Failure Analysis
Systematic Seal Failure Review
Premature seal failure is rarely caused by a single variable. Effective analysis combines visual examination of the failed part with operating data — temperature, pressure, media composition, cycle rate, and installation practice — to isolate the true root cause.
Use this reference to classify common failure modes before requesting Garlast laboratory review. Retain failed samples, document service hours, and capture fluid analysis results to accelerate corrective action.
Recommended Diagnostic Steps
- Record application conditions: media, temperature range, pressure peaks, and duty cycle.
- Measure groove dimensions and compare to design drawings and groove design targets.
- Inspect seal cross-section for asymmetrical wear, flat spots, or nibbling.
- Check for installation damage — spiral twist, nicks, or overstretch during assembly.
- Verify lot traceability and shelf life; review storage and cleanliness controls.
- Compare compound selection against chemical compatibility data.
Common Failure Modes
| Failure Mode | Typical Indicators | Likely Causes | Corrective Actions |
|---|---|---|---|
| Compression set | Seal no longer springs back; flat contact surface | Excessive temperature, long static load, wrong grade | Upgrade elastomer heat resistance; reduce squeeze; shorten service interval |
| Extrusion / nibbling | Ragged edges, material missing on low-clearance side | High pressure, excessive gap, low hardness | Add backup ring; reduce clearance; increase hardness or use FFKM |
| Chemical attack | Swelling, shrinkage, cracking, discoloration | Incompatible fluid, wrong cleaner, mixed media | Re-select compound; confirm CIP/SIP chemistry; review compatibility tables |
| Thermal degradation | Hardening, cracking, loss of elasticity | Peak temperature above compound limit, rapid thermal cycling | Specify higher-temperature grade; add thermal isolation; verify heat soak |
| Abrasion / wear | Polished or worn contact zone, material loss | Dynamic motion, poor lubrication, rough hardware | Improve surface finish; lower squeeze; select abrasion-resistant compound |
| Installation damage | Cuts, spiral marks, localized tears at install | Sharp edges, no lead-in, overstretch, contaminated groove | Add chamfers; use installation tools; clean and inspect grooves |
When to Engage Garlast Engineering
Recurring Field Failures
Multiple failures across sites or batches often indicate a system-level issue — groove design, process change, or compound drift — that benefits from structured review.
Unknown Media Exposure
When fluid composition is uncertain or includes aggressive additives, Garlast can recommend FFKM or FKM grades validated for your operating envelope.
Qualification & PPAP Support
We support automotive, aerospace, and semiconductor customers with failure documentation, corrective action plans, and replacement material recommendations.
Sample Analysis
Submit failed seals with service history for visual and dimensional assessment. Contact our technical team to coordinate shipment and review.
