{"id":1125,"date":"2025-04-17T10:49:53","date_gmt":"2025-04-17T02:49:53","guid":{"rendered":"https:\/\/hengoseal.com\/?p=1125"},"modified":"2025-04-17T10:49:53","modified_gmt":"2025-04-17T02:49:53","slug":"prevent-o-ring-leakage-high-pressure","status":"publish","type":"post","link":"https:\/\/hengoseal.com\/uk\/prevent-o-ring-leakage-high-pressure\/","title":{"rendered":"How to Prevent O-Ring Leakage Under High Pressure?"},"content":{"rendered":"<p>O-ring leaks under pressure are more than an inconvenience \u2014 they can shut down entire systems. Are you struggling with extrusion, blowouts, or pressure failures?<\/p>\n<p>Preventing O-ring leakage in high-pressure environments requires the right materials, designs, and installation practices. Here&#8217;s your expert guide to avoiding common pressure sealing issues.<\/p>\n<p>Standard O-rings often fail under high pressure. In this guide, I\u2019ll show you how to choose the right O-ring and sealing method to withstand pressure, reduce downtime, and extend service life.<\/p>\n<h2>What Causes O-Ring Leakage Under Pressure?<\/h2>\n<p>O-ring blowout, extrusion, or weeping usually result from incorrect material, poor groove design, or overpressure beyond the seal\u2019s tolerance.<\/p>\n<p>In high-pressure environments, common causes include:<\/p>\n<ul>\n<li>Undersized or soft O-ring material<\/li>\n<li>Inadequate gland fill or squeeze<\/li>\n<li>Lack of backup rings for extrusion control<\/li>\n<li>Thermal expansion or movement misalignment<\/li>\n<\/ul>\n<p><img decoding=\"async\" src=\"http:\/\/hengoseal.com\/wp-content\/uploads\/2025\/03\/FKM-O-Rings.jpg\" alt=\"placeholder_image\" \/><\/p>\n<h3>How to Prevent High-Pressure O-Ring Failures<\/h3>\n<p>I\u2019ve worked with hydraulic system designers and OEM engineers who all faced the same problem \u2014 standard O-rings just couldn\u2019t hold up. Here\u2019s how we solve it step-by-step:<\/p>\n<h4>1. Choose the Right Material<\/h4>\n<table>\n<thead>\n<tr>\n<th>\u043c\u0430\u0442\u0435\u0440\u0456\u0430\u043b<\/th>\n<th>\u0421\u0442\u0456\u0439\u043a\u0456\u0441\u0442\u044c \u0434\u043e \u0442\u0438\u0441\u043a\u0443<\/th>\n<th>\u0414\u0456\u0430\u043f\u0430\u0437\u043e\u043d \u0442\u0435\u043c\u043f\u0435\u0440\u0430\u0442\u0443\u0440<\/th>\n<th>Ideal Application<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td><strong>NBR<\/strong><\/td>\n<td>Up to 10 MPa<\/td>\n<td>-40 to 120\u00b0C<\/td>\n<td>Basic hydraulics<\/td>\n<\/tr>\n<tr>\n<td><strong>FKM<\/strong><\/td>\n<td>Up to 20 MPa<\/td>\n<td>-20 to 250\u00b0C<\/td>\n<td>High-temp fluid seals<\/td>\n<\/tr>\n<tr>\n<td><strong>PTFE + Backup<\/strong><\/td>\n<td>30 MPa+<\/td>\n<td>-50 to 300\u00b0C<\/td>\n<td>Chemical, extreme pressure<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>For most hydraulic or pump systems, I recommend <a href=\"https:\/\/hengoseal.com\/uk\/fkm-o-ring-vs-nbr-o-ring\/\" target=\"_blank\">FKM over NBR<\/a> for better compression set resistance.<\/p>\n<h4>2. Use Anti-Extrusion Support<\/h4>\n<ul>\n<li>\u0434\u043e\u0434\u0430\u0442\u0438 <strong>backup rings<\/strong> made of PTFE, nylon, or PEEK<\/li>\n<li>Install backup on the low-pressure side to block extrusion gap<\/li>\n<li>Use X-rings or quad-rings for stability under dynamic movement<br \/>\n\u27a1\ufe0f Check this guide: <a href=\"https:\/\/hengoseal.com\/uk\/high-pressure-hydraulic-o-rings-how-to-choose-the-most-durable-seals\/\" target=\"_blank\">High-Pressure Hydraulic O-Rings<\/a><\/li>\n<\/ul>\n<h4>3. Optimize Groove Design<\/h4>\n<p>Poor gland design is the hidden killer of O-rings.<\/p>\n<ul>\n<li>Maintain correct squeeze (typically 10\u201330%)<\/li>\n<li>Allow room for thermal expansion<\/li>\n<li>Avoid sharp corners (use radius at base of groove)<\/li>\n<li>Use compression calculator if needed<\/li>\n<\/ul>\n<h4>4. Control Installation Conditions<\/h4>\n<ul>\n<li>Clean and dry sealing surface<\/li>\n<li>Use compatible grease or silicone lubricant<\/li>\n<li>Avoid twisting the O-ring during insertion<\/li>\n<\/ul>\n<hr \/>\n<h2>Where Do O-Rings Leak Most Often?<\/h2>\n<table>\n<thead>\n<tr>\n<th>\u0437\u0430\u0441\u0442\u043e\u0441\u0443\u0432\u0430\u043d\u043d\u044f<\/th>\n<th>Common Pressure (MPa)<\/th>\n<th>Problem Area<\/th>\n<th>Recommended Solution<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>\u0413\u0456\u0434\u0440\u043e\u0446\u0438\u043b\u0456\u043d\u0434\u0440\u0438<\/td>\n<td>10\u201325<\/td>\n<td>Rod &amp; piston seals<\/td>\n<td>FKM + PTFE backup<\/td>\n<\/tr>\n<tr>\n<td>Pumps &amp; valves<\/td>\n<td>15\u201335<\/td>\n<td>Housing &amp; shaft seals<\/td>\n<td>PTFE encapsulated O-rings<\/td>\n<\/tr>\n<tr>\n<td>High-pressure testing systems<\/td>\n<td>20\u201360<\/td>\n<td>Static compression seals<\/td>\n<td>Metal-cored seals or PTFE rings<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>Need custom design help? Our team provides <a href=\"https:\/\/hengoseal.com\/uk\/custom-o-rings\/\" target=\"_blank\">tailored O-ring sealing solutions<\/a>.<\/p>\n<hr \/>\n<h2>How to Test Your O-Ring for Pressure Readiness?<\/h2>\n<ul>\n<li>Perform <strong>pressure cycling tests<\/strong> (min 1000 cycles)<\/li>\n<li>Use compressed air leak test (bubble method)<\/li>\n<li>Inspect for flattening, radial cracks, or extrusion trails<\/li>\n<\/ul>\n<p>\ud83d\udccc Tip: Always cross-check with O-ring specs from our <a href=\"https:\/\/hengoseal.com\/uk\/o-ring-cost-selection-guide\/\" target=\"_blank\">O-Ring Selection Guide<\/a><\/p>\n<hr \/>\n<h2>\u0412\u0438\u0441\u043d\u043e\u0432\u043e\u043a<\/h2>\n<p>Preventing O-ring leaks under high pressure isn\u2019t guesswork. It\u2019s engineering \u2014 and it starts with the right material, design, and support elements.<\/p>\n<h2>Need expert advice on sealing under pressure?<\/h2>\n<p>Send us your working pressure, temperature, and size \u2014 we\u2019ll engineer the right solution with no MOQ.<\/p>\n<ul>\n<li><strong>\u0415\u043b\u0435\u043a\u0442\u0440\u043e\u043d\u043d\u0430 \u043f\u043e\u0448\u0442\u0430<\/strong>: info@hengoseal.com  <\/li>\n<li><strong>WhatsApp<\/strong>: +86 17622979498<br \/>\nGet high-pressure O-rings that won\u2019t blow out when it matters most.<\/li>\n<\/ul>\n<style>\n.faq-question {\ncursor: pointer;\nfont-weight: bold;\npadding: 10px;\nbackground-color: #f1f1f1;\nborder: 1px solid #ddd;\nmargin-bottom: 5px;\ncolor: #0073aa;\n}\n.faq-answer {\ndisplay: none;\npadding: 10px;\nborder-left: 3px solid #0073aa;\nbackground-color: #f9f9f9;\nmargin-bottom: 10px;\n}\n<\/style>\n<p><script>\ndocument.addEventListener('DOMContentLoaded', function() {\nconst questions = document.querySelectorAll('.faq-question');\nquestions.forEach(question => {\nquestion.addEventListener('click', function() {\nconst answer = this.nextElementSibling;\nanswer.style.display = answer.style.display === 'block' ? 'none' : 'block';\n});\n});\n});\n<\/script><br \/>\n<!-- JSON-LD FAQ Schema --><br \/>\n<script type=\"application\/ld+json\">\n{\n\"@context\": \"https:\/\/schema.org\",\n\"@type\": \"FAQPage\",\n\"mainEntity\": [\n{\n\"@type\": \"Question\",\n\"name\": \"What pressure can standard O-rings handle?\",\n\"acceptedAnswer\": {\n\"@type\": \"Answer\",\n\"text\": \"NBR handles up to 10 MPa; with backup rings, much more. PTFE options can go up to 60 MPa.\"\n}\n},\n{\n\"@type\": \"Question\",\n\"name\": \"Do I always need backup rings?\",\n\"acceptedAnswer\": {\n\"@type\": \"Answer\",\n\"text\": \"Not always, but they&rsquo;re essential above 10 MPa or in dynamic sealing situations.\"\n}\n},\n{\n\"@type\": \"Question\",\n\"name\": \"What&rsquo;s the most common cause of O-ring blowout?\",\n\"acceptedAnswer\": {\n\"@type\": \"Answer\",\n\"text\": \"Extrusion due to pressure spike + lack of support = sudden failure.\"\n}\n},\n{\n\"@type\": \"Question\",\n\"name\": \"Can I use the same O-ring design for static and dynamic pressure?\",\n\"acceptedAnswer\": {\n\"@type\": \"Answer\",\n\"text\": \"No. Dynamic applications require lower squeeze and better stability.\"\n}\n},\n{\n\"@type\": \"Question\",\n\"name\": \"How do I know if extrusion has happened?\",\n\"acceptedAnswer\": {\n\"@type\": \"Answer\",\n\"text\": \"Look for tiny rubber tails or pieces pushed into the extrusion gap.\"\n}\n},\n{\n\"@type\": \"Question\",\n\"name\": \"Are square rings better for high pressure?\",\n\"acceptedAnswer\": {\n\"@type\": \"Answer\",\n\"text\": \"Yes. X-rings and quad-rings offer better resistance to twist and extrusion.\"\n}\n},\n{\n\"@type\": \"Question\",\n\"name\": \"What&rsquo;s the best lubricant for O-ring under pressure?\",\n\"acceptedAnswer\": {\n\"@type\": \"Answer\",\n\"text\": \"Use silicone grease or fluorinated grease compatible with your O-ring material.\"\n}\n},\n{\n\"@type\": \"Question\",\n\"name\": \"Do you offer burst-tested O-ring kits?\",\n\"acceptedAnswer\": {\n\"@type\": \"Answer\",\n\"text\": \"Yes. We offer <a href=\\\"https:\/\/hengoseal.com\/hydraulic-o-ring-kit-industrial-maintenance\/\\\" target=\\\"_blank\\\">industrial-grade kits tested for hydraulic applications.\"\n}\n}\n]\n}\n<\/script><\/p>\n<h2>\u041b\u044e\u0434\u0438 \u0442\u0430\u043a\u043e\u0436 \u0437\u0430\u043f\u0438\u0442\u0443\u044e\u0442\u044c<\/h2>\n<div class=\"faq-container\">\n<div class=\"faq-question\">1. What pressure can standard O-rings handle?<\/div>\n<div class=\"faq-answer\">NBR handles up to 10 MPa; with backup rings, much more. PTFE options can go up to 60 MPa.<\/div>\n<\/div>\n<div class=\"faq-container\">\n<div class=\"faq-question\">2. Do I always need backup rings?<\/div>\n<div class=\"faq-answer\">Not always, but they\u2019re essential above 10 MPa or in dynamic sealing situations.<\/div>\n<\/div>\n<div class=\"faq-container\">\n<div class=\"faq-question\">3. What\u2019s the most common cause of O-ring blowout?<\/div>\n<div class=\"faq-answer\">Extrusion due to pressure spike + lack of support = sudden failure.<\/div>\n<\/div>\n<div class=\"faq-container\">\n<div class=\"faq-question\">4. Can I use the same O-ring design for static and dynamic pressure?<\/div>\n<div class=\"faq-answer\">No. Dynamic applications require lower squeeze and better stability.<\/div>\n<\/div>\n<div class=\"faq-container\">\n<div class=\"faq-question\">5. How do I know if extrusion has happened?<\/div>\n<div class=\"faq-answer\">Look for tiny rubber tails or pieces pushed into the extrusion gap.<\/div>\n<\/div>\n<div class=\"faq-container\">\n<div class=\"faq-question\">6. Are square rings better for high pressure?<\/div>\n<div class=\"faq-answer\">Yes. X-rings and quad-rings offer better resistance to twist and extrusion.<\/div>\n<\/div>\n<div class=\"faq-container\">\n<div class=\"faq-question\">7. What\u2019s the best lubricant for O-ring under pressure?<\/div>\n<div class=\"faq-answer\">Use silicone grease or fluorinated grease compatible with your O-ring material.<\/div>\n<\/div>\n<div class=\"faq-container\">\n<div class=\"faq-question\">8. Do you offer burst-tested O-ring kits?<\/div>\n<div class=\"faq-answer\">Yes. We offer <a href=\"https:\/\/hengoseal.com\/uk\/hydraulic-o-ring-kit-industrial-maintenance\/\" target=\"_blank\">industrial-grade kits<\/a> tested for hydraulic applications.<\/div>\n<\/div>","protected":false},"excerpt":{"rendered":"<p>O-ring leaks under pressure are more than an inconvenience \u2014 they can shut down entire systems. Are you struggling with [&hellip;]<\/p>","protected":false},"author":1,"featured_media":1126,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"site-sidebar-layout":"default","site-content-layout":"","ast-site-content-layout":"default","site-content-style":"default","site-sidebar-style":"default","ast-global-header-display":"","ast-banner-title-visibility":"","ast-main-header-display":"","ast-hfb-above-header-display":"","ast-hfb-below-header-display":"","ast-hfb-mobile-header-display":"","site-post-title":"","ast-breadcrumbs-content":"","ast-featured-img":"","footer-sml-layout":"","theme-transparent-header-meta":"default","adv-header-id-meta":"","stick-header-meta":"","header-above-stick-meta":"","header-main-stick-meta":"","header-below-stick-meta":"","astra-migrate-meta-layouts":"set","ast-page-background-enabled":"default","ast-page-background-meta":{"desktop":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"ast-content-background-meta":{"desktop":{"background-color":"var(--ast-global-color-4)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"var(--ast-global-color-4)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"var(--ast-global-color-4)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"footnotes":""},"categories":[37],"tags":[],"class_list":["post-1125","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-o-ring-seals"],"_links":{"self":[{"href":"https:\/\/hengoseal.com\/uk\/wp-json\/wp\/v2\/posts\/1125","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/hengoseal.com\/uk\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/hengoseal.com\/uk\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/hengoseal.com\/uk\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/hengoseal.com\/uk\/wp-json\/wp\/v2\/comments?post=1125"}],"version-history":[{"count":0,"href":"https:\/\/hengoseal.com\/uk\/wp-json\/wp\/v2\/posts\/1125\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/hengoseal.com\/uk\/wp-json\/wp\/v2\/media\/1126"}],"wp:attachment":[{"href":"https:\/\/hengoseal.com\/uk\/wp-json\/wp\/v2\/media?parent=1125"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/hengoseal.com\/uk\/wp-json\/wp\/v2\/categories?post=1125"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/hengoseal.com\/uk\/wp-json\/wp\/v2\/tags?post=1125"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}