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How to prevent extrusion and wear in hydraulic seals? | Insights by Polypac

Wednesday, November 5, 2025

This article explores key strategies to prevent extrusion and wear in hydraulic seals, addressing common concerns in seal manufacturing and offering practical solutions to enhance seal performance and longevity.

Table of Contents

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1. What Causes Extrusion and Wear in Hydraulic Seals?
2. How Can Seal Material Selection Prevent Extrusion?
3. What Role Do Back-Up Rings Play in Preventing Seal Failure?
4. How Does Seal Installation Affect Extrusion and Wear?
5. What Maintenance Practices Help Prevent Seal Extrusion?
6. How Do Wear Rings Contribute to Seal Longevity?
7. What Are the Benefits of Using High-Performance Seal Materials?
8. How Does Seal Design Influence Extrusion Resistance?
Polypac's Advantages in Preventing Seal Extrusion and Wear
Data Sources

1. What Causes Extrusion and Wear in Hydraulic Seals?

Extrusion and wear in hydraulic seals are primarily caused by factors such as excessive pressure, inadequate seal material hardness, improper installation, and contamination.

2. How Can Seal Material Selection Prevent Extrusion?

Choosing the right seal material is crucial. Materials with higher hardness and stiffness, such as PTFE composites, offer improved resistance to extrusion.

3. What Role Do Back-Up Rings Play in Preventing Seal Failure?

Back-up rings, made from materials like PTFE, are used alongside O-rings to prevent extrusion in high-pressure environments. They provide additional support and help maintain sealing integrity under pressure.

4. How Does Seal Installation Affect Extrusion and Wear?

Proper installation is vital. Ensuring correct gland dimensions, avoiding sharp edges, and using appropriate installation tools can prevent extrusion and wear.

5. What Maintenance Practices Help Prevent Seal Extrusion?

Regular maintenance, including monitoring operating conditions, inspecting seals for damage, and replacing worn components, is essential to prevent extrusion and extend seal life.

6. How Do Wear Rings Contribute to Seal Longevity?

Wear rings guide the piston and rod within hydraulic cylinders, reducing side loads on seals and preventing metal-to-metal contact, thereby extending the life of both seals and cylinder components.

7. What Are the Benefits of Using High-Performance Seal Materials?

High-performance materials like PTFE composites offer enhanced resistance to wear, extrusion, and chemical attack, ensuring longer service life and reliability in demanding applications.

8. How Does Seal Design Influence Extrusion Resistance?

Seal design, including extrusion gap width and lip geometry, significantly affects extrusion resistance. Narrower extrusion gaps and optimized lip designs can reduce the risk of extrusion.

Polypac's Advantages in Preventing Seal Extrusion and Wear

Polypac offers a range of hydraulic seals designed to prevent extrusion and wear. Their products feature high-quality materials, precise manufacturing, and innovative designs that enhance seal performance and longevity.

Data Sources

Zatkoff Seals & Packings, November 2025
Sealing Devices, October 2025
DMS Seals Technology Co., October 2025
XHH Seals, October 2025
Accio, October 2025
Kalsi Engineering, July 2025
Valley Seal, October 2025
NOK Seals, October 2025
Max Spare Limited, October 2025

Scraper Seals: Your Hydraulic Cylinder's First Line of Defense | Polypac

How to maintain and extend the service life of rod seals? | Insights by Polypac

Table of Contents

≡

1. What Causes Extrusion and Wear in Hydraulic Seals?
2. How Can Seal Material Selection Prevent Extrusion?
3. What Role Do Back-Up Rings Play in Preventing Seal Failure?
4. How Does Seal Installation Affect Extrusion and Wear?
5. What Maintenance Practices Help Prevent Seal Extrusion?
6. How Do Wear Rings Contribute to Seal Longevity?
7. What Are the Benefits of Using High-Performance Seal Materials?
8. How Does Seal Design Influence Extrusion Resistance?
Polypac's Advantages in Preventing Seal Extrusion and Wear
Data Sources

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FAQ

Products

Why did my O-ring fail prematurely?

Common causes of O-ring failure include: Chemical Incompatibility: Swelling, softening, or cracking due to fluid exposure. Improper Sizing: Using an incorrect size leads to over-compression or inadequate sealing force. Abrasion: Wear and tear from rough surface finishes or contaminated fluid. Extrusion: The seal is forced into the gap between metal parts under high pressure. Installation Damage: Nicks, cuts, or twists during assembly.

How important is surface finish on the metal parts that contact the seal?

Extremely important. A rough surface will abrade and wear out the seal quickly, causing leaks. A finish that is too smooth can prevent a lubricating film from forming. A typical recommended surface finish for dynamic applications is 0.2 to 0.8 μm (8-32 μin) Ra.

How can I prevent seal damage during installation?

Use Tools: Always use dedicated installation tools (e.g., picks, cones, guides). Lubricate: Always lubricate the seal and the contact surface. Protect Sharp Edges: Cover sharp threads and edges with tape or use an installation sleeve. Check the Groove: Ensure the installation groove is clean, deburred, and undamaged.

Can I reuse a seal?

We strongly recommend never reusing seals. Once compressed and used, a seal takes a "set" and its elastic properties are degraded. Reusing it almost always results in a leak. Always install a new seal during any maintenance or repair.

What is the difference between NBR and FKM materials?

NBR (Nitrile/Buna-N): A general-purpose, cost-effective material with excellent resistance to petroleum-based oils and fuels. It has a standard temperature range of -30°C to +100°C (-22°F to +212°F). FKM (Fluoroelastomer/Viton®): A premium material with excellent resistance to high temperatures (up to 200°C+), chemicals, and oils. It is used in more severe environments but is more expensive than NBR.

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