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1. Extrusion gap. Caused by excessive pressure, lack of support rings or retaining rings for the seal, excessive clearance, incorrect groove or gland dimensions. Seals should always be used within the recommended pressure range (with appropriate consideration for peak pressure gaps). The solution is to reduce clearance or provide a retaining ring seal, which usually prevents extrusion gaps.
2. Cracking. May result from aging hardening, natural deterioration, low-temperature hardening, overheating due to severe friction (insufficient lubrication or excessive tightness), or wear. Prolonged downtime, especially in low-temperature environments, can accelerate aging. Wear is mainly caused by excessively rough mating metal surfaces. Rubber seals typically require mating surfaces to be finished to 0.4 microns or finer for extended lifespan. The primary solution is to improve seal quality.
3. Twisting. Usually limited to O-rings and often caused by lateral loads. The solution is to use retaining rings to eliminate this issue.
4. Surface damage. Mainly caused by abrasion and wear due to rough mating surfaces or sharp edges on grooves and retaining rings. If the seal surface hardness is below
5, friction accelerates wear. Further surface imperfections like scratches or cuts can lead to premature seal failure. The solution is to improve the precision of mating surfaces.
6. Shrinkage. May result from fluid incompatibility. Rubber exhibits some shrinkage when paired with certain synthetic hydraulic fluids. Aging hardening or drying of seals in closed systems can also cause shrinkage, leading to internal leakage. 6. Damage. Typically caused by excessive mechanical loads combined with seal deterioration. The seal material may be partially incompatible with the fluid, or the seal size may be insufficient for the required load.
7. Compression deformation. Usually caused by excessive loads.
