Form of Cracking
Ozone cracks form in products under tension, but the critical strain is very small. The cracks are always oriented at right angles to the strain axis, so will form around the circumference in a rubber tube bent over. Such cracks are very dangerous when they occur in fuel pipes because the cracks will grow from the outside exposed surfaces into the bore of the pipe, so fuel leakage and fire may follow. Seals are also susceptible to attack, such as diaphragm seals in air lines. Such seals are often critical for the operation of pneumatic controls, and if a crack penetrates the seal, all functions of the system can be lost. Nitrile rubber seals are commonly used in pneumatic systems because of its oil resistance. However, if ozone gas is present, cracking will occur in the seals unless preventative measures are taken.
Ozone attack will occur at the most sensitive zones in a seal, especially sharp corners where the strain is greatest when the seal is flexing in use. The corners represent stress concentrations, so the tension is at a maximum when the diaphragm of the seal is bent under air pressure.
The seal shown at left failed from traces of ozone at circa 1 ppm, and once cracking had started, it continued as long as the gas was present. This particular failure led to loss of production on a semi-conductor fabrication line. The problem was solved by adding effective filters in the air line and by modifying the design to eliminate the very sharp corners. An ozone-resistant elastomer such as Viton was also considered as a replacement for the Nitrile rubber. The pictures were taken using ESEM for maximum resolution.
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