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<p>Elastomeric gaskets serve as critical sealing components across industrial applications; yet, failures remain prevalent despite their fundamental importance. This study presents systematic failure investigations of three independent gasket failures spanning refrigeration, fuel storage, and chemical transport applications. Comprehensive failure analysis methodology was employed following the scientific method including fractography, advanced material characterization (FTIR spectroscopy, EDS elemental analysis, and thermogravimetric analysis), mechanical property testing, and microscopic examination.Three fundamentally different root causes were identified through rigorous investigation: (1) installation procedure deviations resulting in the failure of a refrigeration compressor seal formed by a neoprene gasket; (2) supply chain quality control failure where styrene-butadiene rubber (SBR) was substituted for specified nitrile rubber (NBR) in diesel fuel storage tank seals; and (3) design interaction failure where a manufacturing defect in an upstream component created chemical exposure pathways causing localized Viton A fluoroelastomer degradation in a chemical transport application. The three case studies demonstrate that superficially similar failures arose from completely different mechanisms, underscoring the necessity of systematic, evidence-based investigation over assumption-driven diagnosis.</p>

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Systematic Investigation of Elastomeric Gasket Failures: Three Case Studies Demonstrating Diverse Root Causes and Prevention Strategies

  • 期刊论文

  • 发表日期：

    2026年5月29日

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  • Gaurav Nagalia,
  • Gary Novak,
  • Leah Ginsberg

摘要

Elastomeric gaskets serve as critical sealing components across industrial applications; yet, failures remain prevalent despite their fundamental importance. This study presents systematic failure investigations of three independent gasket failures spanning refrigeration, fuel storage, and chemical transport applications. Comprehensive failure analysis methodology was employed following the scientific method including fractography, advanced material characterization (FTIR spectroscopy, EDS elemental analysis, and thermogravimetric analysis), mechanical property testing, and microscopic examination.Three fundamentally different root causes were identified through rigorous investigation: (1) installation procedure deviations resulting in the failure of a refrigeration compressor seal formed by a neoprene gasket; (2) supply chain quality control failure where styrene-butadiene rubber (SBR) was substituted for specified nitrile rubber (NBR) in diesel fuel storage tank seals; and (3) design interaction failure where a manufacturing defect in an upstream component created chemical exposure pathways causing localized Viton A fluoroelastomer degradation in a chemical transport application. The three case studies demonstrate that superficially similar failures arose from completely different mechanisms, underscoring the necessity of systematic, evidence-based investigation over assumption-driven diagnosis.