The 5 Most Common Causes of Hydraulic Seal Failure

Hydraulic seals are among the unspoken heroes of any system that runs on fluids. They prevent leaks, maintain pressure, and shield vulnerable components from contaminating. However, despite their crucial function, seals are frequently ignored till they break, which leads to expensive downtime, loss of fluid and the possibility of damage to equipment. Knowing the causes behind leaks in seals can be the very first thing in making sure they don't happen.

These are five of the most frequent reasons for failure of hydraulic seals:

1. Contamination: The Silent Killer

What is it: The presence of foreign particles (dirt dust, metal shavings, dust water, rust) in Hydraulic fluid.

What causes it to fail:

• Abrasive Wear Particles of hardness embed themselves into the seal material or scratch off the surfaces of the seal (rod bore) and create pathways that allow fluid to let out.

• Scoring More massive particles may scratch the seal or the mating surfaces, causing rapid degrading.

• Fluid Degradation Chemical contaminants or water may attack the seal directly, causing it expand or shrink, harden or soften.

Prevention:

• Regularly, fluids are filtered and analysed.

• Utilizing high-quality filters and maintaining their quality by maintaining.

• Maintaining reservoirs clean and sealed.

• Cleansing components thoroughly prior to the assembly.

• Employing rod wipers and scrapers on Cylinders.

2. Extreme Temperatures: Too Hot to Handle, Too Cold to Work

What does it mean: Operating the hydraulic system outside of the sealing material's temperature range. This can include extreme high and abnormally low temperatures.

What causes it to fail:

• High Temperatures:

  • Cracking and hardening Seals made of elastomer lose flexibility, become stiff and break.

  • Rapid degradation Heating accelerates breakdown in chemical processes, which leads to destruction of materials and oxidation. properties.

  • Shrinkage or swelling: Materials can expand or contract, but they lose their ability to seal.

• Low Temperatures:

  • Loss of Flexibility Seals get stiffer and do not adhere to sealing surfaces and cause leakage especially at startup.

  • Cracking Seals made of brittle material can break under pressure or during movement.

Prevention:

• Make sure the system is equipped with adequate coolant (or the ability to heat in cold climates).

• Select seals with a rating to operate within the anticipated temperature range.

• Check system temperature and deal with problems with overheating promptly.

• Utilize hydraulic fluids that have high viscosity index that are that are suitable for extreme temperatures.

3. Chemical Incompatibility: A Toxic Relationship

What it is: The hydraulic fluid or any additives/contaminants reacting chemically with the seal material.

What causes it to fail:

• Shrinking or swelling: The seal material absorbs and releases the components, altering its size, hinders proper sealing.

• Softening or Hardening The physical properties of the material change, which can lead to cracking or extrusion.

• Dissolution This fluid dissolves and disintegrates the sealing material with time.

Prevention:

• Always ensure that the seal material is compatible to the type of hydraulic fluid. Check compatibility charts.

• Do not mix different kinds of fluids for hydraulic use.

• Make sure that the cleaning agents that are used on the components are compatible with seals.

4. Improper Installation: The Human Error Factor

What does it mean: Damage to seals in the process of installation due to improper methods, tools or hurriedness.

What causes it to fail:

• Cutting or nicking: Sharp edges on rods, pistons or housing bores may cut or damage the seals when it is assembled.

• Twisting/Spiral Damage The act of twisting an O-ring or lip seal during installation could cause permanent damage and leak pathways.

• Overtorquing/Undertorquing: For seals held by compression, incorrect torque can lead to insufficient sealing or crushing of the seal.

• Unsafe tooling: Using screwdrivers or sharp objects instead of seal-installation tools.

Prevention:

• Use the right tools for installation and methods.

• Chamfer all edges leading to hardware.

• Clean seals and the hardware prior to the assembly.

• Follow the installation instructions of the manufacturer precisely.

• Training technicians on the best practices for seal installation.

5. Excessive Pressure or Pressure Spikes: Beyond the Limit

What is it: Exposing the seal to pressures greater than its limits for design or frequent, rapid changes of the pressure (spikes).

What causes it to fail:

• Extrusion In the event of excessive pressure the seal's material could be pushed into the gap between metal parts, which can cause permanent damage and eventually failure.

• Rapid wear: Pressure that is high, particularly when cycling is fast is a major cause of frictional increase and can accelerate wearing on seals.

• Shatter Damage Pressure spikes that occur suddenly can lead seals break or break.

Prevention:

• Select seals that are designed to handle the highest pressure expected for the system as well as possible spikes.

• Make sure the glands are designed correctly (clearance spaces) to limit extrusion.

• Utilize backup rings that have seals for high-pressure applications.

• Check pressure relief valves regularly to make sure they're operating correctly and prevent overpressurization.