Tag Archives: equipment durability

Why Rubber Parts Wear Out and How to Prevent Early Failure

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Rubber components, such as seals, gaskets, O-rings, hoses, and bushings, and specialty seals perform critical functions in machinery, vehicles, and equipment. The problem is that, although they are flexible and resilient, rubber parts are among the first to fail, resulting in costly downtime, repairs, and replacements. Businesses need to understand why rubber parts wear out and how to prevent early failure to avoid these problems.

Why Rubber Parts Wear Out and How to Prevent Early Failure

1. Heat and Thermal Degradation

Rubber is highly sensitive to temperature. Rubber hardens, cracks, or loses elasticity when it is exposed to heat for a long time. Heat accelerates the chemical reactions within the rubber and breaks down its polymer structure. This is one of the most common causes of failure in engines and industrial machines.

2. Oxidation and Ozone Exposure

Oxygen and ozone in the air can attack rubber over time in a process known as oxidation. This leads to brittleness and surface cracking. Ozone can cause fine cracks that grow deeper with stress.

3. UV Radiation

Sunlight is another problem. UV rays break down rubber at the molecular level. This leads to fading, hardening, and eventual cracking. Outdoor equipment and materials are particularly vulnerable to this problem.

4. Chemical Exposure

Rubber is not universally resistant to all chemicals. Swelling, degradation, or softening can happen due to oils, fuels, solvents, acids, and cleansing agents. The wrong type of rubber, when used in a specific chemical environment, can shorten its lifespan.

5. Mechanical Stress and Wear

Constant friction, pressure, and stretching can cause rubber to wear over time. When seals are repeatedly compressed or hoses continuously vibrate, they may lose their shape or develop leaks. Abrasion can also occur when they come in contact with other surfaces. This can wear rubber down.

6. Poor Storage Conditions

Deterioration can occur even for unused rubber parts when they are not properly stored. Exposure to light, heat, and humidity can cause premature aging. When parts are stored in an open or uncontrolled environment, they can fail before they are even installed.

7. Inferior Material Quality

Not all rubber is created equal. Some use low-quality materials, or poorly manufactured parts may lack the additives needed to resist heat, UV, or chemicals. This causes rubber to degrade more quickly, potentially leading to inconsistent performance.

How to Prevent Early Failure

1. Choose the Right Rubber Material

Different types of rubber are required for different types of applications. For example, nitrile rubber is better for oil resistance, while EPDM performs well outdoors or in UV-exposed environments. To prevent failure, start by choosing the right rubber material for the job.

2. Control Operating Temperatures

Keeping rubber components within their required temperature range is crucial. Insulation, shielding, or cooling systems reduce heat exposure. Even just a small reduction in temperature can help prolong the life of a rubber part.

3. Protect Against the UV or Ozone

Consider protective coatings, covers, or UV-resistant materials. You may also minimize exposure to light and air by storing spare parts in dark, sealed containers.

4. Minimize Chemical Contact

Ensure rubber is compatible with any chemicals it may encounter. Sometimes, exposure is unavoidable. In these cases, choose a rubber compound specifically designed to resist those substances. Regular cleaning with appropriate agents can help you avoid the buildup that accelerates degradation.

5. Reduce Mechanical Stress

Ensure that the rubber part is properly installed and aligned. Avoid over-tightening, excessive stretching, or misalignment as they put unnecessary strain on rubber parts. Reduce friction and wear whenever appropriate by using a lubricant.

6. Follow Proper Storage Practices

    Rubber components need a cool, dark, and dry environment. Keep them away from direct sunlight, ozone surface, and fluctuating temperatures. Keep them in sealed packaging until it is time to use them.

    7. Inspect and Replace Proactively

      Catch any signs of wear, like cracks, hardening, or deformation, by doing a routine inspection. Replace parts that need replacing even before they fail to avoid unexpected breakdowns and protect surrounding components from damage.

      At Real Seal, we understand that durability is not an option. It is a requirement. With our engineered rubber components, you can be assured of strength and consistent performance over time. Whether you need custom solutions or high-quality replacements, contact us today so we can help you choose the right materials and specifications for your operations.

      The Importance of Proper Lubrication for Seal Components

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      If you’re most people, you probably haven’t thought much about using lubricants on your machineries—unless they’re already making noticeable sounds.

      But you don’t have to wait until your gears are all rusty and worn out before you use lubricants. In fact, it’s better to lubricate regularly the seal components of your machines.

      Here’s why. Proper lubrication:

      • Reduces friction and heating of moving parts
      • Prevents premature wear and tear of seal components
      • Maintains the integrity of machines and other industrial applications

      Machineries operate better when the seal components are lubricated. There’s less resistance and chafing, so the parts last longer. Some seals are prone to cracking easily, but when they are properly lubricated, they don’t snap just as easily.

      Are all lubricants the same?

      Lubricant, oil, and grease. What’s the difference between the three?

      People like to use those terms interchangeably, and they somewhat correct in doing so. But lubricant is an umbrella term for both grease and oil. For purposes of clarifying what a lube really is and what it does, let’s establish their differences.

      The difference between the oil and grease lies in their application:

      • If you have machines that operate at high temperatures and speed, use oil.
      • If your machine operates at regular temperature and speed, use grease.

      That’s the most basic explanation. But of course, there are specific types of lubricants for specific types of operations:

      1. Penetrating Lubricant
      This is a good choice if you’re dealing with rust on mechanical seals. This lube cuts through rust after a few hours. It comes in both spray and liquid type—your choice depends on the type of seal component you have and the severity of rusting.

      2. Silicone Spray
      If you are looking for a lubricant that makes the least mess, then a silicone spray is your friend. It is relatively good lubricant. It’s perfect for components that are prone to rusting as it offers a bit of waterproofing as well.

      3. PTFE or Teflon Spray
      PTFE is often associated with the trademark Teflon. Similar to a silicone spray, this also offers corrosion protection, so it’s best used as a lubricant for machineries that operate at high temperatures.

      4. Dry Lube
      Also called graphite lube, dry lube is best used on small parts. Unlike most liquid lubricants, dry lube does not gum up small components. It comes in powder form, but the spray form dries rather quickly and doesn’t affect the integrity of seal components.

      5. Lithium or White Grease
      White grease is best used on devices that work at high temperatures. It’s thicker than other lubricants, so it stays put no matter how much pressure is applied to seal components.

      Keeping your seal components well lubricated prevents friction from ruining your machinery. Even if you don’t notice any obvious wear and tear, you should make lubricating small parts a habit to make them last longer.

      Lubricants are not all the same in terms of viscosity and effectiveness. The kind of lubricant that you should use depends on what kind of application you have and on whether your apparatus works at high temperatures or not.

      While lubricating extends the life of seal components, they will eventually require a replacement. Real Seal is a manufacturer of sealing products and other mechanical goods. Contact Real Seal to order replacement parts for your machinery.