Additive manufacturing (AM) processes can be used to make engine O-rings under emergency conditions when the part is not available and engine operation is essential to complete a mission. The swelling behaviors of O-rings made from AM (Flex 80A), commercially-produced polymers (Buna N, silicone, EPDM, neoprene, AFLAS, polyurethane, and acrylate), and Ford O-rings were measured after exposure to gasoline, individual gasoline components, and solvents. The swelling was determined using mass differences and images of the O-rings before and after exposure. The tensile strengths of a subset of the O-rings was determined using an ADMET MTest Quattro tensile tester. The swelling behavior of the commercial O-rings followed the pattern expected using the Hansen solubility parameter, and the AM O-ring swelling pattern was similar to that of commercially-made acrylate O-rings. Tensile strengths of AM O-rings decreased after exposure to the fuel and fuel components. Evaporation returned many O-rings to the original tensile strength, but permanent damage was found in some cases.

Swelling and tensile strength of additively manufactured and commercially produced O-rings upon exposure to gasoline and gasoline components

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