Alpine supports many extrusion testing parameters for O-rings and backup rings
Extrusion damage is a common failure mode in elastomers and plastics exposed to extreme operating conditions.
This type of damage typically occurs when seals or back-up rings are subjected to sustained high pressure and temperature. Under these conditions, the material becomes stressed and can be forced into clearances or gaps between mating surfaces. The larger the gap, the more likely it is that extrusion occurs. Over time, this results in tearing, deformation, and loss of sealing material, which ultimately leads to leaks or complete seal failure. Some examples can be seen below..
Extrusion-related failures can cause operational delays, reduced efficiency, and even catastrophic system breakdowns. To avoid these risks, it is critical to select elastomer compounds that are proven to resist extrusion under the specific temperature and pressure conditions they will face.
Alpine offers extrusion resistance testing to help customers validate elastomer performance in high-pressure environments. Our professional testing services provide detailed data on extrusion behavior, enabling better material selection and helping ensure long-term reliability in critical sealing applications.
Alpine Expanded Capabilities
Test conditions we support:
- Many custom fixtures with different squeeze percentages and extrusion gaps
- Short-term (minutes) and long-term (days) testing periods
- Testing with or without backup rings
- Pressures from vacuum to 40,000 psi
- Temperatures from cryogenic up to 400 °C
- Precise data and control software
- Detailed photos throughout testing process
At Alpine, we understand that seal applications can vary widely depending on their operating conditions. That’s why we offer a highly customizable extrusion resistance test designed to replicate these environments. Parameters such as squeeze percentage, extrusion gap, pressure, and temperature can all be tailored to specific requirements. Testing can be performed with or without a backup ring to emulate different sealing configurations.
Testing Details
The testing process for extrusion resistance begins by assembling the seals onto a precision fixture. These fixtures have different squeeze percentages and extrusion gaps that allow for different specific testing conditions. The fixtures are then installed in an oven and connected to a pressure control system. Thermocouples are installed to monitor temperature in the fixtures as well as the ambient air in the oven. The test is controlled by an attached computer, which can precisely set the temperature, pressure and monitor the time passed.
Overnight, the oven reaches the appropriate temperature. The system is then bled of excess air. Water is pumped into the fixture up to the baseline pressure which varies based on test parameters. The samples are then exposed to the pressure and temperature for the determined amount of time (minutes, days, weeks). Once the testing period is over, the pressure is slowly and constantly adjusted until the goal pressure is reached or the seal fails.