineral oil conforming to the ISO VG 68
1 5122 19.4 16.8 specification was used during the test. The test chamber was
2 5280 19.8 15.5 initially charged to a pressure of 20 MPa. The rod surface finish
3 5368 120.2 15.5
4 5378 121.5 15.5
(Ra) and the rod speed were 0.2 μm and 2 m/s, respectively. A
5 5392 121.2 15.5 white colored pure PTFE back-up ring having tensile strength
6 7042 120.0 15.6 of 28 MPa was used. Specially developed black colored carbon
7 7128 18.7 15.5 composite of carbon fiber plus resin and ring machined out of
composite sheet having tensile strength of 135 MPa was used in
the current investigation. All of the above parameters are gen-
Table 2
erally used in a typical hydro-pneumatic shock absorber.
Sensors and their specifications.
S. No. Sensor Range Output Error 3.1. Variation of annular clearance
1 Pressure transducer-1 0–60 MPa 4–20 mA 0.25%
2 Pressure transducer-2 0–160 MPa 4–20 mA 0.50%
Linear actuators involving longer strokes and larger diam-
3 Temperature transducer −25 °C–100 °C 7–15 V DC ±1.5% eters will experience large dynamic/shock loads. Therefore, the
4 Load cell 0–750 kg 0–2 mV/V 2 g/m annular/diametral clearance/gap should be large enough to
5 Linear transducer 0–500 mm 0–10 V DC 0.05% avoid metal to metal abrasion in the system. Depending on the
6 Data recorder – – 0.10% size and type of seal in linear actuators under dynamic loading
conditions, 0.3 mm annular gap is recommended. However, in
the case of linear actuators subjected to shock loads that are
temperature sensor (100 °C) connected to a data recorder, transferred between rod and gland, annular gap of the order of
which is capable of capturing data within a span of 2 ms. 0.3–0.5 mm is preferred. Annular gap less than 0.3 mm could
Different types of sensors along with their specifications are cause metal to metal contact at rod/gland or piston/tube inter-
given in Table 2. face, thus damaging seal sliding surfaces. On the other hand,
annular gap more than 0.5 mm results in seal extrusion. There-
3. Experimental fore, in the present work, annular gap ranging between 0.3 mm
Nitrile Butadiene Rubber (NBR) O-ring seal of 36 mm inter- and 0.5 mm has been considered to study seal behavior. A
nal diameter and 3.53 mm cross-sectional diameter with shore schematic of annular clearance in test cylinder for shock load is
hardness of A70 and A90, with and without back-up ring under illustrated in Fig. 4.
shock loading conditions, has been considered in the current
3.2. Results and discussion
investigation. Shock tests have been carried out on (a) bare
O-ring seals, (b) O-ring seal with PTFE back-up rings and (c) The pressure in the test chamber due to impact load is built
O-ring seal with carbon composite back-up rings to study seals up to 120 MPa and the rate of pressure rise in the test chamber
under different operating conditions until failure. The shock is 1200 MPa/s as shown in Fig. 5. The peak pressure is attained
load test arrangement for three configurations is shown in in 100 ms and is maintained for 1695 ms duration. This added

Fig. 4. Schematic of annular/diametral clearance in the test cylinder for shock load.

Please cite this article in press as: Shankar Bhaumik, A. Kumaraswamy, S. Guruprasad, Enhancement of seal life through carbon composite back-up rings under shock loading
conditions in defence applications, Defence Technology (2015), doi: 10.1016/j.dt.2015.08.003
 ARTICLE IN PRESS
S. BHAUMIK et al. / Defence Technology ■■ (2015) ■■–■■ 5

Fig. 5. Pressure in the test chamber.

pressure for impact load is obtained from the accumulator into increased annular gaps (0.4 mm: 75 ± 25 shock pulses and
the impact cylinder. 0.5 mm: only 20 shock pulses).
It may also be noted that there is a sudden drop of pressure
in the impact cylinder as the impact load is applied. A rate of 3.4. Effect of back-up rings on seal life
pressure rise at 2000 MPa/s in the test chamber can also be
Shock load experiments were conducted on O-ring hydraulic
obtained by applying impact load as shown in Fig. 5. The peak
seals of shore hardness A70 and A90 using conventional PTFE
pressure of 130 MPa is obtained in the test cylinder in 50 ms,
and carbon composite back-up rings considering annular/
then reduced to 120 MPa and remained constant for 1350 ms.
diametral gap of 0.3, 0.4 and 0.5 mm. The number of shock
The pressure was reduced to 4 MPa upon removal of the load
pulses, which the seal can sustain before failure with and
and the cycle was continued until seal failure takes place.

3.3. Effect of annular clearance on seal life

Shock tests were carried out on a set of three similar NBR
O-ring seals (made of the same material duly inspected for
dimensional tolerances chosen from the same manufacturing
lot) to ascertain repeatability of results, considering diametric
clearance of 0.3, 0.4 and 0.5 mm. The number of shock pulses,
which the seal can sustain before failure, is plotted in Fig. 6 and
the extent of seal damage is shown in Fig. 7. It was observed
that seal without back-up ring at a lower annular gap of 0.3 mm Fig. 7. Extent of seal damage with annular/diametral gap (without back-up
was capable of sustaining oil pressure up to 275 ± 25 repeated ring).
shock pulses, while seal ceased to function satisfactorily at

Fig. 6. Effect of annular/diametral gap on seal life. Fig. 8. Seal extrusion under shock load.

Please cite this article in press as: Shankar Bhaumik, A. Kumaraswamy, S. Guruprasad, Enhancement of seal life through carbon composite back-up rings under shock loading
conditions in defence applications, Defence Technology (2015), doi: 10.1016/j.dt.2015.08.003
 ARTICLE IN PRESS
6 S. BHAUMIK et al. / Defence Technology ■■ (2015) ■■–■■

Table 3
No. of shock pulses the seal can sustain before failure (shore hardness: A90).
Diametral No. of shock pulses the seal can sustain before failure
gap (/mm) Without With PTFE With carbon composite
back-up ring back-up ring back-up ring
0.3 274 1754 6512
0.4 75 806 3458
0.5 20 452 1785

without back-up rings, is plotted as a function of diametral gap

as shown in Fig. 8 and listed in Table 3. The number of shock
pulses the seal could sustain before failure followed a regres-
sion type of second-order polynomial. It was observed that use
of high strength conventional PTFE back rings delayed the seal
failure due to extrusion and back-up rings failed due to higher
frictional force before the seal failure as shown in Fig. 9. Moti-
vated by these observations, the analysis was further extended
to investigate the seal life with carbon composite back-up rings
possessing high strength, low load-to-deflection ratio, low fric-
tion, high resistance to wear and self-lubricating properties. It is
interesting to note that the life of the sealing system was
enhanced by 4–5 times compared to seal life with conventional
PTFE back-up ring as seen in Fig. 10.
3.5. Effect of rate of pressure rise and oil temperature on
seal life
The effect of rate of pressure rise on seal life under shock
loading was investigated by conducting tests on O-ring seals of

Fig. 11. Effects of rate of pressure rise and oil temperature on seal life without
back-up ring (shore hardness A90).

shore hardness A90 with annular gaps of 0.3, 0.4 and 0.5 mm
and rate of pressure rise of 600, 1200 and 2400 MPa/s. It can be
seen in Fig. 11 that the seal life with rate of pressure rise of
2400 MPa/s is slightly inferior compared to the rate of pressure
rise of 600 MPa/s, indicating that seal life is weakly affected by
the rate of pressure rise.
Fig. 9. Improved seal life with PTFE back-up ring. The effect of oil temperature on seal life under shock load
was investigated by conducting tests on O-ring seals of Shore
hardness A90 with annular gaps of 0.3, 0.4 and 0.5 mm and
temperatures of 30 °C, 50 °C and 70 °C. It may be observed
from Fig. 11 that the number of shock pulses that the seal could
sustain before failure decreased with an increase in temperature
due to swelling of seal at elevated temperatures. It may be noted
that the effect of pressure rise on seal life is not as much as the
effect of temperature. The number of shock pulses the seal can
sustain was reduced with an increase in annular gap from 0.3 to
0.5 mm in both cases as described in the previous sections.
4. Conclusions
1) Catastrophic seal failure has taken place within 20–50
Fig. 10. Enhanced seal life with carbon composite back-up ring. shock pulses with annular gap of 0.5 mm without

Please cite this article in press as: Shankar Bhaumik, A. Kumaraswamy, S. Guruprasad, Enhancement of seal life through carbon composite back-up rings under shock loading
conditions in defence applications, Defence Technology (2015), doi: 10.1016/j.dt.2015.08.003
 ARTICLE IN PRESS
S. BHAUMIK et al. / Defence Technology ■■ (2015) ■■–■■
back-up ring, while seal failure was delayed (up to 300
shock pulses) when the annular gap was reduced to
0.3 mm.
2) The seal life was enhanced significantly with carbon
composite back-up ring at reduced annular clearances
compared to seal life with conventional PTFE back-up
ring and without back-up rings.
3) The seal life at higher rate of pressure rise is slightly
inferior compared to lower rate of pressure rise, indicat-
ing that seal life is weakly affected by the rate of pressure
rise.
4) The number of shock pulses that the seal could sustain
before failure decreased with an increase in temperature
due to swelling and hardening of seal. Further, the effect
of the rate of pressure rise on seal life is not as much as
the effect of temperature.
Acknowledgments
The authors would like to extend thanks to Mr. Rakesh, Mr.
Abhishek Kumar, Mr. CK Waghmare and Mr. Manoj Bhujbal of
R&DE (Engrs), Pune, India, for providing assistance during the
course of the work. One of the authors, Shankar Bhaumik,
would like to thank Vice Chancellor, DIAT (DU), Pune for
permitting him to do PhD.
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Please cite this article in press as: Shankar Bhaumik, A. Kumaraswamy, S. Guruprasad, Enhancement of seal life through carbon composite back-up rings under shock loading
conditions in defence applications, Defence Technology (2015), doi: 10.1016/j.dt.2015.08.003
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