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Common Causes of O-Ring Failure

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Common Causes of O-Ring Failure

No one wants seals to fail, however it can happen. In this handy guide, indications of the common
causes of O-Ring failure are given with possible contributing factors. But remember, involving
Trelleborg Sealing Solutions in the design stage can avoid such issues.
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The failure types identified below are based on historical data and extensive industry research.
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CHEMICAL DEGRADATION

Indications: Blisters, cracks, voids or discoloration.

Contributing Factors: Incompatibility with the chemical and/or thermal environment.

INSTALLATION DAMAGE

Indications: Small cuts, nicks or gashes

Contributing Factors: Sharp edges on glands or components. Improper sizing of elastomer. Low-modulus / hardness
elastomer. Elastomer surface contamination.

OVERCOMPRESSION

Indications: Parallel flat surfaces corresponding to contact areas; possible circumferential splits.
Contributing Factors: Improper design – failure to account for thermal or chemical volume changes, or excessive
compression. in the groove magazine

ABRASION

Indications: Flat surface parallel to the direction or motion; loose particles and scrapes on surface
Contributing Factors: Rough sealing surfaces. Excessive temperature. Process environment containing abrasive
particles. Dynamic motion Poor elastomer surface finish.

CONTAMINATION

Indications: Foreign material on the surface or within the cross section

Contributing Factors: Process environment deposition. Reactions or degradation of the elastomer.

COMPRESSION SET

Indications: Flat-sided cross section corresponding to mating seal surfaces

Contributing Factors: Excessive compression. Excessive temperature. Incompletely cured elastomer. Elastomer with
high compression set. Excessive volume swell in chemical.

EXTRUSION/NIBBLING

Indications: Ragged edges, generally on the low pressure side

Contributing Factors: Excessive clearances. Excessive system pressure. Irregular clearance gaps due to eccentricity.
Sharp gland edges. Low-modulus/hardness elastomer. Softening of elastomer due to fluid incompatibility. Excessive
gland fill.

SPIRAL FAILURE

Indications: Cuts or marks spiraling around circumference

Contributing Factors: Difficult or tight installation (static). Slow reciprocating speed. Low-modulus/ hardness
elastomer. Irregular O-Ring surface finish (including excessive parting line). Excessive gland width Irregular or rough
gland surface finish. Inadequate lubrication
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EXPLOSIVE DECOMPRESSION

Indications: Surface blisters, pits or pocks. Absorption of gas at high pressure and subsequent rapid decrease in
pressure; elastomer surface blisters and ruptures as pressure is rapidly removed.
Contributing Factors: Rapid pressure changes. Low-modulus/ hardness elastomer.

PLASTICIZER EXTRACTION

Indications: Often difficult to visually detect; may exhibit a decrease in cross-sectional size
Contributing Factors: Improper or improperly cured elastomer. High vacuum levels. Low hardness/ plasticized
elastomer.

WEATHERING/OZONE CRACKING

Indications: Small surface cracks perpendicular to the direction of stress

Contributing Factors: Exposure to ozone, UV radiation or other air pollutants. Excessive seal stretch

THERMAL DEGRADATION

Indications: May exhibit radial cracks on the highest temperature surfaces; certain elastomers may exhibit signs of
softening or a shiny surface.
Contributing Factors: Elastomer thermal properties. Excessive temperature excursions or cycling.

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