Technical Resource
O-Ring Failure Modes
Visual and diagnostic guide to common O-ring failure patterns — extrusion, compression set, chemical attack, explosive decompression, spiral twist and abrasion — with the design or material change that typically resolves each.
Diagnosis
Failure mode vs. typical cause & fix
| Failure Mode | Cause & typical fix |
|---|---|
| Extrusion | Gap too wide or pressure too high for the compound — add a backup ring or increase hardness |
| Compression set | Seal loses recovery over time — reduce squeeze, raise heat resistance, or switch compound |
| Chemical attack | Swelling, softening or cracking — re-check compatibility against actual chemistry |
| Explosive decompression | Blistering after rapid pressure drop — specify an RGD-resistant FKM/FFKM grade |
| Spiral twist | Ribbon-like deformation in dynamic seals — check gland design and lubrication |
| Abrasion | Surface wear from dynamic movement — increase hardness or move to HNBR/PTFE |