O-ring
This article is about the mechanical seal. For other uses, see Oring.
Typical O-ring and application
An O-ring, also known as a packing, or a toric joint, is a mechanical gasket in the
shape of a torus; it is a loop of elastomer with a round cross-section, designed to be
seated in a groove and compressed during assembly between two or more parts,
creating a seal at the interface.
The O-ring may be used in static applications or in dynamic applications where there is
relative motion between the parts and the O-ring. Dynamic examples include
rotating pump shafts and hydraulic cylinder pistons.
O-rings are one of the most common seals used in machine design because they are
inexpensive, easy to make, and reliable and have simple mounting requirements. They
can seal tens of megapascals (thousands of psi) of pressure.
1Manufacturing
2History
3Theory and design
o
3.1Typical applications
3.2Vacuum applications
3.3High temperature applications
4Sizes
5Material
6Other seals
7Failure modes
8Challenger disaster
9Future
10Standards
10.1ISO 3601 Fluid power systems O-rings
11See also
12References
13External links
Manufacturing
O-rings can be produced by extrusion, injection molding, pressure molding or transfer
molding.
[1]
History
The first patent for the O-ring, is dated May 12, 1896 as a Swedish patent. J. O.
Lundberg, the inventor of the O-ring, received the patent. The US patent for the O-ring
was filed in 1937 by a then 72-year-old Danish-born machinist, Niels Christensen. Soon
after migrating to the USA in 1891, he patented an air brake system
for streetcars (trams). Despite his legal efforts, his intellectual property rights were
passed from company to company until they ended up at Westinghouse. During World
War II, the US government commandeered the O-ring patent as a critical war-related item
and gave the right to manufacture to other organizations. Christensen received a lump
sum payment of US$75,000 for his efforts. Litigation resulted in a $100,000 payment to
his heirs in 1971, 19 years after his death.
[2]
[3]
[4]
[4]
[5]
Theory and design
O-ring mounting for an ultra-high vacuum application. Pressure distribution within the cross-section of the O-ring. The orange
lines are hard surfaces, which apply high pressure. The fluid in the seams has lower pressure. The soft O-ring bridges the
pressure over the seams.
O-rings are available in various metric and inch standard sizes. Sizes are specified by the
inside diameter and the cross section diameter (thickness). In the US the most common
standard inch sizes are per SAE AS568C specification (e.g. AS568-214). ISO 36011:2012 contains the most commonly used standard sizes, both inch and metric,
worldwide. The UK also has standards sizes known as BS sizes, typically ranging from
BS001 to BS932. Several other size specifications also exist.
Typical applications
Successful O-ring joint design requires a rigid mechanical mounting that applies a
predictable deformation to the O-ring. This introduces a calculated mechanical stress at
the O-ring contacting surfaces. As long as the pressure of the fluid being contained does
not exceed the contact stress of the O-ring, leaking cannot occur. Fortunately, the
pressure of the contained fluid transfers through the essentially incompressible O-ring
material, and the contact stress rises with increasing pressure. For this reason, an O-ring
can easily seal high pressure as long as it does not fail mechanically. The most common
failure is extrusion through the mating parts.
The seal is designed to have a point contact between the O-ring and sealing faces. This
allows a high local stress, able to contain high pressure, without exceeding the yield
stress of the O-ring body. The flexible nature of O-ring materials accommodates
imperfections in the mounting parts. But it is still important to maintain good surface finish
of those mating parts, especially at low temperatures where the seal rubber reaches
its glass transition temperature and becomes increasingly crystalline. Surface finish is
also especially important in dynamic applications. A surface finish that is too rough will
abrade the surface of the O-ring, and a surface that is too smooth will not allow the seal
to be adequately lubricated by a fluid film.
Vacuum applications
In vacuum applications, the permeability of the material makes point contacts quite
useless. Instead, higher mounting forces are used and the ring fills the whole groove.
Also, round back-up rings are used to save the ring from excessive deformation
Because the ring feels the ambient pressure and the partial pressure of gases only at
the seal, their gradients will be steep near the seal and shallow in the bulk (opposite to
the gradient of the contact stress See: Vacuum flange#KF.2FQF. High-vacuum systems
below 10 Torr use copper or nickel O-rings. Also, vacuum systems that have to be
immersed in liquid nitrogen use indium O-rings, because rubber becomes hard
and brittle at low temperatures.
[6][7]
[8]
[9]
High temperature applications
In some high-temperature applications, O-rings may need to be mounted in a tangentially
compressed state, to compensate for the .
Sizes
O-rings come in a variety of sizes British Standard (BS) which are imperial sizes or metric
sizes. Typical dimensions of an O-ring are internal dimension (id), outer dimension (od)
and thickness / cross section (cs)
Metric O-rings are usually defined by the internal dimension x the cross section. Typical
part number for a metric O-ring - ID x CS [material & shore hardness] 2x1N70 = defines
this O-ring as 2mm id with 1mm cross section made from Nitrile rubber which is 70Sh
BS O-rings are defined by a standard reference.
Material
Some small O-rings
O-ring selection is based on chemical compatibility, application temperature, sealing
pressure, lubrication requirements, durometer, size and cost.
[10]
Synthetic rubbers - Thermosets:
Butadiene rubber (BR)
Butyl rubber (IIR)
Chlorosulfonated polyethylene (CSM)
Epichlorohydrin rubber(ECH, ECO)
Ethylene propylene diene monomer (EPDM): good resistance to hot water and
steam, detergents, caustic potash solutions, sodium hydroxide solutions, silicone oils
and greases, many polar solvents and many diluted acids and chemicals. Special
formulations are excellent for use with glycol-based brake fluids. Unsuitable for use
with mineral oil products: lubricants, oils, or fuels. Peroxide-cured compounds are
suitable for higher temperatures.
[11]
Ethylene propylene rubber (EPR)
Fluoroelastomer (FKM): noted for their very high resistance to heat and a wide
variety of chemicals. Other key benefits include excellent resistance to aging and
ozone, very low gas permeability and the fact that the materials are selfextinguishing. Standard FKM materials have excellent resistance to mineral oils and
greases, aliphatic, aromatic and chlorinated hydrocarbons, fuels, non-flammable
hydraulic fluids (HFD) and many organic solvents and chemicals. Generally not
resistant to hot water, steam, polar solvents, glycol-based brake fluids and low
molecular weight organic acids. In addition to the standard FKM materials, a number
of specialty materials with different monomer compositions and fluorine content (65%
to 71%) are available that offer improved chemical or temperature resistance and/or
better low temperature performance.
[11]
Nitrile rubber (NBR, HNBR, HSN): a common material for o-rings because of its
good mechanical properties, its resistance to lubricants and greases, and its
relatively low cost. The physical and chemical resistance properties of NBR materials
are determined by the acrylonitrile (ACN) content of the base polymer: low content
ensures good flexibility at low temperatures, but offers limited resistance to oils and
fuels. As the ACN content increases, the low temperature flexibility reduces and the
resistance to oils and fuels improves. Physical and chemical resistance properties of
NBR materials are also affected by the cure system of the polymer. Peroxide-cured
materials have improved physical properties, chemical resistance and thermal
properties, as compared to sulfur-donor-cured materials. Standard grades of NBR
are typically resistant to mineral oil-based lubricants and greases, many grades of
hydraulic fluids, aliphatic hydrocarbons, silicone oils and greases and water to about
80 C. NBR is generally not resistant to aromatic and chlorinated hydrocarbons, fuels
with a high aromatic content, polar solvents, glycol-based brake fluids and nonflammable hydraulic fluids (HFD). NBR also has low resistance to ozone, weathering
and aging. HNBR has considerable improvement of the resistance to heat, ozone
and aging, and gives it good mechanical properties.
[11]
Perfluoroelastomer (FFKM)
Polyacrylate rubber(ACM)
Polychloroprene (neoprene) (CR)
Polyisoprene (IR)
Polysulfide rubber (PSR)
Polytetrafluoroethylene (PTFE)
Sanifluor
Silicone rubber (SiR): noted for their ability to be used over a wide temperature
range and for excellent resistance to ozone, weathering and aging. Compared with
most other sealing elastomers, the physical properties of silicones are poor.
Generally, silicone materials are physiologically harmless so they are commonly
used by the food and drug industries. Standard silicones are resistant to water (to
100 C), aliphatic engine and transmission oils and animal and plant oils and fats.
Silicones are generally not resistant to fuels, aromatic mineral oils, steam (short term
to 120 C is possible), silicone oils and greases, acids or alkalis. Fluorosilicone
elastomers are far more resistant to oils and fuels. The temperature range of
applications is somewhat more restricted.
[11]
Styrene-butadiene rubber (SBR)
Thermoplastics:
Thermoplastic elastomer (TPE) styrenics
Thermoplastic polyolefin (TPO) LDPE, HDPE, LLDPE, ULDPE
Thermoplastic polyurethane (TPU) polyether, polyester: Polyurethanes differ from
classic elastomers in that they have much better mechanical properties. In particular
they have a high resistance to abrasion, wear and extrusion, a high tensile strength
and excellent tear resistance. Polyurethanes are generally resistant to aging and
ozone, mineral oils and greases, silicone oils and greases, nonflammable hydraulic
fluids HFA & HFB, water up to 50 C and aliphatic hydrocarbons.
[11]
Thermoplastic etheresterelastomers (TEEEs) copolyesters
Thermoplastic polyamide (PEBA) Polyamides
Melt Processible Rubber (MPR)
Thermoplastic Vulcanizate (TPV)
Chemical Compatibility:
Air, 200 - 300 F Silicone
Beer - EPDM
Chlorine Water Viton (FKM)
Gasoline Buna-N or Viton (FKM)
Hydraulic Oil (Petroleum Base, Industrial) Buna-N
Hydraulic Oils (Synthetic Base) Viton
Water EPDM
Motor Oils Buna-N
Other seals
This section appears to contradict itself about scope of the term "O-ring". Please see the talk page for
more information.(November 2014)
O-ring and other sealing profiles
For sealings, there are variations in cross-section design other than circular. The shape
can have different profiles, an x-shaped profile, commonly called the X-ring, Q-ring, or by
the trademarked name Quad Ring. When squeezed upon installation, they seal with 4
contact surfaces2 small contact surfaces on the top and bottom. This contrasts with the
standard O-ring's comparatively larger single contact surfaces top and bottom. X-rings
are most commonly used in reciprocating applications, where they provide reduced
running and breakout friction and reduced risk of spiraling when compared to O-rings.
There are also rings with a square profile, commonly called square-cuts, lathe cuts, or
Square rings. When O-rings were selling at a premium because of the novelty, lack of
efficient manufacturing processes and high labor content, Square rings were introduced
as an economical substitution for O-rings. The square ring is typically manufactured by
molding an elastomer sleeve which is then lathe-cut. This style of seal is sometimes less
expensive to manufacture with certain materials and molding technologies (compression
molding, transfer molding, injection molding), especially in low volumes. The physical
sealing performance of square rings in static applications is superior to that of O-rings,
however in dynamic applications it is inferior to that of O-rings. Square rings are usually
only used in dynamic applications as energizers in cap seal assemblies. Square rings
can also be more difficult to install than O-rings.
Similar devices with a non-round cross-sections are called seals, packings or gaskets.
See also washers.
[13]
Automotive cylinder heads are typically sealed by flat gaskets faced with copper.
Knife edges pressed into copper gaskets are used for high vacuum.
Elastomers or soft metals that solidify in place are used as seals.
Failure modes
O-ring materials may be subjected to high or low temperatures, chemical attack,
vibration, abrasion, and movement. Elastomers are selected according to the situation.
There are O-ring materials which can tolerate temperatures as low as -200 C or as high
as 250+ C. At the low end, nearly all engineering materials become rigid and fail to seal;
at the high end, the materials often burn or decompose. Chemical attack can degrade the
material, start brittle cracks or cause it to swell. For example, NBR seals can crack when
exposed to ozone gas at very low concentrations, unless protected. Swelling by contact
with a low viscosity fluid causes an increase in dimensions, and also lowers the tensile
strength of the rubber. Other failures can be caused by using the wrong size of ring for a
specific recess, which may cause extrusion of the rubber.
Elastomers are sensitive to ionizing radiation. In typical applications, O-rings are well
protected from less penetrating radiation such as ultraviolet and soft X-rays, but more
penetrating radiation such as neutrons may cause rapid deterioration. In such
environments, soft metal seals are used.
There are a few common reasons for O-Ring Failure:
1. Installation Damage This is caused by improper installation of the O-ring.
2. Spiral Failure Found on long-stroke piston seals and to a lesser degree on rod
seals. The seal gets hung up at one point on its diameter (against the cylinder wall) and
slides and rolls at the same time. This twists the O-ring as the sealed device is cycled
and finally causes a series of deep spiral cuts (typically at a 45 degree angle) on the
surface of the seal.
3. Explosive Decompression - An O-ring embolism, also called gas expansion rupture,
occurs when high pressure gas becomes trapped inside the elastomeric seal element.
This expansion causes blisters and ruptures on the surface of the seal.
Challenger disaster
Main article: Space Shuttle Challenger disaster
The failure of an O-ring seal was determined to be the cause of the Space
Shuttle Challenger disaster on January 28, 1986. A crucial factor was cold weather prior
to the launch. This was famously demonstrated on television by Caltech physics
professor Richard Feynman, when he placed a small O-ring into ice-cold water, and
subsequently showed its loss of pliability before an investigative committee.
The material of the failed O-ring was FKM, which was specified by the shuttle motor
contractor, Morton-Thiokol. When an O-ring is cooled below its T (glass transition
temperature), it loses its elasticity and becomes brittle. More importantly, when an O-ring
is cooled near, but not beyond, its T , the cold O-ring, once compressed, will take longer
than normal to return to its original shape. O-rings (and all other seals) work by creating
positive pressure against a surface thereby preventing leaks. On the night before the
launch, exceedingly low air temperatures were recorded. On account of this, NASA
technicians performed an inspection. The ambient temperature was within launch
parameters, and the launch sequence was allowed to proceed. However, the
temperature of the rubber O-rings remained significantly lower than that of the
surrounding air. During his investigation of the launch footage, Feynman observed a
small out-gassing event from the Solid Rocket Booster (SRB) at the joint between two
segments in the moments immediately preceding the disaster. This was blamed on a
failed O-ring seal. The escaping high temperature gas impinged upon the external tank,
and the entire vehicle was destroyed as a result.
g
The rubber industry has gone through its share of transformation after the accident. Many
O-rings now come with batch and cure date coding, as in the medicine industry, to
precisely track and control distribution. For aerospace and military/defense applications,
O-rings are usually individually packaged and labeled with the material, cure date, and
batch information. O-rings can, if needed, be recalled off the shelf. Furthermore, O-rings
and other seals are routinely batch-tested for quality control by the manufacturers, and
often undergo Q/A several more times by the distributor and ultimate end users.
[14]
As for the SRBs themselves, NASA and Morton-Thiokol redesigned them with a new joint
design, which now incorporated three O-rings instead of two, with the joints themselves
having onboard heaters that can be turned on when temperatures drop below 50 F
(10 C). No O-ring issues have occurred since Challenger, and they did not play a role in
the Space Shuttle Columbia disaster of 2003.
Future
An O-ring is one of the simplest, yet highly critical, precision mechanical components
ever developed. But, there are new advances that may take some of the burden of critical
sealing away from the O-ring. There are cottage industries of elastomer consultants
assisting in designing O-ring-less pressure vessels. Nano-technology-rubber is one such
new frontier. Presently, these advancements are increasing the importance of O-rings.
Since O-rings encompass the areas of chemistry and material science, any advancement
in nano-rubber will affect the O-ring industry.
Already, there are elastomers filled with nano-carbon and nano-PTFE and molded into Orings used in high-performance applications. For example, carbon nanotubes are used in
electrostatic dissipative applications and nano-PTFE is used in ultra
pure semiconductor applications. The use of nano-PTFE
in fluoroelastomers and perfluoroelastomers improves abrasion resistance, lowers
friction, lowers permeation, and can act as clean filler.
Using conductive carbon black or other fillers can exhibit the useful properties
of conductive rubber, namely preventing electrical arcing, static sparks, and the overall
build-up of charge within rubber that may cause it to behave like a capacitor (electrostatic
dissipative). By dissipating these charges, these materials, which include doped carbonblack and rubber with metal filling additives, reduce the risk of ignition, which can be
useful for fuel lines.
Standards
ISO 3601 Fluid power systems O-rings
ISO 3601-1:2012 Inside diameters, cross-sections, tolerances and designation
codes
ISO 3601-2:2008 Housing dimensions for general applications
ISO 3601-4:2008 Anti-extrusion rings (back-up rings)