Mechanical Seal Face Materials
Mechanical Seal Face Materials
Mechanical Seal Face Materials
Review Paper
B S Nau
BHR Group Limited, Cranfield, Bedford
Abstract: Mechanical seal face materials are described with an explanation of the properties affecting
performance and the significance of surface texture including bi-Gaussian surface statistics. Aspects of
seal behaviour attributable to face materials are discussed in detail, including random fluctuations of
friction and thermal excursions. Boundary lubrication mechanisms of carbongraphites and other ceramics
are described. The role of tribolayers and transfer layers is highlighted. Failure modes are discussed
including structural fracture, surface crazing, pitting and scoring, blistering, solids deposition and `squeal'
(`ringing'). Many references are given.
NOTATION
WC, cobalt-bonded 105 4.5 650 880 6900 1300 15 000 300
brevity these non-typical carbon-based ceramics will be sive strength much higher than tensile strength, while the
referred to as `carbon', unless the context requires a more seal design usually, but not always, results in radial
specific definition. The seal faces are nominally plane, compression. However, when the higher fluid pressure acts
operating with mixed-film or fluid-film lubrication, and on the inside the ring is in tension and care is needed to
frictional heat is dispersed by conduction through the body avoid tensile failure. A metal-reinforcing band may be
of the seal. The residual waviness is about 0.11 m fitted on the periphery.
peak-to-peak; this is significant as it is comparable to the The brittle nature of ceramics presents quite different
lubricating-film thickness. Working conditions are com- design considerations to those for ductile metals (5). A
monly in the following ranges, but these are by no means flaw larger than a critical size ac grows rapidly, and one
absolute limits: net specific load 0.15 MPa, sliding speed such flaw can result in structural failure. The critical size
120 m=s and sealed-fluid temperature 20300 8C. The increases with the material's fracture toughness K c . Table
chemical nature of the fluid `lubricant' is diverse and can 2 gives indicative values with mild steel included for
be liquid or gas, and may change phase in the interface. It comparison. The value of ac in a region of stress is
is whatever fluid is to be sealedan infinite range of given by
inorganics, hydrocarbons, etc. Such diversity has implica-
tions for the tribochemistry of boundary lubrication in S Kc 2
a p (1)
mechanical seals.
Unfortunately, much tribo-testing reported in the litera-
ture is carried out under conditions quite different to the where S is a shape factor, approximately unity for a
above and therefore of doubtful relevance to mechanical seal ring. As an example, for a silicon carbide material
seals. Thus in pin-on-disc tribometers the disc sees a the critical flaw size in a stress field of 100 MPa is
periodic transit of the pin but most of the time is 0.3 m.
unloaded and exposed. Both mechanical and tribochem- Notice that tensile strength of ceramics varies more
ical environments are very different to those in a seal and widely than that of metals, being governed by the prob-
care is clearly necessary when interpreting such data. A ability distribution of the size of microscopic (or even
compendium of general studies of ceramic tribology is macroscopic) flaws. Weibull statistics defining the scatter
given in reference (1) and a recent review in reference of tensile strength are used to quantify the batch consis-
(2). The former includes several significant mechanical tency of ceramics (6). The variability of a batch is
seal papers, including those of Paxton and Hulbert (3), indicated by the Weibull parameter m, being greater
which gives insight into seal carbon tribology, and Labus
(4), which contains useful friction data.
Table 2 Examples of fracture toughness K c in
MPa m0:5 at 20 8C
2 SIGNIFICANCE OF PHYSICAL PROPERTIES Material Fracture toughness
Mild steel 140
2.1 Strength Cast iron 620
Tungsten carbide, cobalt-bonded 15
Strength is not usually a major concern since most seal Alumina 4
Silicon carbide 3
rings are ceramic based and most of these have compres-
Proc Instn Mech Engrs Vol 211 Part J J00397 # IMechE 1997
MECHANICAL SEAL FACE MATERIALS 167
when m is smaller; typically m is about 10 for engineer- tance RT (8C) is the maximum temperature difference
ing ceramics. that can be tolerated without tensile failure. The product
For a specific material quality the probability of occur- kRT is thus a measure of resistance to thermal shock and
rence of a critical flaw increases with the volume of surface crazing and is sometimes approximated by k RT
material, so is more likely in a large ceramic seal than in (7, 8). To complete the picture requires a measure of the
a small one. Also, tensile strength of ceramics is often transient heat flux H (for a transient face rub this is
measured by a beam-bending test where stress varies fPV), while for transient cooling it depends on the heat
linearly through the thickness, from compression through transfer rate to the cold fluid. In general the risk of
zero to tension. Only in the tensile surface is a flaw thermal stress damage increases with j Hj=(kRT ).
exposed to the maximum tensile stress; hence bending
strength is greater than tensile strength (about 31:7).
2.4 Surface energy
Therefore in using tensile strength data for ceramics care
must be exercised to take account of the method of From time to time, surface energy, or wettability, of faces
measurement. has been considered as a factor that might control the
sealing function, by virture of meniscus curvature. The
2.2 Elastic properties surface energy of engineering surfaces is not normally that
of a chemically clean surface as contamination from the
Young's modulus E affects the stiffness of a sealing ring atmosphere commonly includes grease, which reduces
and, in turn, ring-mode face deflections (coning) and wettability (9). However, there is little detailed documented
induced surface waviness. It is generally easier to control evidence for the role of wettability, especially at the
these if the ring stiffness is high, values ranging between elevated temperatures and very high shear rates that occur
20 GPa for resin-impregnated carbon and 650 GPa for between seal faces in practice. Often mechanical seals
tungsten carbide. Hardness H v is important when sealing appear to `seal'. There is no visible liquid leakage, but
abrasive media; values are given in Table 1. vapour phase leakage is measurable with a sensitive
detector. This is explained by a boiling interface some-
where between the inner and outer edges of the seal.
2.3 Thermal properties
Surface energy also plays a role in solids deposition on
Thermal conductivity k has a crucial role in the dispersal of seal faces (10, 11). Figure 2 shows that deposits form on
heat, from the sealing interface through the seal body to the carbon `C' when its wetting energy is high but not when
surrounding fluid. Other things being equal, the higher the low, and similarly with the alumina counterface `A'. If
value of k the lower is the interface temperature and the both faces have high wetting energy then deposits form
less the risk of the interface film boiling and lubrication on the carbon. Such deposits lead to abrasive wear and
failing. Imagine a mechanical seal of 50 mm diameter and premature failure, discussed later.
suppose that 100 W of heat is conducted away through one
of the mating sealing rings. The temperature differential
2.5 Tribological properties
needed to conduct this heat is proportional to k. For resin-
impregnated carbon the temperature differential is calcu- For face material combinations, tabulated values of opera-
lated to be 70 8C; at the other extreme, for reaction-bonded tional properties such as friction coefficient, the factor
silicon carbide, only 5 8C is required. The advantage of the (PV )max and wear coefficient K w are less useful than might
high conductivity of silicon carbide is clear (but its value be expected. This is because mechanical seals operate most
falls significantly with increasing temperature).
The thermal expansion coefficient affects several
aspects of seal behaviour.
1. Coning of the faces and, if thermal expansion varies
circumferentially, face waviness are affected.
2. Relative expansion between a seal ring and its shrink-
fit housing can cause the ring either to loosen or be
overstressed and changing stresses also modify face
alignment and hence seal performance.
3. Thermal stress increases with E, affecting susceptibil-
ity to failure by surface crazing (discussed later) and
structural fracture. Clearly, lower values of are
generally advantageous.
Fig. 2 Solids deposition on the faces of a carbon (C)
Thermal diffusivity k measures the ability to flatten versus alumina (A) seal in relation to face wetting
transient temperature gradients; the higher its value the energy of each face (0 indicates no deposits)
smaller are any transient gradients. Thermal stress resis- [based on references (10) and (11)]
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168 B S NAU
of the time with full-film or mixed-film lubrication of the instance, 316 steel has a thermal conductivity of only 16
sealing faces. The parameters therefore vary with the many W=mK (at 20 8C)about half that of alumina.
complex factors that determine hydrodynamic pressures in
the interface. Values also vary between seals because 3.2 Typical ceramics
interactions between design and materials change face
deformations. A value of (PV )max is sometimes quoted for Ceramics are composites (Figs 3 and 4) and most are based
a specific seal design but, of course, this can only refer to a on oxides, carbides or nitridescarbongraphite is a
specified fluid at a specified temperature. It is not a general notable exception. Seal face grades of ceramics will be
constant, even for this seal. Table 3 lists some values of this classified here, somewhat arbitrarily, as `typical' and
parameter to give a general indication of the variation `untypical'. In typical ceramics there is normally only a
between materials. trace of binder and the porosity is inherently low. Reaction-
When seal faces do make contact then tribological bonded silicon carbides contain a relatively large amount
characteristics of the face material combination determine of silicon binder, about 10 per cent, but it is convenient
survival or failure of the seal. In this situation the here to include this with the typical ceramics. `Untypical'
operational parameters f, (PV )max and K w may be sig- ceramics, carbongraphites and cermets, normally contain
nificant but, as will be seen later, even then instability of a significant amount of metal or hydrocarbonresin. These
the boundary lubrication mechanism can be overriding. act as a binder and reduce porosity; the proportion is
typically about 10 per cent but sometimes it is much more.
Corrosion resistance depends on the nature and quantity of
the binder or impregnant, the ceramic phase being very
3 FACE MATERIAL CHARACTERISTICS resistant. Table 4 illustrates corrosion rates.
The `typical' ceramics used in mechanical seals are
For convenience the materials commonly used as mechani- mainly grades of alumina or silicon carbide, both notable
cal seal running faces will be grouped under the following for low density and silicon carbide for its high thermal
headings. conductivity (Table 1). Silicon nitride has been used in
roller bearings in recent years, but the ability to with-
stand localized high stresses is not a major consideration
3.1 Metal alloys
in mechanical seals so it does not find a place in the
The following metal alloys are often used as low-cost seal present list. Chromium oxide has been used as a hard
faces, almost invariably running against a carbon: coating on seal faces, as have various other ceramics and
chromium plating, but these are not widely used. Further
`Meehanite' cast iron
background information on ceramics is given in refer-
`Ni-Resist' cast iron
ences (12) and (13).
Aluminiumbronze
Alumina (Al2 O3 ) seal face materials are sintered poly-
Stainless steel
crystalline materials ranging in purity between 95 and
`Stellite' (CoCrW alloys)
99.5 per cent. The grains are 15 m in size, variably
The principal failure mechanism for these is tribological, separated by a glassy phase (Fig. 3a). Properties are very
normally associated with loss of fluid-film lubrication dependent on microstructure; this varies with powder
due to operational or design factors. The cast irons and purity, firing temperature and duration and therefore
bronze tend to fail progressively rather than suddenlya varies between grades and batches, and sometimes within
useful feature. The low thermal conductivity of stainless batches (14, 15).
steels accounts for their limited use as face materials. For Silicon carbide (SiC) forms a particularly important
group of materials for mechanical seals. They are poly-
crystalline materials with SiC crystallites 280 m in
size, i.e. large compared with the interfacial fluid film in
Table 3 Approximate PV limit values most mechanical seals. The size distribution may be
(MPa m=s) for water at 40 8C unimodal or bimodal and the crystallite aspect ratio can
(8) vary, e.g. 1:15:1, the SiC may be an or crystal
Face Counterface (PV )max
SiC Carbon 20 Table 4 Examples of ceramic corrosion rates (g=m2 yr)
SiC SiC 20
WC Resincarbon 8 Sintered SiC WC 6% Co Alumina, 99%
WC WC 4
`Stellite' Metalcarbon 3 Sulphuric acid, 98% 20 10 000 650
`Ni-Resist' Carbon 3 Hydrochloric acid, 25% ,2 900 700
Alumina Carbon 3 Sodium hydroxide, 50% 3 50 750
Leadbronze Metalcarbon 2
Based on data in: Corrosion=erosion resistant components for the
Stainless steel Metalcarbon 1 chemical processing industry, Carborundum Company, 1983.
Proc Instn Mech Engrs Vol 211 Part J J00397 # IMechE 1997
MECHANICAL SEAL FACE MATERIALS 169
(a)
(b) 10 m
(c) 20 m
Fig. 3 Schematics of the structure of `typical' ceramics: (a) alumina, (b) sintered SiC, (c) reaction-
bonded SiC
phase and free carbon is present in some grades. Physical graphite ring with silicon vapour to form a surface layer
properties and performance vary significantly between of SiC, ca. 2 mm thick. This is a lower cost alternative
grades and, as with alumina, between batches and even to the preceding, but less robust, so is not recommended
within batches (14, 16, 17). There are two important for abrasive duties.
groups of SiC materials used in mechanical seals: GraphiteSiC is made from carbongraphite infiltrated
with liquid silicon to give homogeneous SiC with 3050
1. Sintered SiC is made from -SiC powder with a trace
per cent free graphite, to improve boundary lubrication.
of binder (, 2% boron or aluminium), sintered at ca.
This material is not widely used.
2000 8C without pressurization. It is widely used in
mechanical seals, especially for corrosive duties. Fig-
ure 3b illustrates the structure. 3.3 Untypical ceramics
2. Reaction-bonded SiC is made from -SiC powder and
`Untypical' ceramics comprise carbongraphites on the
graphite, infiltrated with silicon liquid or vapour to
one hand and cermets on the other, discussed separately
form a bonded composite of -SiC, -SiC and silicon.
below.
It is widely used in mechanical seals, having particu-
larly good tribological properties, including a high
thermal conductivity. The silicon binder is vulnerable 3.3.1 Carbongraphites
to chemical attack, limiting suitability for use with
The many commercial grades of carbongraphites (`car-
aggressive fluids. Figure 3c illustrates the structure.
bon') are the most widely used materials for mechanical
Siliconized carbon is made by infiltrating a carbon seal faces. Traditionally they are not regarded as ceramics
J00397 # IMechE 1997 Proc Instn Mech Engrs Vol 211 Part J
170 B S NAU
although this is what they are. They are not `typical' material and binder, e.g. synthetic or natural graphite,
ceramics since they nearly always contain a significant detailed structure, nature of trace contaminants, etc. They
proportion of resinous or metallic impregnant, to reduce also depend on details of the manufacturing process.
porosity and enhance other properties (Fig. 4a). The These factors make it difficult to get truly identical
proportion of impregnant is typically 515 per cent, but in materials from different suppliers. There are many stan-
grades designed for moulding in mass production, resin is a dard specifications for measurement of carbongraphite
much higher proportion. Normally it is the impregnant that properties [e.g. see reference (19)] but experience sug-
is degraded when exposed to aggressive fluids or high gests that control of such properties is not necessarily
temperatures. sufficient to control tribological performance.
The basic constituent is grains composed of graphite Phenolic resin impregnation is widely used for light
crystallites, the latter being 0.0050.100 m in size, i.e. duties but antimony impregnation is preferred for its
small compared with typical interfacial film thicknesses higher conductivity in more demanding applications, at
in mechanical seals. The binder is carbonized material higher speeds and pressures for instance. Grades impreg-
derived from such precursors as coal-tar pitch, petroleum nated with other metals (e.g. silver, copper, babbitt) are
pitch, resin, etc., and may be amorphous or graphitic in sometimes used but are susceptible to chemical attack.
varying degrees. There can also be additives including Non-toxic grades for food processing may have polyester
processing aids, antioxidants and boundary lubrication resin impregnation. For high-speed service, e.g. gas tur-
promoters. Paxton (18) describes the complexities of the bine engines, a graphitized fine-grained grade with anti-
manufacturing process. oxidant incorporated may be used.
The properties of carbons are very dependent on the Porosity, hardness and thermal conductivity vary
nature and sources of the raw materials used for base widely between grades and, as with corrosion resistance,
temperature limits are determined by the properties of the
filler and less often by oxidation of carbon. Connected-
cell porosity is monitored during manufacture; it deter-
Crystallite grains mines fluid permeation through the seal ring, though this
is rarely a problem in service. Closed-cell porosity in
excess can lead to serious delamination failure (20).
Binder
Principal failure mechanisms of carbons are tribologi-
cal failure and blistering (discussed later).
Impregnant
3.3.2 Cermets
Porosity
Cermets came to the fore in the 1960s and 1970s but are
now supplanted by silicon carbide. Cermets contain
ceramic crystallites bound by a metallic binder, and
crystallite size is typically about 1 m (Fig. 4b). The
ceramic is usually tungsten carbide (WC) but titanium
(a)
carbide has also been used, being more corrosion resistant,
although expensive. The usual binder is cobalt (e.g. 715
per cent) or nickel (e.g. 6 per cent). Cermets are
manufactured by pressing and presintering; then conven-
tional machining is possible. After final sintering any
finishing is carried out by diamond, SiC or BC grinding or
lapping.
As usual, physical properties vary significantly be-
tween grades, which can differ in grain size and binder
type and amount. The principal failure mechanisms are
surface crazing, tribological, or matrix corrosionagain,
any corrosion normally attacks the metal binder. Abrasion
resistance increases with fracture toughness, microhard-
ness and smaller grain size (21).
Fig. 4 Schematics of the structure of `untypical' cera- So far attention has focused on face materials individually.
mics: (a) carbongraphite, (b) cermet However, in service faces are used in mating pairs. This
Proc Instn Mech Engrs Vol 211 Part J J00397 # IMechE 1997
MECHANICAL SEAL FACE MATERIALS 171
can be illustrated by some representative examples in hydrodynamic lubrication under full-film and mixed-film
common use. conditions. The residual surface waviness of lapped car-
For light duties (about 5 m=s, 5 bar pressure, say) the bons is commonly modified by exposure to liquid or
first choice, carbon, is usually a resin-impregnated grade changing temperature (8), and further changes occur dur-
running against one of several light-duty counterfaces. ing running (Table 5).
For example, a `Meehanite' cast iron counterface could Roughness refers to a similar height variation but with
be used for oil, aluminiumbronze for water or `Ni- a horizontal scale of only 10100 m and a ratio of
Resist' cast iron for mildly corrosive fluids. An alterna- 10 103 (Fig. 6). Roughness is not normally an issue
tive to the latter is 304 stainless steel, although its unless the seal operates in a mixed-film mode. The
thermal conductivity is too low for really satisfactory roughness of a lapped unused ceramic seal face does not
performance. `Stellite 1' is an option if the fluid is also have the simple Normal height distribution commonly
abrasive, but alumina (95 per cent pure) is hard and assumed when applying the average-flow form of Rey-
reasonably resistant to corrosion so is a more economic nolds equation to rough surfaces [e.g. see references (8)
choice. Where reliability is important a combination from and (23)]. In reality, the height distribution is extremely
a higher duty category would be considered. skewed due to removal of peaks by lapping (Fig. 6).
For higher dutieshigher speeds, pressures, tempera- Leefe and Williams (24) show that the profile is domi-
turesthe choice of carbon is commonly antimony-im-
pregnated and the counterface would usually be silicon
Table 5 Development of carbon waviness in service (22)
carbide. For the latter a reaction-bonded grade with high
(resincarbon versus Ni-Resist, 2900 r=min, 70
thermal conductivity is advantageous or sintered grades
8C, distilled water, 6 seals)
with corrosive attack are a possibility.
For abrasive duties both faces need to be hard materi- Time (h) 0 0.1 0.25 1 24
Wave height (m p.t.p.) , 0.2 1.644 35 1.56 528
als. Two practical options are silicon carbide against
tungsten carbide or silicon carbide against itself. If the
duty is also corrosive, only sintered SiC against either
itself or perhaps WC Ni is likely to give a reasonable
life. For the most corrosive duties, without abrasives,
an option is glass-filled PTFE (polytetrafluoroethylene)
against 99.5 per cent pure alumina.
5 SURFACE CHARACTERISTICS
nated by two roughness scales: a large-amplitude peak- Secondly, lapping is a tribological process in its own right
lopped component and a small-amplitude `sinusoidal' and may therefore generate a tribolayer on the lapped
component. It appears that the first characterizes the surface. Clearly the nature of the lapping fluid used could
method of finishing and the second the grain structure of be significant in this respect.
the material. Undoubtedly there are finer-scale compo-
nents as yet unstudied. The dominant components have
interesting properties revealed by plotting the percentage 6 CERAMICS TRIBOLOGY
of surface below a given height versus height. This shows
a bilinear relationship resembling a Weibull plot with two
6.1 Carbongraphites
failure modes, i.e. the two components of height distribu-
tion have separate Gaussian distributions, so the combina- Often it is not appreciated that the wear and friction of
tion is `bi-Gaussian' (Fig. 7). Both unused and used carbons can be very high in an inert environment, such as
ceramic faces exhibit this characteristic (25). The ability an inert fluid or a vacuum. This became apparent in World
to characterize surface profiles in this way provides a War II when carbon brushes on electrical generators in
valuable tool for gaining insight into the relationship high-flying aircraft suffered high wear rates. Savage (31
between surface finishing, material structure and seal 33) showed that this is the normal behaviour of chemically
performance. Although little used as yet, Leefe has clean graphite. Only in the presence of `contaminant'
applied it in a computer model of the elastohydrody- molecules (e.g. H2 O, oxygen and various hydrocarbon and
namic lubrication of real seal faces in the mixed-film inorganic species) does `carbon' exhibit low-friction, low-
mode (25). wear behaviour. Boundary lubrication of carbongraphite
Other surface topography parameters have been investi- involves a rather complex mechanism. Initially, hyper-fine
gated experimentally (2629) from which the radius of particles of comminuted carbon crystallites are generated
curvature of asperities appears to play a key role in seal by wear of the unprotected carbon. Due to its large
tribology. Friction and wear decrease with increasing surfacevolume ratio the particulate behaves like activated
radius and the leak rate increases; lapping scores, charcoal, although orders of magnitude more reactive. In
although extremely fine, also affect the leak rate. the presence of suitable `contaminant' molecules it links up
to form a surface coating of submicrometre thickness (Fig.
8). So long as this `tribolayer' remains intact, friction and
5.2 Effects of lapping
wear remain low and stable. The existence of a tribolayer
Apart from the effects of lapping on the surface topography, was subsequently noted in mechanical seals (34, 35).
attention should be drawn to two other effects of lapping Figure 9 shows the relative dimensions of carbongraphite
which deserve further study. Firstly, lapping can result in constituents, from atomic spacing to grain size in manufac-
faces becoming impregnated with particles of the lapping tured seal carbons.
compound (30), which could affect seal performance. Savage's findings were also confirmed by Lancaster
5
Scaled bearing fraction
4
5 0 3
Height above datum (m)
Fig. 7 Bi-Gaussian surface-profile height distribution of a lapped carbongraphite seal face (24). (The
bearing fraction is related to the proportion of `solid' along a transect at a given height above
the datum; a normal probability scale is used here)
Proc Instn Mech Engrs Vol 211 Part J J00397 # IMechE 1997
MECHANICAL SEAL FACE MATERIALS 173
Tribolayer
(a)
Plane-to-plane
C-hexagon Graphite
crystal
CC
Fig. 10 Transition to high-friction, high-wear-rate for
0.1 nm 1 10 100 1 m 10 100 carbon on carbon [based on reference (37)]
Size
1.0
Pin-on-disc:
A...I alumina versus alumina
a...i SiC versus SiC (sintered)
Friction coefficient
0
1012 Specific wear rate (mm/s mm) 105
a, Anitrogen e, Eair
b, B water vapour f, F 50 % relative humidity
c, C ethanol vapour g, G 100 % relative humidity
d, D benzene vapour h, Hwater, 0.1 m/s
i, Iwater, 0.8 m/s
Fig. 14 Measured friction and wear of SiC and alumina sliding against themselves in the presence of
various `contaminants' [data from reference (50)]
200
Face temperature (C)
Fail
100
20
0 5 10
Specific load (MPa)
Fig. 15 High load capacity of seal faces (44), apparently due to fluid film hydrodynamics in
conjunction with the ultra-flat tribolayer
shows data for a commercial seal with waterglycerol output measuring seal housing reaction; it was supported in
solutions at 120 bar pressure, 105000 r=min of Ni- bearings. Figure 18b shows random thermal excursions of
Resist versus resincarbon (52). The wide random scatter another commercial seal in a different test rig; the faces
of the friction is characteristic of many similar tests on this were Ni-Resist versus phenolic-impregnated carbon and the
and other commercial seals, with a variety of face material fluid was distilled water (22). The excursions are relatively
combinations. The scatter is upwards from an `envelope' infrequent, but random. Figure 18c is yet another seal
resembling a Stribeck curve and approaches an upper limit configuration in another test rig. The faces are reaction-
corresponding to boundary lubrication. The seal was well bonded SiC versus phenolic-resin-impregnated carbon and
away from the thermal instability due to vaporization of the data were logged at a relatively high rate by computer (45).
fluid film. Data were read periodically from the transducer The 4:1 fluctuations in friction are too rapid to affect
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176 B S NAU
Table 6 Specific net transition load (P, MPa) and Young's supply frequency and the 42 Hz peak may be a resonance
modulus (E, GPa) of the higher modulus materi- of the transducer installation. It is not obvious why the
al, for plane annular rings in distilled water at 6 friction should fluctuate synchronously with the shaft.
m=s (44) Fluctuations of friction in mechanical seals have been
Material combination P E observed by numerous workers [e.g. see references (53)
to (56)] and a similar effect has been seen with dry-
WC versus SiC 14 580
WC versus antimonycarbon 11.513.5 580
sliding alumina in a four-ball tester. This was suppressed
SiC versus antimonycarbon 5.78.7 410 by contaminants (57).
SiC versus resincarbon 4.27.3 410 From the available evidence there can be little doubt
Ni-Resist versus antimonycarbon 2.2 110
Ni-Resist versus resincarbon 2.2 110
that the random fluctuation of friction in mechanical
Alumina versus resincarbon 1.2 350 seals is a real effect. The similarity of fluctuations during
wet and dry operation eliminates fluid-film instability as
an explanation. It seems likely that the effect is asso-
ciated with the tribolayer (or transfer layer), and this is
carbon temperature, due to thermal inertia; the interface supported by the condition of faces observed in tests
continued in cyclic equilibrium for 90 hours until stopped. halted in different operating regimes. Seals stopped and
Figure 18d shows behaviour during a continuation of the dismantled when operating at above-normal face tempera-
preceding test after draining the water, with the seal ture (e.g. 140 8C) have been found to have flake-like
running dry. The friction still fluctuates and the lower remnants of a thick tribolayer on the carbon face (Fig.
envelope drifts up; the face temperature built up until the 11). The very high load capacities sometimes observed
run was abandoned at 250 8C. Some carbons do not suffer may also be attributable to an intact tribolayer (and=or
this thermal run-away and are able to run dry in cyclic transfer layer). However, plausible explanations have yet
equilibrium for 24 hours or more. Figure 19 is a fast to be offered for two aspects of carbon behaviour in
Fourier transform spectral analysis of the fluctuating seals. How can a tribolayer cause friction fluctuations
friction during dry running in a similar test, (a) during when the seal is operating in the hydrodynamic region of
stable operation and (b) during a friction excursion. The the Stribeck curve? Secondly, in tests under carefully
main peak is shaft rotation (70 Hz), 50 Hz is the electrical controlled conditions, carbon performance exhibits sto-
120
Seal face temperature (C)
(a)
20
1.0
(b)
Friction coefficient
.1
Slope 0.5
.01
.001
.0001
1010 109 108 107 106 105
Duty parameter
Fig. 16 Performance of plane annular test samples of SiC versus antimony-impregnated carbon in
distilled water: (a) face temperature versus duty parameter; (b) friction versus duty parameter;
[redrawn from reference (44)]
Proc Instn Mech Engrs Vol 211 Part J J00397 # IMechE 1997
MECHANICAL SEAL FACE MATERIALS 177
20
0
109 Duty parameter G 104
Fig. 17 Dependence of specific wear rate on duty parameter for a commercial mechanical seal
[redrawn from reference (52)]
chastic behaviour wherein even carbons from one batch and propagate into the interior and the pads curl up at the
can vary widely in time-to-failure under nominally iden- edges, like drying mud in a puddle. This forms an
tical conditions. What is the underlying mechanism? extremely abrasive surface which abrades the counterface
and severe leakage soon develops.
Surface crazing occurs with all types of ceramic. The
7 FAILURE MODES cause is generally believed to be transient thermal stres-
ses in the surface, induced either by sudden cooling or
by sudden heating of the face. Sudden cooling can result
7.1 Fracture
from an influx of cold liquid to the sealing interface and
After tribolayer (or transfer layer) instability the most heating can result from a brief face rub. The resulting
common material failures of typical ceramics are brittle differential thermal expansion of the surface relative to
fractures. At its simplest this can be structural, originating the substrate generates subsurface shear stresses. These
at a stress raiser such as a drive slot. A less obvious cause stresses are sufficient to cause the material to fail in
has been reported in carbon rings where the crack compression or tension, depending on whether it is
originates on the sealing face (5860). This is thought to heated or cooled. Several factors affect crazing:
be due to mismatch of thermal expansion of fillers.
1. Sufficiently high temperature gradients are only likely
Alumina fractures have been attributed to straightforward
to arise under transient conditions. Therefore a high
thermal shock (14).
thermal diffusivity of the material is beneficial in
If both seal faces are hard ceramic and the seal
suppressing surface crazing.
operates continuously with its interfacial film temperature
2. The ability of the material to resist such stresses is
close to boiling, damage arises in a different fashion.
indicated by the thermal stress resistance (see Section
Fluid-phase instability causes the faces to separate peri-
2.3 and Table 1).
odically (at one side), as the fluid film vaporizes and
3. A higher dry-sliding friction coefficient is more likely
expands. The faces then crash together as hydrodynamic
to cause crazing in the event of a rub as the heat input
and hydrostatic load support is lost. The resulting impacts
will be greater.
can cause extensive structural damage to brittle ceramics
(Fig. 20).
7.3 Face pitting and scoring
7.2 Surface crazing
A quite different and very localized form of surface
In less extreme circumstances fracture is commonly fracture occurs in all types of ceramics but is particularly
localized in the surface layer of the running face, forming a common in carbons. This is characterized by formation of
network of shallow hair-line cracks, `surface crazing' (or small pits in the surface. Material detached from the pit is
`heat checking'). The cracks are either more-or-less dragged away downstream and an arc-shaped score mark
uniformly spaced radial cracks or form a `crazy-paving' forms, fading as the material is ground up (Fig. 22). Such
network of `pads' of rather uniform size (Fig. 21a, b). pits are commonly about 0.1 mm in depth and diameter.
During the early stages cracks are sparse and very fine, but Sometimes there are large numbers and damage is
visible at 310 magnification. As they develop they broaden sufficiently serious to cause seal failure. The initial particle
J00397 # IMechE 1997 Proc Instn Mech Engrs Vol 211 Part J
178 B S NAU
1.0
Slope 0.5
Friction coefficient
0.1
0.01
1011 1010 109 108 107 106 105 104
(a) Duty parameter G
40
T/(C)
0
0 100 200 300
(b) Run time (h)
Face temperature (C)
100 100
Friction coefficient ( 100)
0 0
(c) Run time (h) 100 (d) Run time (h) 5
Fig. 18 Fluctuating friction of mechanical seals. (a) Commercial seal in waterglycerol over a range
of speeds, pressures and viscosities; resincarbon versus Ni-Resist [redrawn from reference
(22)]. (b) Temperature transients of a commercial seal face in distilled water at constant
operating conditions; resincarbon versus Ni-Resist [redrawn from reference (22)]. (c)
Friction and face temperature of seal rings in a material test-rig at constant operating
conditions in distilled water; reaction-bonded SiC versus phenoliccarbon; data logged by
computer (45). (d) Continuation of run shown in (c) but running dry for tribolayer breakdown
at 4 h (45)
Proc Instn Mech Engrs Vol 211 Part J J00397 # IMechE 1997
MECHANICAL SEAL FACE MATERIALS 179
(a)
Amplitude (arbitrary units)
(b)
(a)
0 50 100
Frequency (Hz)
7.6 Squeal
A seal otherwise running normally may emit unacceptable
high-frequency squeal at about 0.3 or 1.2 kHz (also called
`ringing'). This is difficult to eliminate and can be an
Fig. 23 Schematic section through a seal face blister annoying problem in domestic washing machines and
[based on reference (65)] automotive coolant pumps. This behaviour reflects the high
resonant frequency of small lightweight seals under
torsional excitation. Squeal has been the subject of study
fluid is unable to flow out fast enough to relieve the over many years [e.g. see references (71) to (76)]. It occurs
resulting pressurization of the internal fluid, the surface of more with tap water than ethylene glycol solution and it
the carbon is deformed upwards, fracturing locally to form also occurs over a wider speed range as the fluid tempera-
a blister. This mechanism depends on porosity of the ture increases. The origin lies in stick-slip at the sealing
surface of the carbon and therefore on the grade and quality interface; this, of course, depends on the slope of the
of carbon; more resistant grades are available. It has also frictionspeed relationship. Torque fluctuations up to
been found that a high value of k= reduces the occurrence 1.5 kHz have been recorded in such seals (72).
of blistering (62). Avoiding an exceptionally flat counter-
face also helps, as the hydrodynamic lift associated with a
certain amount of face waviness reduces the risk of large
thermal transients. 8 CONCLUSIONS
There are also physical interactions between the fluid 8 Lebeck, A. O. Principles and Design of Mechanical Face
and face material. Diffusion of fluid into the pore struc- Seals, 1991 (John Wiley, New York).
ture of the substrate, and subsequent thermal transients, 9 Jagger, E. T. Rotary shaft seals: the sealing mechanism of
can cause blistering. This can be either in the form of synthetic seals running at atmospheric pressure. Proc. Instn
localized `volcanoes' or involve delamination over a Mech. Engrs, Part 1, 1966, 181.
10 Komiya, M., Kiryu, K., Masuya, H., Okada, K. and
wider area. In another class of problems, solids from the
Hirabayashi, H. Effect of silicate in coolant on sealing
sealed fluid, including leachate from system components,
performance of mechanical seals for water pumps of auto-
even at ppm levels, are deposited on the faces. This may motive engines. In Proceedings of Japan International Tribol-
occur locally, causing abrasion, or extensively, causing ogy Conference, Nagoya, 1990.
delamination=blistering. Deposition depends on surface 11 Kiryu, K., Hirata, O., Yoshino, A., Masuya, H., Okada, K.
energy and fluid phase transition between the seal faces. and Hirabayashi, H. The relationship between sealing per-
The surface texture of lapped ceramic seal faces has formance of mechanical seals and composition of coolants for
two main components: a peak-lopped component charac- automotive engines. In ASTM STP 1192 (Ed. R. E. Beal),
teristic of the machining and lapping processes, and a 1993 (American Society for Testing and Materials, Philadel-
finer component characteristic of the material structure. phia, Pennsylvania).
The combination gives a bi-Gaussian distribution of 12 Richerson, D. W. Modern Ceramic Engineering: Properties,
Processing and Use in Design, 1982 (Marcel Dekker, New
cumulative height. Decomposition of the profile into
York).
these components facilitates computer modelling of
13 Kato, K. Tribology of ceramics. Wear, 1990, 136, 117133.
mixed-film lubrication and provides a basis for under- 14 Wallis, R. Influence of the microstructure of ceramic mate-
standing the separate roles of material and the manufac- rials on their wear behavior in mechanical seals. Lubric.
turing processes. Engng, 1994, 50(10), 789799.
Other phenomena impairing seal performance include 15 Chen, Y. M., Rigaut, B. and Armanet, F. Friction and wear
structural fracture, thermal stress surface fractures (craz- of alumina ceramics at high sliding speeds. Lubric. Engng,
ing) and face pitting; `squeal' is a cosmetic problem of 1991, 47(7), 531537.
lightweight seals subject to fluctuating torque. 16 Klimek, E. J. Selection, properties and quality assurance of
face materials for rotating mechanical seals. Lubric. Engng,
1987, 44, 719725.
17 Klimek, E. J. Microstructure of silicon carbide materials.
ACKNOWLEDGEMENTS Microstructural Sci., 1987, 16, 295304.
18 Paxton, R. R. Manufactured Carbon: A Self-lubricating
Material for Mechanical Devices, 1979 (CRC Press, Boca
The author wishes to acknowledge the support of BHR
Raton, Florida).
Group Limited and organizations that have supported the
19 Anon. ASTM Standards on Manufactured Carbon and Gra-
mechanical seal work on which this account has drawn, phite Products. PCN 06-305081-09, 1981 (American Society
including: Amoco, BP, European Space Agency, Britoil, for Testing and Materials, Philadelphia, Pennsylvania).
Caltex, ICI, Shell Expro, BW=IP, John Crane, EG&G 20 Nau, B. S. Research in mechanical seals. Proc. Instn Mech.
Sealol, Lucas Aerospace, T&N, Morganite Special Carbons Engrs, Part C, 1990, 204(C6), 349376.
and the Department of Trade and Industry. 21 Wayne, S. F., Baldoni, J. G. and Buyljan, S.-T. Abrasion and
erosion of WCCo with controlled microstructures. Tribology
Trans., 1990, 33(4), 611617.
22 Flitney, R. K. and Nau, B. S. A study of factors affecting
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