Common Causes Of Failure In Elastomers..

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1 Common Causes Of Failure In Elastomers.. Gary S. Crutchley BSc (hons) Lead Consultant Polymer Consultancy Group Smithers Rapra Technology 1 1

2 Failure Why do we need to know how rubber materials fail? 2 2

3 Rubber Failure Where Is The Knowledge? When failures occur, those involved understandably do not wish to publicise the occurrence. Diagnosticians investigating failures are often prevented from disclosing the details due to the restraints of their contracts. For these reasons failure diagnosis activities are very often covert. Opportunities for learning from previous mistakes is limited. Knowledge and skills required to diagnose failure not generally freely available. 3 3

4 Understanding Failure How Can It Help? Prevent future failures by understanding the cause and applying lessons learned. Avoid the costs associated with product failure. Avoid loss of reputation. Avoid expensive litigation costs. 4 4

5 Failure Common Causes Of Rubber Component Failure 5 5

6 Rubber Failure Human Causes 6 Poor material process 20% Reason for Failure Product abuse 15% Poor product design 20% Material misselection and poor specification 45% 6 6

7 Rubber Failure Service Related Causes 7 Common Service Related Causes Of Failure Chemical Heat Fatigue Abrasion Tear Set Ozone 21% 26% 12% 5% 12% 7% 17% Note: UV attack can be an issue with elastomers 7 7

8 Failure Human Causes 8 8

9 Failure Human Causes 1. Incorrect Material 9 9

10 Human Causes Incorrect Material Material Selection Is No Simple Task! Successful material selection requires a judicious scientific approach in order to evaluate the requirements of the application. Need to match the application to the properties of the material. Incorrect material selection is one of the most common causes of failure. 1 10

11 Failure 11 Human Causes 2. Poor Product Design 1 11

12 Human Causes Product Design What do we need to consider when in the design stage?? Select the most appropriate material? Understand fully the service conditions? Understand the expected lifetime of the product? Is the application dynamic or static?? What stresses and strains can we expect in service?? What will the product be in contact with or exposed to?? What are the material s property limits?? How are they affected by the design? 1 12

13 Failure Human Causes 3. Poor Material Processing 1 13

14 Human Causes Poor Material Processing Don t Engineer-In Product Failure! Correct and appropriate material processing is a key factor in the product life cycle. Even if we select the correct materials, and design the right rubber compound, all is lost if processing is poor. We need to consider material processing from start to finish. 1 14

15 Failure Human Causes 4. Product Abuse 1 15

16 Human Causes Product Abuse Product abuse accounts for approximately 15% of all rubber component failures. It can result from many factors such as: Product designers not understanding their materials fully. In appropriate use. Excessive use. Deliberate damage Users who do not understand the limitations of the products they use. 1 16

17 Human Causes Product Abuse Example Hot Water Bottle Product abuse can be dangerous! 1 17

18 Human Causes Product Abuse Example Engine Mount & Truck Tyre Engine Mount Diesel Truck Tyre 1 18

19 Failure Service Related Failures 1 19

20 Failure Service Related Failures 1. Chemical Attack 2 20

21 Service Related Failures Chemical Attack 21 There are a large number of chemical agents that can degrade elastomers. The severity and effect depends on the chemical agent and the chemistry of the elastomer being attacked Smithers Rapra 2010

22 Service Related Failures Chemical Attack 22 When considering an elastomer for an application, we need to be aware of any contact media that can cause the following to occur: Polymer chain scission leading to molecular weight reduction. Increased cross linking of the matrix. Polymer chain modification as a result of cyclisation, chlorination or other chain modifications Smithers Rapra 2010

23 Service Related Failures Chemical Attack 23 Examples of chemical attack: Degradation of a butterfly valve seal by chlorine containing species 2 23 Smithers Rapra 2010

24 Service Related Failures Chemical Attack 24 Examples of chemical attack: Degradation of a NR/CR pipe expansion joint by metal ion accelerated thermooxidation Smithers Rapra 2010

25 Failure Service Related Failures 2. Heat 2 25

26 Service Related Failures - Heat 26 Effect of Heat: Thermal degradation is highly complex, depending on the material exposed and the contact media. There is no single diagnostic effect. As the temperature increases, the rate of reaction of degradation processes also increases. rubber This principle applies to elastomers operating in oxygen environments, but also to rubbers exposed to other degrading chemicals or environments. Excessive exposure to heat leads a deterioration in material properties, and ultimately chemical degradation of polymer itself Smithers Rapra 2010

27 Service Related Failures - Heat 27 Example of the effect of heat: SBR rubber shock absorber: Internal heat build up. Not visible externally Thermal degradation Reversion 2 27 Smithers Rapra 2010

28 Failure Service Related Failures 3. Fatigue 2 28

29 Service Related Failures - Fatigue 29 What is fatigue? A Function of the Polymer Time related Related to compounding Related to duty/service Can be affected by design Micro cracks start at flaws in the material Cracks propagate through the material leading to ultimate failure Fatigue cracking in a cycle handlebar grip 2 29 Smithers Rapra 2010

30 Failure Service Related Failures 4. Abrasion 3 30

31 Service Related Failures - Abrasion 31 What is abrasion? It is a highly complex process. Often loosely described as wear. Abrasion involves the removal of rubber from a component through contact with another surface Smithers Rapra 2010

32 Service Related Failures - Abrasion 32 What is abrasion? Abrasion is a function of the polymer, compound and service. Types of abrasion are: Abrasive - Hard asperities cutting the rubber Fatigue - Dynamic local stress Adhesive - Transfer of rubber onto another surface 3 32 Smithers Rapra 2010

33 Failure Service Related Failures 5. Tear 3 33

34 Service Related Failures Tear (Cracking) 34 What is tearing? Tearing initiates at weak points with the material. Two processes are involved: Tear initiation Tear growth Critical in highly stressed components: Tyres, bushes, tank pads Tearing is: A Function of the Polymer Compounding Processing Duty Design 3 34 Smithers Rapra 2010

35 Failure Service Related Failures 6. Set 3 35

36 Service Related Failures - Set 36 What is set? A Function of the Polymer Compounding Tension maintained for a period of time and then released Duty Design Stress A permanent deformation Can occur in tension or compression A permanent set termed tension set Leads to reduced sealing force in sealing applications. Strain 3 36 Smithers Rapra 2010

37 Service Related Failures - Set 37 Examples of compression set: Tap washer Soft drink bottle seal c Smithers Rapra 2010

38 Failure Service Related Failures 7. UV Attack 3 38

39 Service Related Failures UV Attack Unsaturated elastomers can be attacked by Ultraviolet light unless they are protected. Those susceptible include: Natural Rubber (NR) Synthetic Polyisoprene (IR) Butyl rubber (IIR) Polybutadiene (BR) Styrene-butadiene Rubber (SBR) Nitrile Rubber (NBR) Hydrogenated Nitrile Rubbers (HNBR) Saturated elastomers such as EPDM are more resistant, but still affected in strong sunlight 3 39

40 Service Related Failures UV Attack 40 Carbon black used as a filler in rubber compounds can act as a UV screen, but it is never completely effective in preventing attack. Titanium dioxide can be added to light coloured compounds as a UV screen, but it is expensive especially when used at filler loadings. Tinuvin P can be added as an absorber of UV light. 2-(2H-benzotriazol-2-yl)-p-cresol - hydroxyphenyl benzotriazole 4 40

41 Service Related Failures UV Attack 41 Initially - a surface effect. Chalkiness and mud cracking on light coloured articles Increasing exposure - attack depth increases and bulk physical properties change. Faster bulk effects in transparent items 4 41

42 Service Related Failures UV Attack Examples of UV Attack 4 42

43 Failure Service Related Failures 8. Ozone Attack 4 43

44 Service Related Failures Ozone Attack44 Atmospheric or electrically generated ozone affects unsaturated polymers. C C C O + O C O 3 Polymers strongly affected: Natural rubber, Polybutadiene, Styrene-butadiene rubber, Nitrile rubber. Polymers affected: Butyl Resistant polymers: EPDM, Silicone, Fluoroelastomers, Polychloroprene 4 44 Smithers Rapra 2010

45 Service Related Failures Ozone Attack45 Ozone is a naturally occurring gas, present in the atmosphere at concentrations of pphm. Ozone can be generated by electrical equipment, and is often present in concentrations up to 50 pphm. Ozone is also present in higher concentrations in polluted urban environments Smithers Rapra 2010

46 Service Related Failures Ozone Attack46 Example of Ozone Attack: A basketball exposed to the atmosphere for a number of months. Material is under strain Smithers Rapra 2010

47 Service Related Failures Ozone Attack47 Example of Ozone Attack: A golf club grip. Material is under strain, cracks at 90º to the strain direction Smithers Rapra 2010

48 And Finally... Thank-you for your attention Gary S. Crutchley is part of the Polymer Consultancy group at Smithers Rapra. 48 The company provides a complete range of services inclusive but not exhaustive of: Polymer failure diagnosis Polymer analysis Polymer materials and product testing Design services: Materials selection FEA, Mould flow, Long term design data generation and accurate lifetime predictions services to the performance of a part. Contact Gary S. Crutchley directly on or via at: gcrutchley@rapra.net 4 48 Smithers Rapra 2010

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