O-Ring Failure Analysis | Extrusion, Swell, Thermal Aging

Field symptoms and corrective actions for extrusion, swell, thermal aging, compression set, and installation damage.

Common failures

  • Extrusion/cuts at gaps
  • Chemical swell/softening
  • Compression set/flattening
  • Thermal cracks/embrittlement
  • Installation nicks/twists

Fixes

  • Add PTFE backup rings, tighten gaps, raise hardness.
  • Switch to FKM/FFKM/PTFE for aggressive media.
  • Tune squeeze (static 15–25%, dynamic 10–20%), reduce heat.
  • Improve surface finish/chamfers, use lube, avoid twisting.

Prevention

  • Validate media compatibility; request MSDS.
  • Control pressure/temperature cycles.
  • Use traceable batches and inspect regularly.
  • Store cool/dry/ozone-free; FIFO.