Evaluating the thermal, mechanical and swelling behavior of novel silicone and polyurethane additively manufactured O-rings in the presence of organic liquids and military fuels

This work investigates the physical properties and swelling behavior of additively manufactured (AM) and traditionally manufactured (TM) polyurethane (PU) and silicone O-rings when exposed to organic liquids and military fuels. Polymer properties were explored using differential scanning calorimetry, thermal gravimetric analysis, and tensile testing, and two AM print orientations (vertical and horizontal) were investigated. The AM polyurethane vertical and horizontal O-rings formed from a selective laser sintering (SLS) process had similar thermal features to each other and differed slightly from the un-sintered polymer in the temperature at which the greatest rate of mass loss occurred in the TGA analysis. The thermal features of the AM silicone O-rings formed using stereolithography (SLA) were more similar to those of a commercial soft silicone than to those of a commercial high purity silicone. The horizontal print orientation for each polymer had a higher tensile strength than its respective vertically oriented print. A 1-week exposure of the AM O-rings to the various organic liquids reduced the tensile strength of AM O-rings by as much as 80% (tensile strength exposed/tensile strength unexposed = 0.2). Polyurethane AM O-rings swelled from 3 to 74% with the greatest swelling occurring from exposure to acetone. Silicone AM O-rings swelled from 13 to 258% with the greatest swelling occurring from exposure to iso-octane. In general, the commercial O-rings swelled less than their AM counterparts, had higher tensile strengths, and had smoother surfaces. The maximum swelling for the PU O-rings occurred at an overall Hansen solubility parameter (HSP) between 18 and 20 MPa 1/2 , while the maximum for silicone occurred at an HSP of 14.3 MPa 1/2 . These values are consistent with literature values, which can vary widely.