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Additively Manufactured O-rings: Tensile Strength and Swelling Behavior in the Presence of Gasoline and Surrogate Mixtures

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Abstract

This work investigates the swelling and physical properties of additively manufactured (AM) acrylate and traditionally manufactured (TM) O-rings when exposed to gasoline and organic mixtures. Fuel chemical compositions were determined using gas chromatography/mass spectrometry. Polymer properties were found using differential scanning calorimetry, thermal gravimetric analysis, and tensile testing. Exposure to gasoline for 24 h caused the AM and TM O-ring to lose from 54 to 80% of their unexposed failure strength. AM O-ring failure strength varied more (~ 20%) than TM O-rings (~ 7%). AM O-rings swelled from 46 to 110% with greater swelling in E10 than in E85 or ethanol-free gasolines. Volume changes ranged from −5 to 175% for commercial polymers. Aromatic compounds increased O-ring swelling. For ternary mixtures with 30% toluene, decane, and ethanol, increasing the ethanol up to mass 35% increased the swelling from 30 to 100 vol.%, after which the swelling remained level. Subsequent fuel evaporation from the polymers returned most of them to their original size and tensile strength, suggesting that the 24-h exposure caused no permanent damage. One AM O-ring exposed to 30% toluene/70% ethanol showed visible structural changes accompanied by a tensile strength less than half that of those with no visible changes.

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Acknowledgments

This work was supported by a grant from Northrup Grumman. The authors thank Mr. Andrew Pullen for making the tensile tester O-ring half-shell apparatus.

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Authors and Affiliations

  1. Chemistry Department U. S. Naval Academy, 572M Holloway Road, Annapolis, MD, 21402, USA

    Nicholaus J. Adams, David P. Durkin & Dianne J. Luning Prak

  2. Independent Researcher, 444 Washington Blvd, Jersey City, NJ, 07310, USA

    Jeanne L. VanBriesen

  3. Mechanical Engineering Department U. S. Naval Academy, 590 Holloway Road, Annapolis, MD, 21402, USA

    Brad W. Baker, Jim S. Cowart & Joel J. Schubbe

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  1. Nicholaus J. Adams
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Adams, N.J., Baker, B.W., VanBriesen, J.L. et al. Additively Manufactured O-rings: Tensile Strength and Swelling Behavior in the Presence of Gasoline and Surrogate Mixtures. J. of Materi Eng and Perform 32, 803–815 (2023). https://doi.org/10.1007/s11665-022-07124-5

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