What is an O-ring?

An O-ring is a simple and versatile ring-shaped packing and sealing device with a circular cross section. O-ring functions as compact and reliable sealing devices by absorbing the tolerance stack-up between closely mated surfaces in both dynamic and static applications. Although O-rings can be made from a variety of materials, they are most commonly molded in one piece from an elastomeric material.

What is an O-ring seal?

O-ring seal is used to prevent the loss of a fluid and gas between two closely spaced surfaces. The O-ring is generally installed in a machined groove in one of the surfaces to be sealed. As the two surfaces are brought together, forming a gland, they s uee!e the cross section of the O-ring. This s uee!ing action results in a deformation of the O-ring cross section. With O-rings, the greater the s uee!e, the larger the deformation. "isted below are some of the outstanding characteristics that make O-rings one of the most versatile, dependable, yet ine#pensive seals available, with sealing capability from hard vacuum to high pressure. - They seal over a wide range of pressure, temperature and tolerance - $ase of service, no smearing or retightening - %o critical tor ue on tightening, therefore unlikely to cause structural damage - O-rings normally re uire very little room and are light in weight - &n many cases an O-ring can be reused, and advantage over non-elastic flat seals and crush-type gaskets - The duration of life in the correct application corresponds to the normal aging period of the O-ring material - O-ring failure is normally gradual and easily identified - They are cost-effective - Where differing amounts of compression effects the seals function, an O-ring is not effected because metal to metal contact is generally allowed for. - O-ring compounds can be selected to resist most environmental e#tremes &t is a uni ue characteristics of the elastomer material used in O-rings that makes O-ring such a good seal. The elastomer, a highly viscous, incompressible fluid with high surface tension, has a capacity for remembering its original shape for a long time. &n low-pressure applications 'that is, where the confined fluid e#erts little or no pressure on the O-ring(, the tendency of the elastomer to maintain its original shape creates the seal. As the O-ring is deformed when the mating surfaces are brought together, it e#erts a force against the mating surfaces e ual to the force it takes to s uee!e it. The areas of contacts between the O-ring and the mating surfaces 'contact bands( act as a barrier to block the passage of the fluid. &n applications where higher pressure is e#erted by the confined fluid, the sealing action of the O-ring caused by the s uee!e of its cross-section is augmented by fluid pressure, transmitted through the elastomer. The O-ring is forced to the side of the gland, away from the pressure. As it is pressed against the side, the O-ring, cross section is deformed. The elastomer e#erts e ual force in all directions and is forced up to the gap between the mating surfaces.

ROTARY APPLICATIONS &n rotary O-ring applications, the O-ring continuously moves against tire same portions to the shaft. )eat due to friction is continuously generated ion the same place, and elastomers are poor thermal conductors. &f heat is generated more uickly than it can be dissipated, temperature rise is rapid and seal failure uickly follows. Where surface speeds do not e#ceed *+, feet-minute, or where rotation is brief and intermittent, this is rarely a problem and gland design criteria for reciprocating service are applicable. .or continuous rotation at surface speeds over *+, feet-minute some developmental ad/ustments are often re uired to achieve acceptable performance. &n applications where rotating motions occur, the designer should consider the following0 i( 1easures should be taken to reduce heat buildup0 - 2rovide absolute minimal s uee!e, as little as ,.,,345 to minimi!e friction. This may permit some leakage - 2rovide ample diametric clearance to increase fluid flow and facilitate better dissipation of heat - 6elect O-ring with smallest cross section. - 1aintain low system pressure 'not over 37,psi( ii( 8se a shaft of diameter no greater than that of the rela#ed O-ring &.9. This is important because when an O-ring is heated under stress, it will tend to contract. :ontraction of the O-ring could cause it to sei!e the shaft and increase friction and heat resulting in rapid failure. iii( The gland should be located as close as possible to the lubricating fluid and as far as possible from the shaft support bearings. This allows the O-ring to receive the ma#imum amount of cooling lubricant and minimi!es the effects of bearing-generated treat. iv( ;elative motion must occur e#clusively between the O-ring &9 and the rotating shaft. ;otation of the O-ring within the gland will lead to rapid wear and leakage.
- 1inimi!e out-of-round shafts and eccentric rotation. 1a#imum eccentricity should not e#ceed ,.,,*45 - .inish of the moving surface contacting the O-ring should not e#ceed *<;16. A rougher surface is desired within the groove to rotation= >3 ;16 is recommended. - 8tili!e an O-ring of a hard, self-lubricating compound specifically developed for rotary service. discourage

2$;1$A?&"&T@
Aases diffuse into and through elastomaric compounds at various rates depending on the elastomer type and nature of the individual compound. Aenerally, harder compounds which have more carbon black added have lower diffusion rates. Of the popular elastomer, epichlorohydrin and butyl have the lowest permeability, followed by fluorocarbons, polyurethanes, nitrites, heoprenes, polyacrylates, and 6?;. The fluorosilicons and silicones have higher rates. .or any given compound, the permeability through the O-ring depends on the amount of its compression or s uee!e, the area of the seal, and the pressure, temperature and type of gas begin sealed. .or the ma/ority of applications, the rate of gas permeation through the O-ring is inconse uential and standard groove dimensions are applicable. Where gas pressure e#ceeds 7,,psi, and pressure is released alter a soak period, gas within the O-ring may e#ert considerable force under the lower e#ternal pressure and may cause damage. The O-ring may blister or chunks of rubber may even be blown out.

2%$81AT&: 6$A"6
%o special consideration is usually warranted for pneumatic applications if they are static. With dynamic applications, the problem is lack of a system li uid to provide lubrication and cooling. &f reasonable life is to be achieved sortie lubricant must be provided. 2articularly where operating temperature approaches the capabilities of the O-ring, an elastomer resistant to o#ygen should be chosen 4B Aas temperature increase due to compression re uires consideration in determining system temperature. :onventional gland designs are applicable for pneumatic service. )owever, since slight leakage is usually not important, and friction

is, reduced s uee!e is desirable in reciprocating pneumatic applications.

BA:881 6$A"6
Bacuum seals also warrant separate mention. 8nlike pneumatic seals, even slight leakage is often unacceptable in vacuum applications. They have only one atmosphere differential pressure, so essentially all the sealing force must be provided by compression of the O-ring. The following factors should be considered0 9ynamic vacuum seals re uire proper lubrication due to the absence of system li uids. 8se of vacuum grease is also desirable with static seals An especially smooth finish in the gland is important to insure contact between the elastomer and the metal parts. &n applications where absolute minimum leakage is a necessity, gland depth should be reduced to increase the amount of s uee!e To minimi!e the possibility of gases begin trapped under the O-ring and escaping into the vacuum, reduced groove width and the use of suitable vacuum grease to fill the e#cess void are recommended. O-rings may be used in series in vacuum applications, preferably with a separate vacuum between them.

9;&B$ ?$"T6
O-rings provide e#cellent service in low power drive belt applications. Tire primary concern for O-rings used as drive belts is the compound from which they are made. 6everal elastomers have been used successfully in drive belt applications. $thylenepropylene has provided superior performance due to its low stress rela#ation, high temperature resistance, and overall reliability silicon has also been used in high temperature applications and lacking good wear and abrasion resistance, it provides reliable but somewhat limited service life. 2olyurethane has been used successfully but it should not be used at temperatures above *7+o. 'C,o:(. When utili!ing O-rings as drive belts, the following factors should be considered0 &.9, stretch should be app. *,D--3E,
2ulley grooves should be round, of depth and radius e ual to the radius of the O-ring cross sections. 2ulley diameter 'at the bottom of groove( should be no less than four times the O-ring cross section diameter

:omparison of :ommon 6eal Types

A number of common seals types, T-seals, 8-cups, B-packing and other devices, have been, and are still used for both dynamic and static seals. When compared with an O-ring seal, these seal types may show one or more design disadvantages which might be overcome by use of an O-ring. As an aid in assessing the relative merits of and O-ring, below table lists several of the important factors that must be considered in the selection of any effective seal geometry.

BASIC O-RING ELASTOMERS

The following paragraphs briefly review the various elastomers currently available for use in O-rings and other elastomeric seals. 1. A r!l"nitrile- B#ta$iene %NBR& %itrile ;ubber '%?;( is the general term for acrylonitrile butadiene terpolymer. The acrylonitrile content of nitrile sealing compounds varies considerably '*+E to 7,E( and influences the physical properties of the finished material. The higher the acrylonitrile content, the better the resistance to oil and fuel. At the same time, elasticity and resistance to compression set is adversely affected. &n view of these opposing realities, a compromise is often drawn, and a medium acrylonitrile content selected. %?; has good mechanical properties when compared with other elastomers and high wear resistance. %?; is not resistant

to weathering and o!one. 'eat Resistan e 8p to *,,F: '3*3F.( with shorter life G *3*F: '37,F.(. C"l$ (le)i*ilit! 9epending on individual compound, between ->HF: and -7CF: '->,F. and -C,F.( Che+i al Resistan e Aliphatic hydrocarbons 'propane, butane, petroleum oil, mineral oil and grease, diesel fuel, fuel oils( vegetable and mineral oils and greases. ).A, ).? and ).: fluids 9ilute acids, alkali and salt solutions at low temperatures. Water 'special compounds up to *,,F:( N"t "+,ati*le -ith. .uels of high aromatic content 'for fle# fuels a special compound must be used.( Aromatic hydrocarbons 'ben!ene( :hlorinated hydrocarbons 'trichloroethylene( 2olar solvents 'ketone, acetone, acetic acid, ethylenester( 6trong acids ?rake fluid with glycol base. O!one, weather and atmospheric aging.

/. Car*")!late$ Nitrile %0NBR&

:arbo#ylated %itrile 'I%?;( is a special type of nitrile polymer that e#hibits enchanced tear and abrasion resistance. .or this reason, I%?; based materials are often specified for dynamic applications such as rod seals and rod wipers. 'eat resistan e 8p to *,,F: '3*3F.( with shorter life G *3*F: '37,F.(. C"l$ (el)i*ilit! 9epending on individual compound, between -*+F: and -H+F: ',F. and -77F.( Che+i al resistan e Aliphatic hydrocarbons 'propane, butane, petroleum oil, mineral oil and grease, diesel fuel, fuel oils( vegetable and mineral oils and greases. ).A, ).? and ).: fluids 1any diluted acids, alkali and salt solutions at low temperatures Water 'special compounds up to *,,F:( N"t "+,ati*le -ith. .uels of high aromatic content 'for fle# fuels a special compound must be used( Aromatic hydrocarbons 'ben!ene( :hlorinated hydrocarbons 'trichloroethylene(. 2olar solvents 'ketone, acetone, acetic acid, ethyleneester( 6trong acids ?rake fluid with glycol base.

1.Eth!lene A r!late %AEM& $thylene acrylate is a mi#ed polymer of ethylene and methyl acrylate with the addition of a small amount of carbo#ylated curing monomer. $thylene acrylate rubber is not to be confused with ethyl acrylate rubber 'A:1(. 'eat resistan e 8p to *HJF: with shorter life up to *<>F: C"l$ 2le)i*ilit! ?etween -3JF: and -H,F: Che+i al resistan e O!one O#idi!ing media 1oderate resistance to mineral oils N"t "+,ati*le -ith. Ketones .uels ?rake fluids 3.Eth!lene Pr",!lene R#**er %EP4M5 EPM& $21 is a copolymer of ethylene and propylene. $thylene propylene-diene rubber '$291( is produced using a third monomer and it particularly useful when sealing phosphate-ester hydraulic fluids and in brake systems that use fluids having a glycol base. 'eat resistan e 8p to *7,F: 'ma# 3,HF:( in water and -or steam( C"l$ (le)i*ilit! 9own to appro#imately -7CF: Che+i al resistan e )ot water and steam up to *HJF: with special compounds up to 3,HF: Alycol based brake fluids up to *HJF: 1any organic and inorganic acids :leaning agents, soda and potassium alkalis. 2hosphate- ester based hydraulic fluids ').9-;( 6ilicone oil and grease 1any polar solvents 'alcohols, ketones, esters(. O!one, aging and weather resistant. N"t "+,ati*le -ith0 1ineral oil products 'oils, greases and fuels( 6.B#t!l R#**er %IIR& ?utyl 'isobutylene, isoprene rubber, &&;( is produced by many companies in different types and varies widely in isoprene content. &soprene is necessary for proper vulcani!ation. ?utyl has a very low permeability rate and good electrical properties 'eat resistan e

8p to app. *3*F: C"l$ 2le)i*ilit! 9own to app. -7J F:

Che+i al resistan e
)ot water and steam up to *3*F: ?rake fluids with glycol base 1any acids 6alt solutions 2olar solvents, eg. Alcohols, ketones and ester 2oly-glycol based hydraulics fluids ').: fluids( and phosphate-ester bases ').9-; fluids( 6ilicone oil and grease O!one, aging and weather resistant

N"t "+,ati*le -ith. 1ineral oil and grease .uels :hlorinated hydrocarbons 7. B#ta$iene R#**er %BR& 2olybutadiene '?;( is mostly used in combinations with other rubbers to improve cold fle#ibility and wear resistance. ?; is primarily used in the tire industry, for sure drive belts and conveyor belts and is not suitable as a sealing compound. 8. Chl"r"*#t!l R#**er %CIIR& :hlorobutyl ':&&;( is produced by chlorinating butyl polymer. &s chlorine content is appro#imately *.*E to *.>E. Apart from the properties of butyl rubber '&&;(, chlorobutyl ':&&;( shows improved compression set properties and can be compounded with other materials 9. Chl"r",rene R#**er %CR& :hloroprene was the first synthetic rubber developed commercially and e#hibits generally good o!one, aging and chemical resistance. &t has good mechanical properties over a wide temperature range 'eat resistan e 8p to app. *3*F: C"l$ 2le)i*ilit! 9own to app. -H, F: Che+i al resistan e 2araffin base mineral oil with low 92&, eg0 A6T1 oil %o.* 6ilicon oil and grease Water and water solvents at low temperature ;efrigerants Ammonia :arbondio#ide &mproved o!one, weathering and aging resistance compared with %?;

Li+ite$ "+,ati*ilit! %aphthalene based mineral oil '&;1 J,3 and &;1 J,> oils( "ow molecular aliphatic hydrocarbons 'propane, butane, fuels( Alycol based brake fluids N"t "+,ati*le -ith. Aromatic hydrocarbons 'ben!ene( :hlorinated hydrocarbons 'trichloroethylene( 2olar solvents 'ketones, esters, ethers, acetones(. :. Chl"r"s#l2"nate$ P"l!eth!lene %CSM& The polyethylene polymer contains additional chlorine and sulfur groups. :hlorine gives the mineral resistance to flame and mineral oil and also improves the cold fle#ibility 'eat resistan e 8p to *3*F: C"l$ 2le)i*ilit! 9own to app. -3JF: Che+i al resistan e 1any acids 1any o#idi!ing media 6ilicon oil and grease Water and water solvents O!one, aging and weathering resistance Li+ite$ "+,ati*ilit! "ow molecular aliphatic hydrocarbons 'propane, butane, fuel( 1ineral oil and grease "imited swelling in aliphatic oil 'A6T1 oil %o.*( )igh swelling in naphthene and aromatic base oils '&;1 J,3 and &;1 J,> oil( 2olar solvent 'acetone, methyl ether, ketone, ethyl acetate, diethyl ether, dio#ane( 2hosphate-ester based fluids N"t "+,ati*le -ith.
Aromatic hydrocarbons 'be!ene( :hlorinated hydrocarbons 'trichloroethylene(

1;. E,i hl"r"h!$rin %CO5 ECO& $pichlorohydrin is available in 3 types0 the homopolymer ':O( and the copolymer '$:O(. ?oth :O and $:O have good resistance to mineral oils, fuels and o!one. The high temperature resistance is good. :ompression set and the tendency to corrode metal sealing faces increase at *7,F:. $:O has a good cold fle#ibility. :O has a high resistance to gas permeability 'eat resistan e 8p to app. *>7F: C"l$ 2le)i*ilit! 9own to app. -H,F:

Che+i al resistan e 1ineral oil and grease Aliphatic hydrocarbons 'propane, butane, fuel( 6ilicone oil and grease Water at room temperature O!one, aging and weather resistance N"t "+,ati*ilit! -ith. Aromatic and chlorinated hydrocharbons Ketones and esters %on-flammable hydraulic fluids in the groups ).9-; and ).9-6. Alycol based brake fluids 11. (l#"r" ar*"n %(<M& .luorocarbon '.K1( has e#cellent resistance to high temperatures, o!one, o#ygen, mineral oil, synthetic hydraulic fluids, fuels, aromatics and many organic solvents and chemicals. "ow temperature resistance is normally not favourable and for static applications is limited to appro#imately -3<F:, although in certain situations it is suitable down to -H,F:. 8nder dynamic conditions, the lowest service temperature is between -*7F: and -*+F:. Aas permeability is very low and similar to that of butyl rubber. 6pecial .K1 compounds e#hibit and improved resistance to acids, fuels, water and steam. 'eat resistan e 8p to 3,HF: and higher temperatures with shorter life e#pectancy. C"l$ 2le)i*ilit! 9own to -3<F: 'some up to -H,F:( Che+i al resistan e
1ineral oil and grease, low swelling in A6T1 oil %o.*, and &;1 J,3 and &;1 J,> oils %on-flammable hydraulic fuels in the group ).9. 6ilicone oil and grease 1ineral and vegetable oil and grease Aliphatic hydrocarbons 'fuel, butane, propane, natural gas( Aromatic hydrocarbons 'ben!ene, toluene( :hlorinated hydrocarbons 'trichloroethylene and carbon tetrachloride( .uels, also fuels with methanol contents )igh vacuum Bery good o!one, weather and aging resistance

N"t "+,ati*le -ith. Alycol based brake fluids Ammonia gas, amines, alkalis 6uperheated steam "ow molecular organic acids 'formic and acetic acids( 1/. (l#"r"sili "ne %(=M>& .B1L contains trifluoropropyl groups ne#t to the methyl groups. The mechanical and physical properties are very similar to B1L. .B1L offers improved fuel and mineral oil resistance but poor hot air resistance when compared with B1L. 'eat resistan e

8p to *CCF: ma#. C"l$ 2le)i*ilit! 9own to app. -C>F: Che+i al resistan e Aromatic mineral oils '&;1 J,> oil( .uels "ow molecular weight aromatic hydrocarbons 'ben!ene, toluene(

11. '!$r"genate$ Nitrile %'NBR&

)ydrogenated %itrile is a synthetic polymer that results from the hydrogenation of nitrile rubber '%?;(. &n this process the molecular double bonds in the %?; primiary polymer chain undergo a hydrogenation process and therefore the term hydrogenated nitrile ')%?;(. The allow temperature range e#tends to *HJF: with short periods at higher temperature possible. ?y following design guidelines effective sealing can be achieved at ->3F: for static applications. .or dynamic applications however, operating temperatures are limited to above - 3>F:. )%?; compounds posses superior mechanical characteristics, particularly their high strength. .or sealing applications up to app *7JF:, this is an advantages as it prevents e#trusion and wear. Che+i al Resistan e Aliphatic hydrocarbons Begetable and animal fats and oils ).A, ).? and ).: fluids 9ilute acids, bases and salt solutions at moderate temperature Water and stream up to *HJF: O!one, aging and temperature N"t "+,ati*le -ith. :hlorinates hydrocarbons 2olar solvents 'ketone and ester( 6trong acids 13. Per2l#"r"elast"+er %((<M& The name 2erfluoroelastomer is somewhat misleading. An actual perfluorinated material with a high molecular weight is polytetrafluoroethylene or 2T.$ which has the chemical formula ':.3(n. The molecular of the large bonded fluorine atoms. 2erfluoroelastomer is produced by the copolymeri!ation of tetrafluoroethylene 'T.$( and is perfluorinated ether. The differing resistance to volume swell of the difference perfluoroelastomers is due to the perfluorinated ether elements, where the side-chain can consist of up to four perfluorinated carbon atoms. The e#traordinary chemical resistance is partly due to the fluorine atoms shielding the carbon chain, and partially due to the vulcani!ation system. 'eat resistan e 3>3F: to >,,F: depending on compound C"l$ 2le)i*ilit! -*+F: or -3<F: Che+i al resistan e Aliphatic and aromatic hydrocarbons :hlorinated hydrocarbons 2olar solvents 'acetone, methylethylketone, ethylacetate, diethylether and dio#ane(

&norganic and organic acids Water and steam )igh vacuum with minimal loss in weight N"t "+,ati*le -ith. .luroinated refrigerants ';**, *3, *>, **>, **H, etc(

16. P"l!a r!late %ACM&

A:1 or simply acrylate rubber consists of a polymeri!ed ester and a curing monomer. $thyl acrylate rubber has a good resistance to heat and mineral oil0 on the other hand butyl acrylate has a better cold fle#ibility. 2olyacrylate has a good resistance to mineral oil, o#ygen and o!one even at high temperatures. The water compatibility and cold fle#ibility of A:1 are significantly worse than with %?;. 'eat resistan e 6hortened lifetime up to appro#imately *CCF:. C"l$ 2le)i*ilit! 9own to appro#imately -3*F: Che+i al Resistan e 1ineral Oil 'engine, gear bo#, AT. oil( O!one, weather and aging resistance N"t "+,ati*le -ith. Alycol based brake fluid Aromatics and chlorinated hydrocarbons )ot water, steam Acids, alkalis, amines 17. P"l!#rethane %A?5 E?& One must differentiate between polyester urethane 'A8( and polyether urethane '$8(. A8 type urethanes e#hibit better resistance to hydraulic fluids. 2olyurethane elastomers, as a class, have e#cellent wear resistance, high tensile strength and high elasticity in comparison with any other elastomers. 2ermeability is good and comparable with butyl. 'eat Resistan e 8p to appro#imately +3F: C"l$ 2le)i*ilit! 9own to appro#imately -H,F: Che+i al Resistan e 2ure aliphatic hydrocarbons 'propane, butane, fuel( 1ineral oil and grease 6ilicone oil and grease Water up to 7,F: '$8 type( O!one and aging resistance N"t "+,ati*le -ith.
Ketones, esters, ethers, alcohols, glycols

)ot water, steam, alkalis, amines, acids

18. Sili "ne R#**er %>5 M>5 =M>5 P=M>& The term silicone covers a large group of materials in which vunyl-methyl-silicone 'B1L( is often the central ingredient. 6ilicone elastomers as a group have relatively low tensile strength, poor tear and wear resistance. )owever, they have many useful properties as well. 6ilicones have good heat resistance up to 3>3F:, good cold fle#ibility down to -7JF: and good o!one and weather resistance as well as good insulating and physiologically neutral properties. 'eat Resistan e 8p to appro#imately 3,HF: 'special compound up to 3>3F: ( C"l$ (le)i*ilit! 9own to appro#imately -7JF: to -7HF: with special compounds down to -**7F: Che+i al resistan e $ngine and transmission oil 'eg0 A6T1 oil %o.*( Animal and vegetable oil and grease ?rake fluid 'non-petroleum base( .ire-resistance hydraulic fluid, ).9-; and ).9-6 )igh molecular weight chlorinated aromatic hydrocarbons 1oderate water resistance 9iluted salt solutions O!one, aging and weather resistance N"t "+,ati*le -ith@ 6uperheated water steam over *3*F: Acids and alkalis "ow molecular weight chlorinated hydrocarbons Aromatic mineral oil )ydrocarbon based fuels Aromatic hydrocarbons 'ben!ene, toluene( 19. St!rene-B#ta$iene %SBR& 6?; probably is better known under its old names ?una 6 and A;6. 6?; was first produced under government control between *J>, and *J7, as a replacement for natural rubber. The basic monomers are butadiene and styrene, with styrene content appro#imately 3>.7E. About one third of the world output of 6?; is used in tire production. 6?; is mostly used in seals and nonmineral oil based brake fluid applications 'eat Resistan e 8p to appro#imately *,CF: C"l$ 2le)i*ilit! 9own to appro#imately -7CF: C"+,ati*le -ith. Water, alcohol, glycol and certain ketones 'acetone( %on-mineral oil based brake fluid. 6ilicon oil and grease 9iluted water solutions, weak acids

N"t "+,ati*le -ith. 1ineral oils 2etroleum greases and fuels Aliphatic hydrocarbons like ben!ene, toluene, #ylol. :hlorinated hydrocarbons- such as chloroform, trichloroethylene, carbon tetrachloride O#idi!ing, media like nitric acids, chromic acid, hydrogen pero#ide, chlorine, bromine. 1:. Tetra2l#"r"eth!lene-Pr",!lene %A(LASR& This elastomer is a copolymer of tetrafluoroethylene 'T.$( and propylene. &ts chemical resistance is e#cellent across a wide range of aggressive media. 'eat Resistan e 8p to appro#imately 3>3F: C"l$ (le)i*ilit! 9own to appro#imately -HF: C"+,ati*le -ith. ?ases 2hosphate esters Amines $ngine Oils 6team 2ulp and paper li uors N"t "+,ati*le -ith. Aromatic fuels Ketones :arbon Tetrachloride

6election of ?ase 2olymer

6ystem operating temperatures and compatibility with the media to be sealed are the most important parameters which must be considered when selecting a base polymer. Only when these two factors are identified 'including any lubricants and potential cleaning fluids(, can a reliable recommendation be given concerning selection of the proper elastomer base. .or the seal designed, a compromise often has to be made between specifying high uality, sealing grade materials and cheaper commercial products 'which usually contain less polymer and more ine#pensive fillers( The application temperatures given as shown below chart refer to long-term e#posure to non-aggressive media. At higher temperatures, new crosslink sites may be formed between the polymer chains and lead to a loss of seal fle#ibility. The stiffness in the polymer chains may be observed as e#cessive compression set in highly filled compounds. This condition prevents an O-ring crosssection from re-turning to its original, pre-compressed shape after deformation forces are removed. 9uring compression, a seal changes its original shape to effect a seal and over time, and with e#cessive temperature, elastic memory loss in the elastomer seal element can cause leakage. $#ceeding the normal ma#imum temperature limit for a given compound always result in reduced service life.

2ractically all elastomers undergo a physical or chemical change when in contact with a sealed medium. The degree of change depends on the chemistry of the medium and on the system temperature. An aggressive medium becomes more active with increasing temperature. 2hysical changes are caused by two mechanisms which can work concurrently when0 a. The elastomer absorbs a medium b. 2lastici!ers and other components of the compound are dissolved and e#tracted or leached out by the media. The result is volume changes, i.e, swelling or shrinkage of the elastomer seal. The degree of volume change depends on the type of medium, molecular structure of the rubber compound, system temperature, geometrical seal shape, and the stressed conditions of the rubber part. When deformed and e#posed to a medium, rubber, when confined in a gland, swells significantly less than in free state 'up to 7,E( due to a number of factors including lessened surface area in contact with the medium. The limit of permissible volume change varies with the application. .or static seals, a volume change of 37E to >,E can be tolerated. 6welling leads to some deterioration of the mechanical properties, and in particular, those properties which improve e#trusion resistance. &n dynamic applications, swelling leads to increased friction and a higher wear rate. Therefore, a ma#imum swell of *,E should generally not be e#ceeded. 6hrinkage should also be avoided because the resulting loss of compressive force will increase the risk of the leakage. The e#traction of plastici!er from a seal material is sometimes compensated for by partial absorption of the contact medium. This situation however, can still lead to une#pected shrinkage and resultant leakage when an elastomer dries out and the absorbed fluids

evaporate. A chemical reaction between sealed or e#cluded medium and the elastomer can bring about structural changes in the form of further crosslinking or degrading. The smallest chemical change in an elastomer can lead to significant changes in physical properties, such as embrittlement. The suitability of an elastomer for a specific applications can be established only when the properties of both the medium and the elastomer are known under typical working conditions. &f a particular seal material suits a medium, it is referred to as begin compatible with the medium. C"++"n Seal (ail#res

A*rasi"n

4es ri,ti"n. The seal or parts of the seal e#hibit a flat surface parallel to the direction or

motion. "oose particles and scrapes may be found on the seal surface. C"ntri*#ting (a t"rs. ;ough sealing surfaces. $#cessive temperature. 2rocess environment containing abrasive particles. 9ynamic motion. 2oor elastomer surface finish. S#ggeste$ S"l#ti"ns. 8se recommended gland surface finishes. :onsider internally lubed elastomers. $liminate abrasive components.

C"+,ressi"n Set

4es ri,ti"n. The seal e#hibits a flat-sided cross-section, the flat sides correspoding to the mating seal surfaces. C"ntri*#ting (a t"rs. $#cessive compression. $#cessive temperature. &ncompletely cured elastomer. $lastomer with high compression set. $#cessive volume swell in chemical. S#ggeste$ S"l#ti"ns. "ow compression set elastomer. 2roper gland design for the specific elastomer. :onfirm material compatibility.

Che+i al 4egra$ati"n

4es ri,ti"n. The seal may e#hibit many signs of degradation including blisters, cracks, voids or discoloration. &n some cases, the degradation is observable only by measurement of physical properties. C"ntri*#ting (a t"rs. :ontributing .actors0 &ncompatibility with the chemical and-or thermal environment. S#ggeste$ S"l#ti"ns. 6election of more chemically resistant elastomer.

E),l"siAe 4e "+,ressi"n

4es ri,ti"n. The seal e#hibits blisters, pits or pocks on its surface. Absorption of gas at high pressure and the subse uent rapid decrease in pressure. The absorbed gas blisters and ruptures the elastomer surface as the pressure is rapidly removed. C"ntri*#ting (a t"rs. ;apid pressure changes. "ow-modulus-hardness elastomer. S#ggeste$ S"l#ti"ns. )igher-modulus-hardness elastomer. 6lower decompression 'release of pressure(.

E)tr#si"n

4es ri,ti"n. The seal develops ragged edges 'generally on the low-pressure side( which appear tattered. C"ntri*#ting (a t"rs. $#cessive clearances. $#cessive pressure. "ow-modulus-hardness

elastomer. $#cessive gland fill. &rregular clearance gaps. 6harp gland edges. &mproper si!ing. S#ggeste$ S"l#ti"ns. 9ecrease clearances. )igher-modulus-hard-ness elastomer. 2roper gland design. 8se of polymer backup rings.

Installati"n 4a+age

4es ri,ti"n. The seal or parts of the seal may e#hibit small cuts, nicks or gashes. C"ntri*#ting (a t"rs. 6harp edges on glands or components. &mproper si!ing of elastomer. "ow-modulus-hardness elastomer. $lastomer surface contamination. S#ggeste$ S"l#ti"ns. ;emove all sharp edges. 2roper gland design. 2roper elastomer si!ing. )igher-modulus-hardness elastomer.

O#tgassing B E)tra ti"n

4es ri,ti"n. This failure is often very difficult to detect from e#amination of the seal. The seal may e#hibit a decrease in cross-sectional si!e. C"ntri*#ting (a t"rs. &mproper or improperly cured elastomer. )igh vacuum levels. "ow hardness-plastici!ed elastomer. S#ggeste$ S"l#ti"ns. Avoid plastici!ed elastomers. $nsure all seals are properly post-cured to minimi!e outgassing.

OAer "+,ressi"n

4es ri,ti"n. The seal e#hibits parallel flat surfaces 'corresponding to the contact areas( and may develop circumferential splits within the flattened surfaces. C"ntri*#ting (a t"rs. &mproper design4Ifailure to account for thermal or chemical volume changes, or e#cessive compression. S#ggeste$ S"l#ti"ns. Aland design should take into account material responses to chemical and thermal environments.

Plas+a 4egra$ati"n

4es ri,ti"n. The seal often e#hibits discoloration, as well as powdered residue on the surface and possible erosion of elastomer in the e#posed areas. C"ntri*#ting (a t"rs. :hemical reactivity of the plasma. &on bombardment 'sputtering(. $lectron bombardment 'heating(. &mproper gland design. &ncompatible seal material. S#ggeste$ S"l#ti"ns. 2lasma-compatible elastomer and compound. 1inimi!e e#posed area. $#amine gland design.

S,iral (ail#re

4es ri,ti"n. The seal e#hibits cuts or marks which spiral around its circumference. C"ntri*#ting (a t"rs. 9ifficult or tight installation 'static(. 6low reciprocating speed. "owmodulus-hardness elastomer. &rregular O-ring surface finish 'including e#cessive parting line(. $#cessive gland width. &rregular or rough gland surface finish. & S#ggeste$ S"l#ti"ns. :orrect installation procedures. )igher-modulus elastomer. &nternallylubed elastomers. 2roper gland design. Aland surface finish of +4B*< microinch ;16. 2ossible use of polymer backup rings.

Ther+al 4egra$ati"n

4es ri,ti"n. The seal may e#hibit radial cracks located on the highest temperature surfaces. &n addition, certain elastomers may e#hibit signs of softening4Ia shiny surface as a result of

e#cessive temperatures. C"ntri*#ting (a t"rs. $lastomer thermal properties. $#cessive temperature e#cursions or cycling. S#ggeste$ S"l#ti"ns. 6election of an elastomer with improved thermal stability. $valuation of the possibility of cooling sealing surfaces.

O-RING (AIL?RE ANALYSIS

A seal failure can cost customer time and money as well as possibly endangering personnel. The analysis of premature or une#pected seal failure includes many factors, including the environment, the seal design and the elastomer itself. The appearance of t
&n the semiconductor industry, the failure of a single seal can result in millions of dollars in damaged production, downtime and maintenance costs. &n many environments, a seal failure can result in the complete evacuation of a facilityor worse, the e#p 2revention of seal failures through proper design, material selection and maintenance certainly minimi!es the risk of failure. Attention to the condition of replaced seals, as well as the e uipment performance over time, will result in improved process re O-ring seals often fail prematurely in applications because of improper design or compound selection. This section is designed to provide the viewer with e#amples of common failure modes. ?y correctly identifying the failure mode, changes in the design or .rom the end-userMs point of view, a seal can fail in three '>( general ways0 - "eaking - :ontamination - :hange in Appearance

These three effects are demonstrated with special emphasis on the following three analysis areas. *( $nvironment 3( 6eal 9esign >( $lastomer

EnAir"n+ent Anal!sis One ma/or factor in possible o-ring or seal failure is the e#treme and harsh environment in which o-rings and seals are e#pected to perform. &n the :2& - semiconductor industry, the sealing environment can consist of virtually anything from inert gases at :ontributing factors to seal failure in the sealing environment include0 :hemical 0 - type of chemical's( in service Thermal 0 - operating ranges of the seal 'also any thermal cycling( 2ressure-Bacuum 0 - range of pressures or vacuum levels in the process

Seal 4esign Anal!sis

Analysis of the seal application is crucial to the understanding of possible failure. 1ost seal design is performed by component suppliers and

e uipment manufacturers. The designs are refined as e#perience is gained. As uickly as process technology chang The seal design and application can provide information about the cause of failure0 6tatic 6eals 0 - a#ial and radial, confined or unconfined 9ynamic 6eals 0 - a#ial 'open-close( or radial 'reciprocating or rotary( 6ealing Aland 9imensions 0 - shape 's uare, trape!oidal, etc.( - compression - gland - fill - stretch &nstallation 2rocedures 0 - stretch

Elast"+er Anal!sis
Analytical techni ues are used to identify the specific polymer type and compound. They can also be used to identify contamination sources on the surface, or surface properties which may have contributed to the failure. Traditional elastomer test methods