Gasket failure is rarely due to wear and tear alone. It often signals a system-level issue instead of a problem with a single component. Proper gasket installation, material compatibility, and optimal gasket geometry all help prevent premature failure.
Understanding why gaskets fail is the best way to ensure a longer service life and better system reliability. In this article, we’ll explore the common gasket failure modes so you can reduce downtime, prevent safety risks, mitigate leaks, and avoid costly maintenance.
Whether you’re designing a new system or addressing a persistent leak, American Flexible products can help evaluate your sealing requirements and prevent failures. Contact our team for expert guidance on material selection, fabrication, and installation.
Common Causes of Gasket Failure
Gaskets fail for a variety of reasons. Rather than just replacing them, it’s essential to understand why they fail so that you can prevent repeated issues in the future. Here are a few root causes of gasket failure.
Improper Materials
One of the main reasons gaskets stop working is that the material isn’t suitable for the application based on its composition or the operating conditions.
- Chemical incompatibility can cause the gasket to disintegrate, become brittle, or swell, weakening the seal.
- Thermal incompatibility can cause gaskets to melt, harden, crack, or lose elasticity.
- Environmental incompatibility can cause gaskets to fail if the material is easily degraded by UV, ozone, or moisture.
A rubber gasket seal, for example, may be selected for its flexibility, only to fail prematurely when the rubber reacts with chemicals or high operating temperatures. Choosing the right material is challenging, but American Flexible Products is here to help. With 30 years of industry expertise, we have deep knowledge of the best materials for any application.
Gasket Design or Geometry
Even if you select the correct material, seals can leak if the gasket is not designed properly for the system. The shape, dimensions, and structure of a gasket are all crucial factors in its suitability.
A foam gasket seal may be compatible with the chemicals or environmental conditions it’s exposed to, while still being unsuitable for the application. For example, in fluid systems, using open-cell foam instead of closed-cell foam can cause leaks due to liquid absorption and permeability.
Likewise, a gasket that is too thin may not adequately conform to the flange surface, while a gasket that’s too thick increases the space between components, causing poor sealing and uneven distribution of force.
The width of a gasket also plays an important role. For optimal performance, you will want a suitable ratio between the gasket’s width and thickness. While specific applications vary, you ideally want a >1:1 width-to-thickness ratio, meaning the sealing surface should be at least as wide as the gasket is thick.
Flange Issues
The flange is just as important as the gasket itself. Surfaces that are too rough may damage the gasket, while surfaces that are too smooth may prevent the gasket from sealing properly.
Using a gasket that doesn’t match the type of flange will also cause issues. For example, using a flat gasket on a flange with a raised face can lead to uneven compression, leaks, and premature failure.
Installation Damage
If gaskets are torn, stretched, or misaligned during installation, the system’s performance will be compromised. To ensure proper gasket installation, make sure the surface is cleaned and prepped. For difficult placements, using gaskets with a pressure-sensitive adhesive can help keep the material aligned until the flange is sealed.
During installation, it’s also important to apply even pressure on the gasket. Lubricating bolts and hand-tightening nuts in a crisscross or star pattern helps keep pressure even until torque is applied. Using a calibrated torque wrench and increasing torque uniformly around the flange (following the same star pattern) also ensures consistent pressure.
Aging, Creep & Relaxation
Over time, gaskets will naturally lose their ability to maintain sealing pressure. Repeated vibration, mechanical shock, or sustained gasket compression can all cause seals to deform over time.
While you can’t avoid the natural aging process, you can extend the life of your seals by choosing materials designed with low stress relaxation, such as BISCO® or PORON® materials. Read our guide to compression set and relaxation for more information on how these characteristics affect gasket performance.
Addressing shock and vibration in your design will also help extend the life of system components. Our guide to vibration-damping pads has more information on extending equipment life by controlling vibration.
Inadequate Venting
It may seem counterintuitive that allowing air and fluid to escape the system helps with gasket performance. However, when gas or liquids become trapped within a seal, it can cause localized pressure that exceeds the gasket’s design limits or causes uneven pressure. This can result in blowouts, disrupted seals, and accelerated relaxation.
Designing your system with pressure-equalizing vents can prevent gasket stress and extend their service life. American Flexible Products can help you determine the ideal venting strategy and select the best gasket materials for your application.
How American Flexible Products Helps Prevent Gasket Failure
Gasket failure doesn’t just cause leaks and increased maintenance. It can also lead to impurities and contamination within your system. Blowouts, meanwhile, can cause catastrophic damage, safety hazards, and costly downtime.
At American Flexible Products, we help prevent gasket failure by combining application-driven material recommendations with custom gasket design and fabrication. Our team works closely with engineers to create solutions tailored to each system’s unique requirements.
With a focus on reliability, consistency, and real-world performance, AFP is your partner for gaskets that meet specifications and deliver long-term success. Contact us today to get started.
