AIR1707B - Patterns of O-Ring Failures

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AIR1707 REV. B
AEROSPACE
INFORMATION REPORT Issued 1981-10
Revised 2014-09
Superseding AIR1707A
Patterns of O-ring Failures
RATIONALE
Document was updated for 5-year review and clearer, more legible images were included.
1. SCOPE
The information presented herein describes the commonly observed patterns of O-ring failure by means of both text and
illustration. Possible causes and corrective actions are indicated for alleviating the problem.
1.1 Purpose
This document is intended to provide a guide for analyzing O-rings which have failed in order to correct the circumstances
which have caused the failure. A great deal can be learned toward solving a sealing problem involving O-rings by close
observation of the failed O-ring.
2. REFERENCES
There are no referenced publications specified herein.
3. FAILURE PATTERNS
3.1 General
Failures are usually due to a combination of causes. The patterns of O-ring failure described herein, then, represent the
modes most often encountered. Subtle variations will occur, but the major cause generally predominates.
3.1.1 Note that this document does not advise on rubber compound selections or design details, although some general
guidance comments are made. Consult an applications engineer for material selection, design details, and the
proper use of antiextrusion devices. Also, consider the substitution of other sealing types for the O-ring.
__________________________________________________________________________________________________________________________________________
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SAE INTERNATIONAL AIR1707B Page 2 of 20

3.1.2 The failures discussed herein have been classified under the following headings:
Extrusion and Nibbling 3.2

Spiral Failure 3.3
Abrasion 3.4
Compression Set 3.5
Weather and Ozone Cracking 3.6
Heat Aging and Oxidation 3.7
Plasticizer Extraction 3.8
Installation Damage 3.9
Gas Expansion Rupture 3.10
Failure Due to Backup Ring 3.11
3.2 Extrusion and Nibbling
3.2.1 Occurrence
Usually associated with dynamic rod or piston seals but can occur in a static seal with pressure pulsations, especially where
it opens and closes the clearance.
3.2.2 Appearance
Exhibits many small nibbles removed from the O-ring adjacent to the downstream clearance area, or a small section of the
O-ring may be extruded. Typical of high pressure systems, this process sometimes erodes half of the O-ring cross-section
before major leakage occurs.
3.2.3 Cause
Clearance is too large, pressure is too high, O-ring is too soft, O-ring is softened and swelled by fluid, clearance increases
under pressure, eccentricity causes irregular gap, and corners of O-ring gland are too sharp.
3.2.4 Corrective Action
Closer metal fits (reduce diametral clearance or reduce plate gap,) use of backup rings or other antiextrusion devices such
as cap strips, harder O-ring material, use of O-ring more compatible with system fluid, more rigid or concentric metal
components, and break edges of gland to a radius of about 0.001 to 0.002 inch (0.025 to 0.050 mm). T-seals that fit into
the same gland may also be substituted.
3.2.5 Examples
FIGURE 1 - EXTRUSION AND NIBBLING

FIGURE 2 - EXTRUSION AND NIBBLING (USED WITH PERMISSION FROM R.L. HUDSON)
FIGURE 3 - NIBBLING AND SKIVING

FIGURE 4 - NIBBLING AND ABRADING
FIGURE 5 - NIBBLING AND EXTRUSION

FIGURE 6 - NIBBLING, EXTRUSION, PITTING, AND SPIRAL FAILURE
3.3 Spiral Failure
3.3.1 Occurrence
Usually associated with long stroke piston seals but can occur with dynamic rod seals. Has been observed even on short
stroke pneumatic piston seals.
3.3.2 Appearance
Exhibits a deep spiral cut (usually at about 45 degree) into the O-ring cross-section.
3.3.3 Cause
Conditions which cause segments of the O-ring to slide and others to roll, simultaneously. The O-ring generally gets pinched
or "hung up" at one point of its periphery. Side loads causing the O-ring to get caught in an eccentric component, uneven
surface finishes, poor or uneven dispersion of lubricant and stroke speeds contribute.
Improve metal surface finish to the 10 to 20 microinches (0.25 to 0.50 µm) range, improve lubrication, use backups or other
antiextrusion devices if possible, reduce gap, and consider seals other than O-rings such as T-seals.

3.3.5 Examples
FIGURE 7 - SPIRAL FAILURE
FIGURE 8 - SPIRAL FAILURE (USED WITH PERMISSION FROM R.L. HUDSON)

FIGURE 9 - SPIRAL FAILURE (PHOTO COURTESY OF PARKER HANNIFIN)
3.4 Abrasion
3.4.1 Occurrence
Dynamic seals, either reciprocating or rotary.
3.4.2 Appearance
Flat area on one side of cross-section of O-ring where moving contact is made with metal component. Frequently shows
wear lines on the cross-section parallel to motion of the seal.
3.4.3 Cause
Too rough or too smooth metal surfaces, poor lubrication, high temperatures, or fluid contamination.
Use recommended metal finishes, provide adequate lubrication, use O-ring material compatible with service temperature,
and eliminate fluid contamination. Rapid wear can be expected with finishes below 5 microinches (0.13 µm).

3.4.5 Examples
FIGURE 10 - ABRASION
FIGURE 11 - ABRASION ON ONE SIDE

FIGURE 12 - ABRASION (USED WITH PERMISSION FROM R.L. HUDSON)
3.5 Compression Set
3.5.1 Occurrence
Dynamic and static seals.
3.5.2 Appearance
Flat area on both sides of O-ring cross-section in the area being squeezed.
3.5.3 Cause
Temperature too high (either environmental or frictional) causing hardening, excessive volume increase from fluid causing
overfill, excessive squeeze to achieve seal, O-rings not completely vulcanized, or use of compound with poor set properties.
In extremely rare cases, this can also be caused if a ring is over-cured (reversion.)
Use O-ring material compatible with fluid and temperature service, minimize conditions which increase service temperature,
review squeeze to be sure it is proper, and use an improved, low-set compound if available. A good quality, well-inspected
O-ring is important.
3.5.5 Examples
FIGURE 13 - COMPRESSION SET

FIGURE 14 - COMPRESSION SET ON THREE SIDES (CROSS-SECTION)
3.6 Weather or Ozone Cracking
3.6.1 Occurrence
Dynamic or static seals under stress and exposed to atmosphere containing ozone and air pollutants.
3.6.2 Appearance
Many small cracks perpendicular to the direction of stress may be small enough to be unseen with unaided eye or large
enough to progress entirely through the cross-section (also see 4.8.3). Crazing of the outside surface of the O-ring is the
most common.
3.6.3 Cause
Ozone attacks unsaturated or double bond points in polymer chain of some polymers causing chain scission. The damage
is usually seen on the outside surface, exposed to the atmosphere.
If conditions of service cannot be remedied, the rubber material must be changed. Use rubber materials that are saturated
and inherently resistant to ozone attack. Change storage conditions to reduce exposure time to detrimental environment.
Sufficient improvement can, at times, be obtained by using rubber compounds with antiozonant additives.

3.6.5 Examples
FIGURE 15 - WEATHER OR OZONE CRACKING
FIGURE 16 - CRACKING FROM OZONE

FIGURE 17 - CRACKING FROM OZONE
3.7 Heat Hardening and Oxidation
3.7.1 Occurrence
Dynamic or static seals subjected to elevated temperatures and atmosphere. Common in pneumatic or air service.
3.7.2 Appearance
Hardening of the rubber begins at the surface and progresses through the entire O-ring cross-section. Hardening is
accompanied by high compression set if O-ring is under compression.
3.7.3 Cause
Environmental temperature and oxygen exposure are too high for the selected rubber material, causing hardening due to
additional cross-linking in the rubber, evaporation of rubber plasticizer, or oxidation. It may be a combination of these.
Decrease service temperature, select a rubber material with better resistance to high-temperature and/or oxygen exposure,
or protect surface from oxygen exposure (as wiper seals).

3.7.5 Examples
FIGURE 18 - HARDENING AND OXIDATION
FIGURE 19 - WEATHER CRACKING (USED WITH PERMISSION FROM R.L. HUDSON)

FIGURE 20 - HARDENING AND PITTING
3.8 Plasticizer Extraction
3.8.1 Occurrence
Dynamic and static seals usually in fuel systems subject to dry-out periods, but occasionally in other systems.
3.8.2 Appearance
Small cracks in stressed area of O-ring cross-section, accompanied by loss in volume. This is often difficult to detect with a
visual inspection.
3.8.3 Cause
Extraction of plasticizer by service fluid followed by evaporation of service fluid during dry-out period. Results are hardening
of the rubber material and decrease in elongation to the extent that cracks appear where stressed. This condition is
accelerated in the presence of ozone.
Assuming service conditions cannot be improved, change to a compatible rubber material with low or no extractable
plasticizer content.

3.8.5 Examples
FIGURE 21 - PLASTICIZER EXTRACTION
3.9 Installation Damage
3.9.1 Occurrence
Dynamic and static seals usually installed with squeeze between inside and outside diameter of the O-ring, or stretching an
O-ring over tube ends or threads.
3.9.2 Appearance
Short cuts or notches or a "shinned" surface or a "skived" cut that can extend at a uniform thickness clear around the
periphery of the O-ring and can continue through the cross-section as if it were being peeled. May also present as spiraling
or twisting in certain applications.
3.9.3 Cause
Sharp corners on mating metal parts, threads, or insufficient lead-in chamfer; inside diameter of O-ring too small on rod seal
or too large on piston seal installation. Blind grooves in multiple port valves are especially troublesome.
Adjust dimensions of metal components and O-rings to eliminate cutting or pinching of seals when possible. Lead-in
chamfers should be 20 degrees maximum and "break" sharp corners of chamfer and groove edges. Use tubular installation
tools to cover threads and sharp corners during O-ring installation. If feasible in the application, use an elastomer that is
more resistant to mechanical damage (e.g., EPDM instead of silicone).

3.9.5 Examples
FIGURE 22 - INSTALLATION DAMAGE (USED WITH PERMISSION FROM R.L. HUDSON)
FIGURE 23 - TWISTED AND PUNCTURED INSTALLATION DAMAGE
FIGURE 24 - SKIVED INSTALLATION DAMAGE


3.10 Gas Expansion Rupture
3.10.1 Occurrence
High pressure gas seals subject to fast decompression periods, sometimes called explosive decompression.
3.10.2 Appearance
Short splits or ruptures which may be deep into the O-ring cross-section. When O-ring is first removed, the surface may
have little blisters. They either split or go away.
3.10.3 Cause
Absorption of gas or liquefied gas under high pressure with subsequent lack of escape on decompression causing blistering
and ruptures.
Increase time lapse for decompression or use higher modulus rubber material or special compounds that will resist rupture.
3.10.5 Examples
FIGURE 25 - GAS EXPANSION RUPTURE

FIGURE 26 - RAPID GAS EXPANSION/EXPLOSIVE DECOMPRESSION RUPTURES (CROSS-SECTIONS)
FIGURE 27 - GAS EXPANSION RUPTURES

FIGURE 28 - RAPID GAS RUPTURE/EXPLOSIVE DECOMPRESSION
3.11 O-ring Failure Due to Backup Ring Failure or Scarf-Cut End
3.11.1 Occurrence
More commonly seen in dynamic seals, but may also be present in static seals.
3.11.2 Appearance
Similar to 4.2 except that damaged sections of the O-ring correspond to damage to the backup ring (see Figure 29) or to
the scarf cut or overlap of the backup ring (not shown).
3.11.3 Cause
Thermal changes, pressure surges, installation damage of the backup ring, dimensionally poor-fitting backup ring, use of
hard scarf-cut backup ring with soft elastomer, and extrusion of backup ring into the clearance gap.
When O-ring damage corresponds to backup ring damage, check design details and installation procedures. When O-ring
damage corresponds to the location of the backup ring scarf-cut, consider the uncut type of backup ring. Consider other
seal types.

3.11.5 Examples
FIGURE 29 - O-RING FAILURE DUE TO BACKUP RING DAMAGE
4. NOTES
4.1 A change bar (l) located in the left margin is for the convenience of the user in locating areas where technical revisions,
not editorial changes, have been made to the previous issue of this document. An (R) symbol to the left of the
document title indicates a complete revision of the document, including technical revisions. Change bars and (R) are
not used in original publications, nor in documents that contain editorial changes only.
PREPARED BY AMS COMMITTEE "CE"

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Patterns of O-ring Failures

There are no referenced publications specified herein.

SAE INTERNATIONAL AIR1707B Page 2 of 20

Extrusion and Nibbling 3.2

3.2 Extrusion and Nibbling

3.2.4 Corrective Action

FIGURE 1 - EXTRUSION AND NIBBLING

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FIGURE 3 - NIBBLING AND SKIVING

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FIGURE 4 - NIBBLING AND ABRADING

FIGURE 5 - NIBBLING AND EXTRUSION

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FIGURE 6 - NIBBLING, EXTRUSION, PITTING, AND SPIRAL FAILURE

3.3 Spiral Failure

3.3.4 Corrective Action

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FIGURE 7 - SPIRAL FAILURE

FIGURE 8 - SPIRAL FAILURE (USED WITH PERMISSION FROM R.L. HUDSON)

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FIGURE 9 - SPIRAL FAILURE (PHOTO COURTESY OF PARKER HANNIFIN)

Dynamic seals, either reciprocating or rotary.

3.4.4 Corrective Action

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FIGURE 11 - ABRASION ON ONE SIDE

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FIGURE 12 - ABRASION (USED WITH PERMISSION FROM R.L. HUDSON)

3.5 Compression Set

Dynamic and static seals.

3.5.4 Corrective Action

FIGURE 13 - COMPRESSION SET

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FIGURE 14 - COMPRESSION SET ON THREE SIDES (CROSS-SECTION)

3.6 Weather or Ozone Cracking

3.6.4 Corrective Action

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FIGURE 15 - WEATHER OR OZONE CRACKING

FIGURE 16 - CRACKING FROM OZONE

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FIGURE 17 - CRACKING FROM OZONE

3.7 Heat Hardening and Oxidation

3.7.4 Corrective Action

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FIGURE 18 - HARDENING AND OXIDATION

FIGURE 19 - WEATHER CRACKING (USED WITH PERMISSION FROM R.L. HUDSON)

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FIGURE 20 - HARDENING AND PITTING

3.8 Plasticizer Extraction

3.8.4 Corrective Action

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FIGURE 21 - PLASTICIZER EXTRACTION

3.9 Installation Damage

3.9.4 Corrective Action

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FIGURE 22 - INSTALLATION DAMAGE (USED WITH PERMISSION FROM R.L. HUDSON)

FIGURE 23 - TWISTED AND PUNCTURED INSTALLATION DAMAGE

FIGURE 24 - SKIVED INSTALLATION DAMAGE

SAE INTERNATIONAL AIR1707B Page 17 of 20