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The selection of materials for mechanical seals directly affects the sealing performance, operational reliability, and service life of the equipment. Different materials vary significantly in terms of corrosion resistance, wear resistance, high-temperature resistance, and chemical compatibility. If the material is not suited to the actual operating conditions, it may result in excessive wear of the sealing faces, aging of the elastomers, and metal corrosion—and may even lead to seal failure and media leakage.
This article starts with fluid characteristics, operating pressure, temperature, and speed. It compares common seal face materials such as carbon, ceramic, silicon carbide, and tungsten carbide. It provides a complete mechanical seal material selection guide.
When selecting materials for mechanical seals, the first thing you need to understand is what fluid is being sealed and under what conditions the equipment operates.
This is because mechanical seals must not only prevent fluid leakage but also withstand the effects of media corrosion, temperature fluctuations, pressure, and friction.
The first step is to identify the specific composition of the fluid.
Different fluids cause varying degrees of corrosion and wear on mechanical seal materials; even for the same chemical medium, changes in concentration and temperature can affect the material’s suitability.
Pay attention to the following fluid characteristics:
Next, you need to gain a better understanding of the actual operating environment of the mechanical seal within the equipment. You should focus on confirming the following information:
| Operating Condition | What to Confirm | Why It Matters |
|---|---|---|
| Pressure | Normal, minimum, and maximum seal chamber pressure. | Affects seal face load and material requirements. |
| Temperature | Normal, maximum, and temperature changes. | Affects corrosion resistance, thermal deformation, and aging. |
| Shaft Speed | Normal and maximum shaft speed. | Affects face speed, friction, and heat. |
| Operating Cycle | Continuous, frequent start-stop, or intermittent operation. | Affects lubrication and thermal cycling. |
| Lubrication Conditions | Whether a stable fluid film forms between the seal faces. | Poor lubrication accelerates face wear. |
Tip: Normal operating conditions are not necessarily the most severe conditions. For example, there may be a brief period of insufficient lubrication when the equipment starts up; some fluids may crystallize after shutdown; and sudden temperature changes may cause thermal stress in the materials.
Once the fluid and operating conditions are understood, material requirements can be preliminarily determined based on the operating conditions:
When selecting materials for mechanical seals, pressure, temperature, and rotational speed are three critical operating parameters. They not only determine the mechanical loads the seal must withstand but also affect friction, heat generation, deformation, and service life at the sealing faces.
Operating pressure directly affects the forces acting on the sealing faces. Excessive pressure increases friction and heat generation, accelerating wear. Insufficient sealing force can lead to leakage due to separation of the sealing faces. Under high-pressure conditions, special attention should be paid to:
Tip: Hard materials such as silicon carbide and tungsten carbide are suitable candidates for high-pressure applications, but hardness alone should not be the sole consideration. Under high-pressure conditions, balanced mechanical seals should also be evaluated; by adjusting the effective pressure-bearing area of the sealing faces, the hydraulic closing load can be reduced, thereby controlling frictional heat generation.
Temperature fluctuations can affect the reliability of the sealing faces, auxiliary seals, and metal components. High temperatures may cause thermal deformation of the sealing faces, accelerate material aging, and reduce the fluid’s lubricating ability. Key considerations include:
Tip: Silicon carbide offers good thermal conductivity and wear resistance and may be considered for certain high-temperature applications; however, the specific grade, chemical environment, and seal configuration must be verified. In high-temperature or frequently fluctuating temperature conditions, attention should be paid to the actual sealing face temperature rather than just the medium temperature.
Higher shaft speed increases sealing-face sliding speed, raising demands on heat dissipation and lubrication. But sliding speed depends on both RPM and the effective friction diameter, so identical RPMs can produce different sliding speeds if face diameters differ.
At high sliding speeds, materials need suitable friction properties, thermal conductivity, and wear resistance. Higher hardness alone does not guarantee suitability; sealing-face compatibility and stable fluid-film formation must also be considered.
Pressure, temperature, and speed interact. Meeting each limit individually does not guarantee safe seal operation.
High face load plus higher sliding speed increases frictional heat. High fluid temperature makes lubrication harder and can cause thermal deformation.
PV value can help assess friction conditions. For mechanical seals, use face load as the pressure term, not pump discharge pressure times shaft speed.
PV alone cannot confirm material suitability. Seal design, fluid lubricity, temperature, and cooling conditions also matter.
Common materials used for sealing faces include carbon graphite, ceramics, silicon carbide, and tungsten carbide. These materials differ significantly in terms of hardness, wear resistance, corrosion resistance, thermal conductivity, and mechanical strength.
| Comparison | Carbon Graphite | Ceramic | Silicon Carbide (SiC) | Tungsten Carbide (WC) |
|---|---|---|---|---|
| Material Features | Soft face material with good friction properties. | Usually alumina ceramic with high hardness. | High hardness with good wear resistance and thermal conductivity. | High hardness, strength, and toughness. |
| Wear Resistance | Sensitive to hard abrasive particles. | Good for mild wear conditions. | Excellent for abrasive service. | Excellent for demanding wear conditions. |
| Corrosion Resistance | Depends on grade and impregnation. | Good resistance to many fluids. | Excellent, but varies by SiC grade. | Depends strongly on binder type. |
| Thermal Conductivity | Generally good. | Relatively low. | Good for removing friction heat. | Generally good. |
| Impact Resistance | Lower strength; avoid mechanical damage. | Brittle and impact-sensitive. | Brittle; avoid impact and thermal stress. | Generally tougher than SiC. |
| Main Advantage | Good friction behavior and self-lubricating ability. | Economical with good wear resistance. | Strong balance of wear, heat, and chemical resistance. | Good wear resistance, strength, and impact resistance. |
| Main Limitation | Not ideal for severe abrasive service. | Sensitive to impact and thermal stress. | Risk of brittle cracking; corrosion resistance varies by grade. | Metal binder may corrode. |
| Typical Applications | Clean water, oils, and general industrial fluids. | Water pumps and mild operating conditions. | Chemical pumps and abrasive or corrosive fluids. | Industrial pumps with impact or abrasive loads. |
| Selection Guide | Best for clean, low-particle fluids with good lubrication. | Best for clean fluids and mild service. | Best for high wear, heat, or corrosion resistance needs. | Best for impact or abrasive service; check binder compatibility. |
Tip: Carbon graphite, ceramics, silicon carbide, and tungsten carbide each have their own advantages; no single material is suitable for all operating conditions. When making an actual selection, you need to comprehensively consider the fluid’s corrosiveness, solid particle content, lubrication conditions, and equipment operating parameters, and confirm the specific material grades and sealing face pairing requirements.
Soft-hard pairings, which combine carbon graphite with ceramics, silicon carbide, or tungsten carbide, offer superior friction properties. Hard-hard pairings, on the other hand, use two hard materials—such as silicon carbide and silicon carbide—to enhance the end face’s resistance to abrasive particles.
Definition: One contact face is made of a softer material, while the other is made of a harder material. Common combinations include carbon graphite/ceramic, carbon graphite/silicon carbide, and carbon graphite/tungsten carbide.
Advantages: Good friction performance. Carbon graphite possesses self-lubricating properties and helps reduce friction even when the liquid film is thin; when paired with a suitable hard face, it helps control frictional heat and wear.
Applicable Conditions: When conveying clean water, certain types of oil, or other liquids with low particle content, soft-hard face pairing is generally the preferred option.
Limitations: Carbon graphite has relatively low hardness. When the medium contains a large amount of hard particles—such as sand or crystals—the carbon graphite face will experience accelerated wear; some particles may also become embedded in the soft face, causing further wear to the hard material on the opposite side.
Definition: Both sealing faces are made of hard materials. Common combinations include silicon carbide/silicon carbide, tungsten carbide/tungsten carbide, and the proven silicon carbide/tungsten carbide pairing.
Advantages: Both sealing faces feature high hardness and excellent wear resistance, effectively reducing the abrasive wear that soft sealing faces are prone to in media containing hard particles.
Applications: The proven hard-on-hard pairing should be considered when conveying sand-laden water, certain slurries, or liquids prone to forming crystalline particles.
Limitations: More sensitive to lubrication conditions. A sufficient lubricating film must be maintained between the two sealing faces; if the film is lost, significant frictional heat may be generated, leading to face wear, thermal cracking, or even seal failure.
| Comparison | Soft-Hard Pairing | Hard-Hard Pairing |
|---|---|---|
| Common Combinations | Carbon/Ceramic, Carbon/SiC, Carbon/WC | SiC/SiC, WC/WC, SiC/WC |
| Friction Performance | Generally good; carbon offers some self-lubrication. | Depends more on material pairing and stable lubrication. |
| Abrasion Resistance | Soft faces are more sensitive to hard particles. | Better suited to higher abrasion risk. |
| Lubrication Requirement | More tolerant of short-term lubrication loss. | Requires a more stable fluid film. |
| Corrosion Resistance | Depends on carbon impregnation and hard-face material. | Depends on hard material type and grade. |
| Main Advantage | Good friction behavior for many general applications. | High wear resistance on both faces. |
| Main Limitation | Soft face may wear quickly with hard particles. | Poor lubrication can cause rapid overheating or damage. |
| Typical Applications | Clean water, oils, and general industrial fluids. | Sandy fluids, slurries, and some crystallizing media. |
Step 1: Examine the particles. If the fluid is clean and contains few particles, you can start with a soft-hard pairing; if there are many hard particles, you need to evaluate a hard-hard pairing to reduce face wear.
Step 2: Examine lubrication. If the equipment is prone to frequent fluid shortages, the pump is not fully primed during startup, or the sealing faces are prone to vaporization, a hard-on-hard pairing is also susceptible to damage. Lubrication issues should be addressed first, rather than simply switching to harder materials.
Step 3: Verify compatibility and operating conditions. Confirm that both sealing face materials are compatible with the fluid and can withstand the actual pressure, temperature, and sliding speed.
Tip: For applications involving severe abrasion or complex lubrication conditions, simply changing the face material may not be sufficient to resolve the issue; the seal supplier should also confirm whether the entire seal configuration is suitable.
In addition to relying on rotating and stationary rings to control leakage, mechanical seals also require elastomeric seals, such as O-rings, to prevent fluid from leaking through the gaps between the sealing rings and the shaft, shaft sleeve, or housing.
Elastomers are made of rubber-like materials with elastic properties that can fill sealing gaps by deforming under pressure. However, different elastomers exhibit significant variations in their resistance to oils, acids, alkalis, solvents, and high-temperature environments.
Common elastomers for mechanical seals include NBR, EPDM, FKM, and FFKM. Selection should be based on fluid type and temperature.
| Material | Main Advantages | Main Limitations | Typical Applications |
|---|---|---|---|
| NBR | Good mineral oil resistance and relatively low cost. | Limited for strong oxidizers, ketones, and high-temperature steam. | Lubricating oils, mineral hydraulic oils, petroleum-based fluids. |
| EPDM | Good resistance to water, hot water, and some steam. | Generally unsuitable for petroleum oils and fuels. | Water treatment, hot-water systems, water-based chemicals. |
| FKM | Good heat resistance and compatibility with many oils and chemicals. | Some amines, ketones, hot water, and steam may cause degradation. | High-temperature oils, fuels, and chemical fluids. |
| FFKM | Broad chemical resistance; some grades handle high temperatures. | High cost and performance varies by grade. | Highly corrosive fluids, complex chemicals, and high-temperature service. |
Temperature directly affects the flexibility, sealing performance, and service life of elastomers:
High temperatures: Prone to thermal aging, leading to hardening, cracking, and reduced resilience; prolonged compression may also cause permanent compression set, which cannot be reversed after pressure is released, thereby reducing sealing contact pressure and increasing the risk of leakage.
Low temperatures: Flexibility decreases, preventing the elastomer from fully conforming to the sealing surface, which reduces sealing performance.
Key Selection Criteria: Both the minimum temperature, normal operating temperature, and maximum temperature must be confirmed; pay particular attention to startup, shutdown, and conditions involving sudden temperature changes.
Chemical compatibility refers to a material’s ability to maintain performance that meets sealing requirements after coming into contact with a medium. Elastomers with similar temperature resistance may perform completely differently when exposed to the same liquid.
Assess compatibility in the following order:
Misconception 1: High temperature resistance ≠ good chemical resistance. There is no inherent correlation between the two.
Misconception 2: Do not focus solely on normal operating temperatures. Temperature fluctuations during cleaning, startup, and shutdown can also cause irreversible damage.
Misconception 3: Do not replace seals based solely on material abbreviations. You must also verify that the dimensions, hardness, and compression requirements match those of the original design.
In addition to the sealing faces and elastomers, mechanical seals also include metal components such as springs, shaft sleeves, gland nuts, and retaining rings. These components are primarily responsible for supporting the sealing structure, transmitting mechanical loads, and helping the sealing faces maintain proper contact.
Corrosion resistance is a metal’s ability to resist erosion by chemical media. Prolonged contact with corrosive liquids can cause surface corrosion, localized perforation, or cracking in mechanical seal components.
Common metal materials:
Springs are the key elastic components of mechanical seals; they primarily provide the initial sealing force and help the sealing faces accommodate axial displacement and wear.
Common spring materials:
| Metal Material | Main Advantages | Main Limitations | Typical Applications |
|---|---|---|---|
| 304 Stainless Steel | Cost-effective with good general corrosion resistance. | Susceptible to localized corrosion in some chloride environments. | Clean water and mildly corrosive service. |
| 316 / 316L Stainless Steel | Better corrosion resistance than 304 and widely used. | Still vulnerable to chloride pitting and stress corrosion cracking. | Industrial pumps and some chemical services. |
| Duplex Stainless Steel | High strength and better chloride resistance. | Performance depends on grade and fluid conditions. | High-chloride and high-load applications. |
| Hastelloy C-276 | Strong resistance to many aggressive chemicals. | High cost; compatibility still needs verification. | Highly corrosive chemicals and corrosion-resistant springs. |
| Inconel Series | Good high-temperature strength and fatigue resistance in some grades. | Performance varies by grade and cost is high. | High-temperature springs and special service conditions. |
The actual selection process can be determined by following these three steps:
Step 1: Identify which metal components come into contact with the fluid.
Step 2: Assess the actual corrosion environment.
Step 3: Determine the requirements for structural components and springs, respectively.
When selecting materials for mechanical seals, it is necessary to consider not only pressure, temperature, and chemical corrosion, but also solid particles in the fluid, abrasiveness, and the lubrication conditions of the sealing faces.
Abrasion refers to the phenomenon in which solid particles cause scratches, wear, or material loss as they slide or press against a material’s surface.
When assessing the risk of abrasion, you should consider the following factors:
Unlike dry running: Poor lubrication does not mean the complete absence of fluid, but rather an unstable or insufficient liquid film on the sealing faces.
Risks of low-viscosity media: Fluids with lower viscosity have a harder time forming a stable lubricating film, which may increase friction and wear on the sealing faces.
Vaporization disrupts the liquid film: When temperatures rise or pressure in the seal chamber is insufficient, the fluid may vaporize near the sealing faces, disrupting the continuous liquid film.
Long-term consequences: Increased friction, localized temperature rise, and abnormal wear, ultimately leading to reduced sealing performance or failure.
Different operating conditions place different demands on mechanical seal materials. You can use the table below to make a preliminary assessment.
| Operating Issue | Main Risk | Material / Selection Guide |
|---|---|---|
| Hard Particles in Fluid | Face scratching and abrasive wear. | Consider SiC/SiC and particle-control measures. |
| High-Solids Slurry | Face wear, buildup, and moving-part blockage. | Use slurry-specific seal designs and wear-resistant materials. |
| Crystallizing Fluids | Deposits and sticking of moving parts. | Use anti-deposit designs and suitable support systems. |
| Dry-Running Risk | Overheating, thermal cracks, and face failure. | Prevent loss of liquid; use dry-running seals if required. |
| Low-Lubricity Fluids | Unstable fluid film, higher friction, and heat. | Evaluate friction behavior, face load, and lubrication. |
| Volatile Fluids | Fluid-film breakdown and local overheating. | Check pressure margin, cooling, and seal design. |
In the food, beverage, and pharmaceutical industries, you need to consider the production medium, CIP/SIP conditions, hygienic design, and applicable regulations—rather than simply selecting materials based on whether they are labeled as food-grade.
Food Contact Compliance: Materials must meet food-grade requirements; while 316L is commonly used, it does not automatically ensure compliance with hygiene standards—attention must also be paid to surface finish, structure, and resistance to cleaning.
Elastomer Selection: Food-grade EPDM, FKM, and other materials may be selected based on the medium and cleaning conditions; specific grades and supplier documentation must be verified.
Hygienic Design: The structure should minimize residue and dead spots; if there are dead spots that cannot be cleaned, hygiene requirements may not be met even if the materials are compliant.
Stricter Requirements: Pharmaceutical equipment must simultaneously prevent liquid leakage and the ingress of external air and microorganisms; the reliability of the seal directly affects the sterility barrier.
Three Criteria: Materials must be compatible with the pharmaceutical solution and cleaning media; the structure must be cleanable and sterilizable; and the equipment must maintain continuous contamination control during operation.
Double-ended Seals: For high-demand aseptic equipment, sanitary double-ended seals can be selected; these create a positive-pressure barrier using an isolation fluid or sterile gas to reduce the risk of external contamination.
Selection Principles: Not all pharmaceutical equipment requires double-ended seals; the decision should be based on the product’s contamination risk, process conditions, and aseptic grade.
The food and pharmaceutical industries are subject to various regulations and technical standards. You must first identify the region where the equipment will be used, the product type, and the hygiene level before determining which requirements apply to mechanical seals.
Common regulations and standards include:
| Regulation / Standard | Main Focus | What to Confirm |
|---|---|---|
| FDA 21 CFR 177.2600 | Requirements for reusable rubber articles in food-contact applications. | Verify that wetted rubber formulations and finished parts meet applicable requirements. |
| EC 1935/2004 | General EU safety requirements for food-contact materials. | Confirm that food-contact materials meet applicable requirements. |
| EC 2023/2006 | Good Manufacturing Practice for food-contact materials. | Check supplier quality control and documentation systems. |
| EHEDG GL 25 | Mechanical seal design and selection for hygienic and aseptic applications. | Confirm cleanability, sterilizability, and hygienic design. |
| ASME BPE | Materials, design, fabrication, and hygienic requirements for bioprocess equipment. | Verify applicable project requirements for equipment and seal components. |
When selecting materials for mechanical seals, the material selection matrix is only a preliminary screening tool and does not directly prove that a particular mechanical seal material is suitable for actual operating conditions. Ultimately, it is necessary to verify chemical compatibility, material grades, and the operating limits of the entire mechanical seal assembly.
When creating a material selection matrix, you can start by dividing the mechanical seal into three main material components: the sealing faces, the auxiliary seals, and the metal components.
| Fluid / Condition | Face Material Options | Elastomer Options | Metal Options | Key Checks |
|---|---|---|---|---|
| Clean Water / Mild Service | Carbon/Ceramic, Carbon/SiC | EPDM, some NBR grades | 304, 316 Stainless Steel | Temperature, lubrication, and compatibility. |
| Mineral Oils | Carbon/SiC, Carbon/WC | NBR, FKM | 316 Stainless Steel | Oil additives, temperature, and compatibility. |
| Sandy / Abrasive Fluids | SiC/SiC, suitable WC combinations | Selected by fluid compatibility | Selected by corrosion conditions | Particle properties, wear, and lubrication. |
| Corrosive Chemicals | Suitable SiC grades | EPDM, FKM, or FFKM | 316, Duplex Stainless Steel, or Nickel Alloys | Chemical composition, concentration, and temperature. |
| High-Temperature Service | Selected by friction, heat load, and fluid. | Heat-resistant compatible grades | Selected by strength and corrosion requirements | Long-term temperature, thermal cycling, and cooling. |
| Food / Pharmaceutical Fluids | Process-compatible face combinations | Materials with required compliance documentation | 316L or suitable hygienic materials | Cleaning, sterilization, hygienic design, and compliance. |
After completing the initial screening, you’ll need to confirm with the mechanical seal supplier whether the specific material combination meets the actual operating conditions.
| Required Information | Details | Main Purpose |
|---|---|---|
| Fluid Information | Fluid name, composition, concentration, and additives. | Confirm chemical compatibility. |
| Operating Conditions | Pressure, temperature, speed, and operating ranges. | Confirm operating limits. |
| Solids Content | Particle type, size, concentration, and crystallization tendency. | Evaluate abrasion and clogging risks. |
| Equipment Information | Pump model, shaft size, seal chamber, and installation dimensions. | Confirm structural and installation compatibility. |
| Operating Pattern | Continuous, frequent start-stop, or intermittent operation. | Evaluate thermal cycling and lubrication risks. |
| Special Requirements | CIP, SIP, food-contact, and other applicable requirements. | Verify materials and compliance documents. |
Incorrect selection of mechanical seal materials is often not due to poor material quality, but rather because the material properties do not match the actual operating conditions.
| Common Mistake | Why It Fails | Correct Approach |
|---|---|---|
| 1. Assuming Harder Is Always Better | Hard faces can still overheat, crack, or wear under poor lubrication. | Select soft-hard or hard-hard pairs based on abrasion and lubrication. |
| 2. Ignoring Chemical Compatibility | O-rings, springs, and metals may swell, corrode, or leak. | Check fluid composition, concentration, temperature, and all wetted materials. |
| 3. Checking Only Normal Operation | Startup, shutdown, cleaning, and pressure changes may cause dry running or deposits. | Evaluate normal, extreme, startup, and shutdown conditions. |
| 4. Assuming Higher Price Means Better | Expensive materials may increase cost without improving performance. | Choose materials that match the actual operating conditions. |
| 5. Ignoring Solids and Lubrication | Particles cause wear or sticking; poor lubrication causes heat and cracking. | Check solids and lubrication; use suitable materials, designs, and support systems. |
| 6. Changing Materials Without Root Cause Analysis | Vibration, misalignment, installation errors, or vaporization may cause repeat failures. | Inspect failed seals and operating data before changing materials. |
No single material is suitable for all operating conditions. Carbon/graphite and silicon carbide (Carbon/SiC) are common and widely used face combinations that offer good friction characteristics, wear resistance, and thermal conductivity. However, the final selection must still be based on the medium, temperature, pressure, and lubrication conditions.
When operating conditions prioritize chemical resistance, wear resistance, and thermal conductivity, silicon carbide (SiC) should be considered first. If significant mechanical shock is present, certain grades of tungsten carbide (WC) may be more suitable. The specific choice also requires confirmation of the material grade and media compatibility.
“Soft-hard” pairings refer to combinations of carbon graphite with hard materials such as ceramics or silicon carbide (SiC), which are typically suitable for clean, well-lubricated liquids. “Hard-hard” pairings refer to configurations where both seal faces are made of hard materials, such as SiC/SiC. These are generally more suitable for certain abrasive media but require more stringent lubrication conditions.
EPDM (ethylene propylene diene monomer) is typically the material of choice for hot water and certain steam applications. However, not all EPDM grades are suitable for high-temperature steam; the manufacturer’s specifications regarding temperature, pressure, and contact time must be verified.
No. Different chemical media have varying degrees of corrosiveness, and even materials with good corrosion resistance, such as silicon carbide or FFKM, have application limitations. You need to verify chemical compatibility based on the medium’s composition, concentration, temperature, and specific material grade.
Dry running deprives the sealing faces of necessary lubrication and cooling, which can lead to friction-induced overheating, abnormal wear, or cracking. While carbon graphite has some self-lubricating properties, standard mechanical seals cannot operate under dry conditions for extended periods. If dry running cannot be avoided, select a specialized seal explicitly approved by the manufacturer for the corresponding dry operating conditions.
Not necessarily. For highly abrasive media, hard-on-hard combinations such as SiC/SiC are generally worth considering. However, the decision must also take into account particle hardness, size, concentration, and lubrication conditions. Severe abrasive conditions may also require specialized seal designs or auxiliary flushing measures.
This may lead to corrosion or wear of the seal faces, swelling or hardening of O-rings, and corrosion or even fracture of metal springs, ultimately resulting in leaks and equipment downtime. Therefore, during the selection process, the compatibility of the seal faces, elastomers, and metal components with the actual medium and operating conditions must be verified individually.
When selecting mechanical seal materials, you can’t just look at parameters like wear resistance, corrosion resistance, and temperature resistance—the key is to ensure they match the actual operating conditions. From face materials such as carbon graphite, ceramics, silicon carbide, and tungsten carbide, to elastomers like EPDM and FKM and metal components, each material has its own strengths, but there are also situations where they aren’t suitable.
As a professional pump components supplier, Sakowitz can help you select the appropriate mechanical seal materials and components based on your specific operating conditions. If you’re looking for a reliable sealing solution, contact Sakowitz directly.
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