O-rings are among the most common sealing components in the world. Simple in design yet critical in performance, they are used across industries—from oil and gas and aerospace to food, pharmaceutical, and semiconductor manufacturing. Despite their versatility, O-rings are not immune to failure. In fact, O-ring failures account for a large portion of unplanned downtime, leaks, and system inefficiencies.

Understanding the causes, symptoms, and prevention strategies of O-ring failures is essential for engineers, maintenance teams, and procurement specialists. In this guide, we’ll break down the most common O-ring failure modes, what they look like, and how to prevent them with the right materials, designs, and installation practices. For a detailed reference guide to O-ring failure types, see Canyon Components’ dedicated page on O-ring Damage and Failure.

Why O-Ring Failures Matter

When O-rings fail, the consequences go far beyond a simple leak. Failures can result in:

Leakage of critical process fluids or gases
Equipment downtime and costly maintenance
Safety hazards in high-pressure or hazardous fluid systems
Contamination in sanitary or cleanroom applications
Non-compliance with standards such as FDA, USP Class VI, or NSF 61

Even small O-ring failures can cascade into larger operational issues. In regulated industries like food, pharma, and aerospace, failure to maintain reliable sealing can lead to product recalls, regulatory fines, or even catastrophic safety events. This makes prevention and early detection vital.

Common O-Ring Failure Modes

Below are the most common types of O-ring failures, their root causes, identifying symptoms, and strategies for prevention.

1. Abrasion

Abrasion can be a significant factor in O-ring performance, particularly in dynamic applications where maintaining seal integrity is critical.

Cause: Repeated dynamic motion, inadequate lubrication, or rough surface finishes can wear away material over time.

Symptoms: A polished or worn surface on one side of the O-ring, visible flat spots, or thinning.

Prevention:

Use surface finishes within recommended Ra values
Apply appropriate external lubricants
Consider wear-resistant materials like PTFE blends or polyurethane

2. Explosive Decompression (AED Failure)

Explosive decompression can significantly compromise sealing integrity, resulting in leaks or catastrophic failure. By selecting compatible, RGD-resistant materials, managing pressure release, and employing best practices in equipment design and operation, you can greatly reduce the risk of this type of O-ring failure and ensure more reliable, long-lasting sealing performance in high-pressure applications.

Cause: Gas absorbed into the elastomer expands rapidly during decompression, rupturing the O-ring from within.

Symptoms: Blistering, cracks, pitting, or subsurface ruptures in the O-ring cross-section.

Prevention:

Use Anti-Explosive Decompression (AED) materials
Select materials tested against NORSOK M-710 or NACE TM0297
Design systems to depressurize gradually

3. Chemical Attack

Chemical damage can severely impact O-ring performance and is one of the most challenging failure modes to address. By carefully selecting materials suited to the specific chemicals in the environment and regularly inspecting O-rings for early signs of damage, you can ensure reliable performance and longer service life for sealing components.

Cause: Incompatible chemicals extract plasticizers or react with elastomer chains, degrading the material.

Symptoms: Swelling, brittleness, cracking, or softening of the O-ring.

Prevention:

Reference Canyon’s Chemical Compatibility Guide for Plastics and elastomers
Select resistant materials like FKM, FFKM (Kalrez®), or PTFE
Use Canrez® FFKM for extreme chemical environments

4. Compression Set

Compression set is a common issue that can severely impact sealing performance, particularly in static applications where maintaining a reliable seal over time is critical. By selecting materials with low compression set characteristics, controlling compression levels, and performing routine maintenance, compression set can be effectively managed, ensuring that O-rings continue to perform reliably over their intended service life.

Cause: Permanent deformation of the O-ring due to prolonged compression, heat, or chemical exposure.

Symptoms: O-ring remains flattened after removal, fails to rebound.

Prevention:

Choose materials with low compression set, like FFKM
Use proper gland design dimensions
Avoid over-compression and excessive temperature exposure

For more, see Canyon’s post on Compression Set in Elastomers.

5. Extrusion and Nibbling

Cause: High pressure forces O-rings into extrusion gaps, especially without backup rings.

Symptoms: Nibbled, chipped edges, or missing chunks on the O-ring.

Prevention:

Add backup rings
Minimize extrusion gaps in hardware
Use high-strength materials such as HNBR or filled PTFE

6. Installation Damage

Proper handling and installation techniques are essential to prevent damage to O-rings, ensuring they maintain their sealing integrity and longevity. By selecting the right tools, using proper lubrication, and inspecting components before installation, you can effectively avoid installation damage and maximize the reliability and effectiveness of O-ring seals.

Cause: Improper installation practices such as stretching over sharp edges or using incorrect tools.

Symptoms: Cuts, nicks, or spiral failures around the circumference.

Prevention:

Use proper O-ring installation tools
Chamfer edges and lubricate before installation
Train personnel in correct handling practices

7. Thermal Degradation

Thermal damage can significantly impact the performance and longevity of O-rings, leading to leaks, wear, and increased maintenance costs. By choosing the appropriate materials, controlling friction, and implementing preventive measures for thermal stress, industries can minimize thermal damage and maintain reliable sealing performance in high and low-temperature applications.

Cause: Exposure to extreme heat or cold beyond the elastomer’s range.

Symptoms: Hardening, cracking, or embrittlement at low temperatures; softening and discoloration at high temps.

Prevention:

Choose high temperature elastomers or low temperature elastomers
Consider spring-energized seals for cryogenic conditions

8. Outgassing

Outgassing can significantly affect the performance and cleanliness of systems in sensitive applications, particularly those involving vacuums or high temperatures. By selecting low-outgassing materials, utilizing pre-baking, and following best practices for storage and installation, industries can minimize outgassing risks and ensure reliable, contamination-free performance of their O-ring seals.

Description: Outgassing is the release of volatile compounds trapped within an O-ring material, usually occurring in vacuum or high-temperature environments. These compounds, often byproducts from the curing or manufacturing process, gradually escape from the elastomer over time. In highly sanitary environments, outgassing can compromise cleanliness, posing risks in aerospace, medical, electronics, and semiconductor manufacturing.

Causes:

High Temperatures accelerate volatile release
Vacuum Environments promote faster gas escape
Material Formulation with plasticizers or low cross-link density increases outgassing
Manufacturing Residues from curing or additives may remain and release over time
Moisture Saturation can permeate and later escape in vacuum

Signs:

Film or residue buildup on nearby components
Slight loss of seal integrity due to volume changes
Bubbles or particles forming on the surface

Prevention:

Select low-outgassing materials such as FKM, FFKM, or silicone certified for low outgassing
Pre-vacuum bake O-rings to release volatiles before use
Use vacuum-compatible compounds for aerospace or semiconductor applications
Store O-rings in clean, vacuum-sealed packaging
Avoid prolonged high-temperature exposure

Recommended Materials: CanRez® FFKM, Kalrez® FFKM, silicone formulations for aerospace, EPDM for cost-effective low-outgassing needs.

Industries: Aerospace, semiconductor manufacturing, optics, electronics, medical devices.

9. Plasma Damage

Plasma damage poses significant risks to O-rings, especially in high-purity and vacuum environments where contamination is a concern. By selecting appropriate materials, adding protective coatings, and implementing regular inspection, plasma damage can be mitigated, helping ensure reliable, long-lasting sealing performance in challenging plasma-rich environments.

Description: Plasma damage occurs when an O-ring is exposed to plasma, an ionized gas with high energy, resulting in surface erosion, chemical degradation, and structural weakening. Plasma exposure can degrade the O-ring’s sealing properties and contaminate surrounding environments with particles. It is a concern in high-purity or vacuum environments such as semiconductor manufacturing, aerospace, and electronics.

Causes:

Ionized Gas Exposure leading to bond breakage
Chemical Reactivity with gases like oxygen, fluorine, or chlorine
High Temperature accelerating reactions
UV Radiation generated by plasma causing cracking
Vacuum Environments combined with plasma accelerating degradation

Signs:

Surface erosion with pits and roughness
Cracking and hardening
Discoloration or chemical burns
Generation of particulate matter contaminating sensitive environments

Prevention:

Select plasma-resistant materials like FFKM, PTFE, or high-purity silicone
Use plasma-resistant coatings for extra protection
Implement shielding to reduce exposure
Control temperature and UV intensity in plasma environments
Regularly inspect and replace O-rings in plasma applications

Recommended Materials: Canez® FFKM, Kalrez® FFKM, PTFE, Aflas, high-purity silicone.

Industries: Semiconductor manufacturing, aerospace and defense, medical device sterilization, optics, high-purity processing.

10. Spiral Failure

Spiral failure can compromise sealing integrity, leading to leaks and reduced component life. By selecting the right O-ring shape, improving groove design, and ensuring proper lubrication, you can effectively prevent spiral failure and enhance the durability and reliability of O-rings in dynamic applications.

Description: Spiral failure occurs when an O-ring twists or spirals within its groove during dynamic operation, leading to uneven wear, cuts, or tears. This failure mode is common in applications with reciprocating or oscillating motion, such as hydraulic cylinders or piston systems.

Causes:

Dynamic or reciprocating motion creating twisting
Insufficient lubrication increasing friction
Improper groove design allowing movement
High-hardness or low-friction materials that fail to grip
Pressure fluctuations destabilizing the O-ring’s position

Signs:

Diagonal cuts or tears along the O-ring
Twisting or distortion when removed
Leakage due to incomplete contact
Consistent angled wear patterns

Prevention:

Use anti-spiral designs such as X-rings or square rings
Optimize groove design for stable support
Apply internal or external lubrication (PTFE, silicone)
Avoid rapid reciprocating movements or extreme pressure changes

Recommended Materials: X-rings, square rings, HNBR, NBR, polyurethane.

Industries: Hydraulic and pneumatic systems, automotive machinery, aerospace, oil and gas equipment.

11. UV Damage

By selecting UV-resistant materials, employing preventive measures like coatings, and regularly inspecting UV-exposed O-rings, industries can extend the life of their seals and maintain effective sealing in high-UV environments. These best practices help avoid premature failures, reduce maintenance costs, and improve overall reliability.

Description: UV damage occurs when an O-ring is exposed to ultraviolet radiation from sunlight or artificial sources. UV rays break down chemical bonds within the elastomer, leading to cracking, hardening, and reduced sealing integrity. Also known as ozone cracking or sun-checking.

Causes:

Direct sunlight exposure outdoors
Artificial UV light from curing, sterilization, or lighting systems
Ozone created by UV exposure accelerating cracking
Elevated temperatures amplifying UV effects

Signs:

Fine surface cracks or crazing
Loss of elasticity and increased brittleness
Chalking, fading, or discoloration
Surface hardening and fracture under pressure

Prevention:

Choose UV-resistant materials such as EPDM, Viton (FKM), or silicone
Apply UV-blocking coatings or paints
Limit direct exposure with shaded installations
Store O-rings in opaque packaging
Inspect and replace O-rings regularly in high-UV environments

Recommended Materials: EPDM, Viton, silicone, neoprene, fluorosilicone.

Industries: Automotive, construction, aerospace, agriculture, marine and offshore equipment.

12. Over-Compression and Over-Squeeze

Over-compression significantly impacts O-ring reliability, often leading to premature failure and increased maintenance costs. By following installation guidelines, selecting appropriate materials, and adhering to groove and compression specifications, over-compression damage can be effectively avoided. These preventive measures help maintain the longevity and performance of O-rings in a wide range of applications.

Cause: Excessive gland fill or squeeze beyond recommendations.

Symptoms: Flattened, sheared, or distorted seals.

Prevention:

Follow Canyon’s O-ring Groove Design Guide
Ensure proper gland tolerances and hardware dimensions

Prevention Strategies: A Systematic Approach

Preventing O-ring failure requires more than swapping materials. It requires a systematic approach that addresses design, materials, compliance, installation, and maintenance:

Correct Material Selection – Use Canyon’s Chemical Compatibility Resources and compliance hub to select the right elastomer.
Proper Gland Design – Follow recommended groove dimensions and tolerances. See our O-ring Groove Design Guide.
Compliance and Standards – Ensure materials meet certifications such as API 6A, USP Class VI, or FDA.
Quality Manufacturing – Canyon provides cleanroom manufacturing for sanitary and semiconductor seals.
Testing and Identification – Use O-ring bounce testers or FTIR analysis for material ID.
Regular Maintenance – Replace seals proactively before failure. Consider kitting services to keep organized spares.
Reverse Engineering Services – Use Canyon’s reverse engineering to identify unknown or legacy parts and replicate with upgraded materials.

Case Studies: O-Ring Failures in the Field

Oil and Gas: Extrusion in High-Pressure Connections

A drilling operator experienced repeated leaks in hammer union connections. The cause was extrusion damage due to high-pressure cycling. By switching to AED HNBR seals with backup rings, Canyon helped eliminate nibbling and extended service life.

Pharmaceutical: Compression Set in Steam Sterilizers

A pharmaceutical company found its gaskets failed after repeated sterilization cycles. Analysis revealed compression set as the main failure mode. Canyon supplied platinum-cured silicone with improved resistance, doubling service life.

Aerospace: Thermal Degradation in Fuel Systems

In an aerospace application, O-rings exposed to high engine temperatures became brittle and cracked. Canyon recommended Viton™ Extreme and FFKM alternatives, solving the problem.

Semiconductor: Plasma Damage in Etch Chambers

A semiconductor fab faced seal erosion due to plasma exposure. Canyon supplied plasma-resistant FFKM and Parylene-coated elastomers, dramatically reducing downtime.

Canyon Components: Your Partner in Preventing O-Ring Failures

With decades of experience in advanced sealing, Canyon Components helps customers prevent O-ring failures by offering:

Specialty elastomers such as CanRez® FFKM and Kalrez® FFKM
Custom gaskets and cut parts
Reverse engineering and material testing
Compliance expertise across FDA, NSF, USP, NORSOK, and more
Cleanroom and sanitary gasket manufacturing

By combining the right materials, designs, and processes, Canyon helps companies across industries eliminate leaks, reduce downtime, and ensure long-term reliability.

O-ring failures Posts

O-Ring Failures Explained: Causes, Symptoms, and Prevention Strategies