Pneumatic Actuator Seal Leakage Causes
Material, mechanical and system factors affecting seal integrity
Material Degradation
Chemical Exposure
NBR/EPDM seals swell or harden when exposed to oils/solvents/chlorine, creating cracks that allow air escape.
Temperature Extremes
Operation beyond 80°C or below -20°C reduces elasticity, creating seal-housing gaps.
Mechanical Wear
Friction from Cyclic Motion
Thousands of monthly cycles wear lip seals/O-rings, especially in rack-and-pinion actuators with lateral forces.
Improper Installation
Over-tightened end caps or folded diaphragm edges create leakage paths under pressure.
System Pressures & Contaminants
Excessive Pressure Spikes
Surges above 10 bar force seals out of grooves.
Particulate Ingress
50-μm particles in air supply abrade surfaces, causing progressive leaks.
Design & Compatibility Issues
Incorrect Seal Type
Using U-cup seals for static applications fails under pressure.
Clearance Mismatch
Surface roughness Ra >1.6μm or gaps >0.2mm allow air bypass.
Prevention Solutions
Material selection matched to media, 5μm filtration, and precision installation maintain efficiency and safety.
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