UK OFFICIAL

Defence Standard 02-337 Part 1

Issue 2 Date: 23 June 2014
_______________________________________
Requirements for Elastomeric Toroidal
Sealing Rings (‘O’ Rings)
Part 1 – General and Surface Finish
Standards Relative to Manufacturer
_______________________________________

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Def Stan 02-337 Part 1 Issue 2

Contents

Foreword ...........................................................................................................................................................v
0 Introduction............................................................................................................................................vi
1 Scope.......................................................................................................................................................1
2 Warning ...................................................................................................................................................1
3 Normative References ...........................................................................................................................2
4 Definitions ...............................................................................................................................................3
5 Abbreviations..........................................................................................................................................4
6 General ....................................................................................................................................................4
6.1 Dimensions ........................................................................................................................................4
6.2 Measurement .....................................................................................................................................4
6.3 Toroidal Sealing O-ring Material Classification .............................................................................5
6.3.1 Use of Nomenclature ...................................................................................................................5
6.3.2 Commonly Used Materials ..........................................................................................................5
6.4 Acceptance of Material .....................................................................................................................6
6.4.1 Acceptance Process ....................................................................................................................6
6.4.2 Records of Material Acceptance ................................................................................................6
6.4.3 Change of Material Procedure ....................................................................................................6
6.4.4 Age upon Delivery........................................................................................................................6
6.5 Test Samples .....................................................................................................................................7
6.5.1 Sheet Dimensions ........................................................................................................................7
6.5.2 Option for Cylindrical Buttons....................................................................................................7
6.5.3 Vulcanizing of Sample Sheets ....................................................................................................7
6.5.4 Selection of Samples ...................................................................................................................7
6.6 Test Requirements ............................................................................................................................7
6.6.1 Demonstration of Consistency and Type-acceptance Tests...................................................7
6.6.2 Common Test Requirements ......................................................................................................7
6.6.3 Production Quality and Routine Tests.......................................................................................7
6.6.4 Test Tolerances and Test Requirements for Specific Materials .............................................7
6.7 Relationship of Test Procedures .....................................................................................................8
6.7.1 Hardness .......................................................................................................................................8
6.7.2 Density ..........................................................................................................................................8
6.7.3 Tensile Strength and Elongation at Break.................................................................................8
6.7.4 Compression Set..........................................................................................................................8
6.7.5 Volume Change (Resistance to fluids) ......................................................................................8
6.7.6 Resistance to Low Temperature.................................................................................................8
6.7.7 Adhesion to and Corrosion of Metals ........................................................................................9
6.7.8 Dry Heat Air-Ageing Test.............................................................................................................9

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6.8 Enquiries for Service Fluid Specifications and Test Samples of Fluids .....................................9
7 Surface Finish Quality Acceptance Criteria ........................................................................................9
7.1 Mandatory Requirements for ‘Quality Grade S’ .............................................................................9
7.2 Acceptance Criteria...........................................................................................................................9
8 Nitrile (Medium) Toroidal Sealing O-Rings for General Engineering Applications .........................9
8.1 System Applications .........................................................................................................................9
8.2 Temperature Range Qualification....................................................................................................9
8.3 Pressures and the Introduction of Anti-extrusion Rings ............................................................10
8.4 Preferred Range ..............................................................................................................................10
8.5 Material Acceptance, Test and Tolerance Requirements ...........................................................10
8.6 Production Quality Control Test....................................................................................................10
8.7 Routine Tests of Finished O-rings ................................................................................................11
9 Nitrile (High) Toroidal Sealing O-Rings Applications .......................................................................12
9.1 Qualification of Application ...........................................................................................................12
9.2 Pressures and the Introduction of Anti-extrusion Rings ............................................................12
9.3 Preferred Range ..............................................................................................................................12
9.4 Material Acceptance, Test and Tolerance Requirements ...........................................................12
9.5 Production Quality Control Test....................................................................................................12
9.6 Routine Test of Finished O-rings ..................................................................................................12
10 Fluorocarbon Toroidal Sealing O-Ring Applications .......................................................................13
10.1 Temperature Range.........................................................................................................................13
10.2 Pressures and the Introduction of Anti-extrusion Rings ............................................................13
10.3 Preferred Range ..............................................................................................................................14
10.4 Material Acceptance, Test and Tolerance Requirements ...........................................................14
10.5 Oxygen Ageing Test........................................................................................................................14
10.6 Production Quality Control Test....................................................................................................14
10.7 Colour Identification .......................................................................................................................14
10.8 Routine Tests of Finished O-rings ................................................................................................16
11 Hydrogenated Nitrile (Medium) Toroidal Sealing O-Rings for High Endurance ............................16
11.1 System Applications .......................................................................................................................16
11.2 Temperature Range Qualification..................................................................................................16
11.3 Pressures and the Introduction of Anti-extrusion Rings ............................................................16
11.4 Preferred Range ..............................................................................................................................16
11.5 Material Acceptance, Test and Tolerance Requirements ...........................................................17
11.6 Production Quality Control Test....................................................................................................17
11.7 Colour Identification .......................................................................................................................17
11.8 Routine Testing of Finished O-rings .............................................................................................19
12 Hydrogenated Nitrile (High) Toroidal Sealing O-Rings for High Endurance..................................20
12.1 Qualification of Application ...........................................................................................................20
12.2 Temperature Range Qualification..................................................................................................20

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12.3 Pressures and the Introduction of Anti-extrusion Rings ............................................................20

12.4 Preferred Range ..............................................................................................................................20
12.5 Material Acceptance, Test and Tolerance Requirements ...........................................................20
12.6 Production Quality Control Test....................................................................................................21
12.7 Colour Identification .......................................................................................................................22
12.8 Routine Testing of Finished O-rings .............................................................................................22
13 Anti-Extrusion Rings and Housings (Metric and Imperial) ..............................................................22
14 Packaging..............................................................................................................................................22
14.1 Mandatory Individual Packaging Requirements ..........................................................................22

Tables

Table 1 - Material Types and General Description ........................................................................................5

Table 2 - Test Requirements – Medium Nitrile.............................................................................................11
Table 3 - Test Tolerances for Finished O-rings – Medium and High Nitrile..............................................11
Table 4 - Test Requirements – High Nitrile ..................................................................................................13
Table 5 – Test Requirements - Fluorocarbon ..............................................................................................15
Table 6 - Test Tolerances for Finished O-rings - Fluorocarbon ................................................................16
Table 7 - Test Requirements – Medium AC HNBR ......................................................................................18
Table 8 - Test Requirements for Finished O-rings - Medium AC HNBR and High AC HNBR .................19
Table 9 - Test Requirements – High AC HNBR............................................................................................21

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Def Stan 02-337 Part 1 Issue 2

Foreword
AMENDMENT RECORD

Amd No. Date Text Affected Signature and Date

REVISION NOTE
Issue 2 of this Standard is a revision of Issue 1 of Defence Standard 02-337 (NES 337) Part 1 Issue 1,
publication date 1 April 2000 to reflect the changes required from Product Qualification Approval (PQA)
procedures to Product Conformity Certification (PCC).

HISTORICAL RECORD
This standard supersedes the following:

Def Stan 02-337 Part 1 Issue 1 April 2000

NES 337 Part 1 Issue 2 May 1994
NES 337 Part 1 Issue 1 November 1984
DGW(N) Procedure Specification 25077/R1
DGW(N) DOD 1/193C
GMES 2 Section 3.3
DG Ships 273
DG Ships 269A
DG Ships 223

a) This standard provides requirements and guidance for the management and production of Defence
Standards.
b) This standard has been produced on behalf of the Ministry of Defence (MOD) by British Fluid power
Association (BFPA) for DES Ships MPS-MET-FSG.
c) This standard has been reached following broad consensus amongst the authorities concerned with
its use and is intended to be used whenever relevant in all future designs, contracts, orders etc. and
whenever practicable by amendment to those already in existence. If any difficulty arises which
prevents application of the Defence Standard (DStan) shall be informed so that a remedy may be
sought.
d) Please address any enquiries regarding the use of this standard in relation to an invitation to tender or
to a contract in which it is incorporated, to the responsible technical or supervising authority named in
the invitation to tender or contract.
e) Compliance with this Defence Standard shall not in itself relieve any person from any legal obligations
imposed upon them.
f) This standard has been devised solely for the use of the MOD and its contractors in the execution of
contracts for the MOD. To the extent permitted by law, the MOD hereby excludes all liability
whatsoever and howsoever arising (including, but without limitation, liability resulting from negligence)
for any loss or damage however caused when the standard is used for any other purpose.

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0 Introduction
The Ministry of Defence would like to express its thanks for the preparation of this Standard to:

British Fluid Power Association (BFPA) Yvonne Pearman

Jemlyn Limited Jerry Hughes

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Requirements for Elastomeric Toroidal Sealing Rings (O-

Rings)
Part 1 – General and Surface Finish Standards Relative to
Manufacture

1 Scope
1.1 This part of the Def Stan comprises:

a) general information relative to the manufacture

b) material acceptance and test requirements peculiar to the elastomeric toroidal sealing O-rings of a
relevant material composition

c) surface finish standards common to all elastomeric toroidal sealing O-rings

d) test tolerances

e) system and equipment applications

1.2 This Def Stan is applicable to all HM surface ships, submarines, ship and submarine systems
including weapon systems and associated equipments

1.3 Exemptions: examples of the applications which will not be satisfied by the materials specified within
this Def Stan are:

a) explosives

b) special electrical properties

c) those where there are environmental temperature requirements below -30°C

d) Where contract requirements deviate from this standard.

2 Warning
2.1 The Ministry of Defence (MOD), like its contractors, is subject to both United Kingdom and European
laws regarding Health and Safety at Work. Many Defence Standards set out processes and procedures that
could be injurious to health if adequate precautions are not taken. Adherence to those processes and
procedures in no way absolves users from complying with legal requirements relating to Health and Safety at
Work.

2.2 This Def Stan has been written and shall take into account the policy stipulated within JSP 430 –
Management of Ship Safety and Environmental Protection.

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3 Normative References
3.1 The publications shown below are referred to in the text of this standard. Publications are grouped
and listed in alpha-numeric order.

Note: Def Stan’s can be downloaded free of charge from the DStan web site by visiting
<http://www.dstan.dii.r.mil.uk> for those with rli access or <https://www.dstan.mod.uk> for all other
users. All referenced standards were correct at the time of publication of this standard (see 3.2, 3.3 & 3.4
below for further guidance), if you are having difficulty obtaining any referenced standard please contact
the DStan Helpdesk in the first instance.

Number Title
AQAP 2120 NATO Quality Assurance Requirements for Production
BS 4F 68:2002 Controlled storage of vulcanized rubbers for use in aerospace applications
BS 903-1:1995 Physical testing of rubber
Part 1 Guide to the selection and use of methods of test for rubber
BS 4518:1982 Specification for metric dimensions for toroidal sealing rings (O-rings) and
their housings
BS 5106:1988 Specification for dimensions of spiral anti-extrusion back-up rings and their
housings
BS ISO 37:2011 Rubber, vulcanized or thermoplastic – Determination of tensile stress-strain
properties
BS ISO 48:2010 Rubber, vulcanized or thermoplastic – Determination of hardness (hardness
between 10 IRHD and 100 IRHD)
BS ISO 188:2011 Rubber, vulcanized or thermoplastic – Accelerated ageing and heat
resistance tests
BS ISO 812:2011 Rubber, vulcanized or thermoplastic – Determination of low-temperature
brittleness
BS ISO 815-1:2008 Rubber, vulcanized or thermoplastic – Determination of compression set
Part 1 At ambient or elevated temperatures
BS ISO 1629:1995+A1:2007 Rubber and latices – Nomenclature
BS ISO 1817:2011 Rubber, vulcanized – Determination of the effect of liquids
BS ISO 2781:2008+A1:2010 Rubber, vulcanized or thermoplastic – Determination of density
BS ISO 3601-1:2012 Fluid power systems
Part 1 Inside diameters, cross sections, tolerances and designation
codes
BS ISO 3601-2:2008 Fluid power systems
Part 2 Housing dimensions for general applications
BS ISO 3601-3:2005 Fluid power systems
Part 3 Quality acceptance criteria
BS ISO 3601-4:2008 Fluid power systems
Part 4 Anti-extrusion rings (back-up rings)
BS ISO 6505:2005 Rubber, vulcanized or thermoplastic – Determination of tendency to adhere
to and corrode metals
BS ISO 23529:2010 Rubber – General procedures for preparing and conditioning test pieces for
physical test methods
ISO 1432:2013 Rubber, vulcanized or thermoplastic – Determination of low temperature
stiffening (Gehman test).

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Number Title
ISO 3302-1:1996/Amd 1:2001 Rubber – Tolerances for products
Part 1 Dimensional tolerances
ISO 3601-5:2002 Fluid power systems – Part 5: Suitability of elastomeric materials for
industrial applications
Def Stan 02-337 Requirements for elastomeric toroidal sealing O-rings
Part 2 List of preferred elastomeric toroidal sealing O-rings
Part 3 Anti-extrusion rings (back-up rings)
Def Stan 81-60 Packaging of gaskets, seals, O-rings, grommets and similar material
Def Stan 91-4 Fuel, naval, distillate NATO Code: F-76 joint service designation
DIESO F-76
JSP 430: 1 August 2011 Management of Ship Safety and Environmental Protection.

Note In line with MOD policy 79% of normative references listed within this partare national and international
standards

3.2 Reference in this Standard to any normative references means in any Invitation to Tender or contract
the edition and all amendments current at the date of such tender or contract unless a specific edition is
indicated. Care should be taken when referring out to specific portions of other standards to ensure that they
remain easily identifiable where subsequent amendments and supersession’s might be made. For some
standards the most recent editions shall always apply due to safety and regulatory requirements.

3.3 In consideration of clause 3.2 above, users shall be fully aware of the issue, amendment status and
application of all normative references, particularly when forming part of an Invitation to Tender or contract.
Correct application of standards is as defined in the ITT or contract.

3.4 DStan can advise regarding where to obtain normative referenced documents. Requests for such
information can be made to the DStan Helpdesk. Details of how to contact the helpdesk are shown on the
outside rear cover of Defence Standards.

4 Definitions
For the purpose of this standard, the definitions shown below apply.

4.1
Apparent hardness
The hardness of rubber as measured on non-standard test pieces

4.2
Batch
The product of one mixing operation in an intermittent process. It is defined by means of an agreed code or
number on each individual and multi-packaged container for the item.

4.3
Cure date
The date on which the moulding and vulcanization processes occurred. This may be expressed in terms of
the quarter and year in which event the date to be applied is the first day of the quarter.

4.4
Factice
A substance produced by vulcanizing vegetable oils with sulphur or sulphur chloride. Originally used as a
rubber substitute.

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4.5
Flash
Surplus material from the mould on closure under pressure.

4.6
Standard hardness
Measurement of hardness. International Rubber Hardness Degrees (IRHD), the magnitude of which is
derived from the depth of penetration of a special indentor into a test piece under specified conditions see
BS ISO 48 for scale.

5 Abbreviations
IRHD International rubber hardness degrees

MOD DA Ministry of Defence Design Authority

6 General

6.1 Dimensions

The internal diameter and the section diameter of the toroidal sealing O-rings shall comply
with the range of sizes and tolerances given within:

a) BS ISO 3601-1 Class A

b) BS 4518

6.2 Measurement

a) The measurement of dimensions shall be carried out in accordance with ISO 3302-1:-

1) measurements shall not to be made until sixteen (16) hours have elapsed after the moulding
operation, this minimum time being extended to seventy-two (72) hours in the case of a dispute

2) measurements shall be made after conditioning at a temperature of 23°C ±2°C in accordance

with BS ISO 23529

3) measurements shall be made after the removal of flash and other surface defects

4) toroidal sealing rings shall not have been subjected to adverse storage conditions prior to
measurement and shall not to be distorted during measurement

b) Measurements may be made by one or more of the following types of instrument:-

1) micrometer dial gauge: the plunger of which shall not exert a pressure on the rubber greater
than 21 kPa

2) an approved optical measuring instrument

3) gauges for upper and lower limits appropriate to the dimensions being measured

c) Measuring methods applicable to 6.2b) above are contained within BS ISO 23529.

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6.3 Toroidal Sealing O-ring Material Classification

6.3.1 Use of Nomenclature

a) The nomenclature used within this Def Stan as shown within Table 1 column 3 shall be used when
marking or identifying packaged sealing O-rings.

b) Nitrile (medium) and (high) are general terms that do not imply any specific Acrylonitrile Content.

6.3.2 Commonly Used Materials

Table 1 - Material Types and General Description

(The Table makes allowance for viability of registered application requirement)

Material type Code General Description

Acrylonitrile-Butadiene NBR Nitrile (low)
NBR Nitrile (medium)
NBR Nitrile (high)
NBR Nitrile (low compression set)
NBR Nitrile (electrical properties)
Chloroprene (Neoprene)1 CR Chloroprene
2
Fluorinated Hydrocarbon (Viton®) FKM Fluorocarbon
Methyl-Vinyl Siloxane VMQ Silicone
Natural rubber NR Natural rubber
Isobutylene-isoprene IIR Butyl
Ethylene propylene rubber EPM, EPDM EP rubber
Fluorosilicone FVMQ Fluorosilicone
Medium Acrylonitrile content Hydrogenated Medium AC Hydrogenated Nitrile (medium)
Acrylonitrile-Butadiene rubber HNBR elastomer
High Acrylonitrile content Hydrogenated High AC Hydrogenated Nitrile (high)
Acrylonitrile-Butadiene rubber HNBR elastomer
Chlorosuplhonyl polyethylene CSM Hypalon®3

Note 1: 1, 2 and 3 = Trade names.

Note 2: Nitrile (medium and high) and Fluorocarbon are the most widely used materials in main hydraulic
and high pressure air systems. For their particular applications (see clauses 8 to 10)

Note 3: Refer to BS ISO 1629

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6.4 Acceptance of Material

6.4.1 Acceptance Process

a) Manufacturers providing rubber toroidal sealing O-rings in accordance with this Def Stan shall comply
with AQAP 2120.

Note: Accredited third party (or Government issued) Quality Management System (QMS) certification which
includes an appropriate scope to meet the requirement. In the event that no certification is held, the
Company must be able to demonstrate that they operate and maintain a QMS acceptable to the
Department for this requirement.

b) Before a rubber compound can be accepted as complying with this Def Stan, it shall receive MOD
Design Authority Acceptance. Upon completion of all qualification acceptance tests, the manufacturer
shall submit the results to the MOD Design Authority.

c) Reports shall be certified by the manufacturer’s quality manager. Standard rubber test sheets in
accordance with (6.5.1) shall be made available to MOD Design Authority for possible independent
assessment.

d) Following acceptance of a material the manufacturer shall supply details of its composition in
confidence, to the MOD Design Authority. A Letter of Acceptance shall be issued which will remain
valid for five (5) years, after which time re-acceptance is required. Re-acceptance shall be the
responsibility of the manufacturer.

e) If it can be proven that compositions and production methods have not changed, it may be possible to
give renewed Certification without carrying out the full testing procedure.

6.4.2 Records of Material Acceptance

a) The MOD Design Authority shall maintain a record of each accepted material. The record shall be
held for a minimum period of three (3) years following expiry of the manufacturer’s five-year
acceptance, or MOD extension, whichever is the lower.

b) The materials covered by this Def Stan are materials compounded and cured to meet requirements
within (6.6.2 to 6.9) and as amplified within clauses 8 to 12.

6.4.3 Change of Material Procedure

a) If a change is made in the formulation of the material after the formal acceptance by the MOD Design
Authority, the new formulated material shall be subjected to repeat acceptance tests to the satisfaction
of the MOD Design Authority and the outcome recorded in accordance with (6.4.1).

b) The manufacturer shall declare to the MOD Design Authority the percentage composition by weight of
the constituents of compounds type-accepted to this Def Stan. No factice, reclaimed or ground
vulcanized waste is to be used. The ingredients shall be of rubber quality grade and free from foreign
matter.

6.4.4 Age upon Delivery

The age upon delivery of the Toroidal sealing O-rings provided in accordance with this Def Stan shall not
exceed twelve (12) months from the date of cure. The first day of the quarter shall apply when cure dates
are based upon quarterly cycles.

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6.5 Test Samples

6.5.1 Sheet Dimensions

A two-thickness sheet of the following dimensions shall be prepared from each batch of rubber mix for
testing to the requirements within (6.7.1 to 6.9). Each sheet shall be approximately 250mm square with a
section along one side 35mm to 50mm wide and 6,3mm ±0,15mm thick. The remainder of the sheet shall be
2,00mm ±0,15mm thick.

6.5.2 Option for Cylindrical Buttons

For the purpose of compression set tests, a part of the 6,3mm section shall, if preferred by the purchaser, or
manufacturer, be moulded in the form of cylindrical buttons conforming to the Type 1 test piece requirements
defined within BS ISO 815-1. For buttons so moulded the cavities shall be individually charged with pellets
and not formed by the flow of excess rubber from the remainder of the mould. The minimum number of
buttons moulded shall be nine (9) and these shall be in a group at one end of the 6,3mm section.

6.5.3 Vulcanizing of Sample Sheets

The test sheet shall be vulcanized at a temperature appropriate for the rubber mix. No additional
vulcanization shall be applied to the thicker, or button, section of the sheet.

6.5.4 Selection of Samples

a) Sample toroidal sealing O-rings shall be taken from each lot produced from each batch of rubber mix,
for routine density and hardness tests specified (see clauses 8 to 12).

b) The number and the range of sizes of the samples selected for production quality control and routine
testing shall be decided by the manufacturer. The sample selected shall not be used for more than
one of the test procedures.

6.6 Test Requirements

6.6.1 Demonstration of Consistency and Type-acceptance Tests

To demonstrate that the product is consistent in quality and complies with this Def Stan the following Type-
accepted Tests shall be carried out in accordance with (6.7.1 to 6.9) on selected samples of the specified
materials: hardness, density, tensile strength, elongation at break, compression set, volume change,
resistance to low temperature, adhesion and corrosion of metals, air-ageing, and visual inspection.

6.6.2 Common Test Requirements

The common requirements for the testing of fully compounded un-vulcanized rubber, and the reduced rubber
testing procedure for production quality control, are contained within BS 903-1.

6.6.3 Production Quality and Routine Tests

Production quality tests shall include: hardness, density, compression set and volume change in a specified
standard test fluid as defined within clauses 8 to 12. Routine tests on samples of finished O-rings shall be as
specified also within clauses 8 to 12.

6.6.4 Test Tolerances and Test Requirements for Specific Materials

The test tolerances and the additional tests applicable to particular types of material are specified within
clauses 8 to 12.

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6.7 Relationship of Test Procedures

The test procedures specified within (6.7.1 to 6.9) relate to samples prepared from the test sheets described
within (6.5.1). Routine tests shall also be required on samples of finished O-rings.

6.7.1 Hardness

The method of hardness testing, after vulcanisation, shall be by measurement of standard hardness in
accordance with BS ISO 48 Method Nusing the sheet stipulated within (6.5.1). Tests shall also be carried
out on complete O-rings and the apparent hardness shall be established in accordance with BS ISO 48
Method CM, except that wax shall not be used to locate the O-rings under test. For all test purposes the
minimum time lapse between vulcanisation and testing shall be sixteen (16) hours, the maximum time
between vulcanization and testing shall be four (4) weeks.

6.7.2 Density

No values are specified for density but a value is to be established for the particular material composition in
order to provide a control when a series of batches of rubber mix are being provided to the same
composition. The test method is to be in accordance with BS ISO 2781, Method A. Where size permits the
test piece is to consist of a complete toroidal sealing ring. The density is to be as specified (Mg/m3) by the
O-ring manufacturer and the tolerance for subsequent batches is to be within ±0,02 of this agreed value.

Note: For silicone and fluorosilicone rubbers, this may be within ±0,05 of the agreed value.

6.7.3 Tensile Strength and Elongation at Break

Tensile strength (MPa) and the percentage elongation at break shall be established on Type 2 dumb-bell
shaped test pieces 2,0mm thick in accordance with BS ISO 37.

6.7.4 Compression Set

Measurement of compression set shall be made on lubricated Type 1 test pieces (see BS ISO 815-1. The
duration of the test shall be for a period of twenty-two (22) to twenty-four (24) hours after which time the test
piece shall be allowed to recover freely at a temperature of 23°C ±2°C for thirty (30) minutes before
measurements are made.

6.7.5 Volume Change (Resistance to fluids)

The percentage swell that the test piece undergoes after immersion in a test fluid shall be evaluated by the
volumetric method within BS ISO 1817. Tests shall also be required to assess the volume change with the
service fluids listed within clauses 8 to 12. The volume change tolerances are also specified within clauses 8
to 12.

Note: All results are to be accompanied by the appropriate manufacturers’ data sheet relating to the service fluid
used in the test

6.7.6 Resistance to Low Temperature

a) Tests shall be conducted in accordance with ISO 1432 using Ethanol and CO2, or other suitable
cooling medium fluid, to establish the temperature (°C) at which rigidity modulus does not exceed
70 MPa.

b) A further sample shall be exposed to the low temperature test after it has undergone the volume
change test and this sample shall satisfy the low temperature test requirements.

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6.7.7 Adhesion to and Corrosion of Metals

Tests shall be carried out in accordance with BS ISO 6505. There shall be no corrosion or pitting of the
metals and the vulcanizates shall not adhere to the metal surfaces or show any sign of liquid exudation.
Discolouration of the metal surface shall not be regarded as objectionable.

6.7.8 Dry Heat Air-Ageing Test

Materials shall be aged in air in accordance with BS ISO 188 Method A. Subsequent elongation and tensile
strength measurements performed in accordance with BS ISO 37 shall not be reduced by more than the
relevant percentage stated within clauses 8 to 12.

6.8 Enquiries for Service Fluid Specifications and Test Samples of Fluids

Enquiries about service fluid specifications and the provision of fluid test samples are to be addressed to
Design Authority.

7 Surface Finish Quality Acceptance Criteria

7.1 Mandatory Requirements for ‘Quality Grade S’

The acceptance limits of defined and assessed surface imperfections on all elastomeric toroidal sealing O-
rings shall comply with ‘quality grade S (special)’ as specified within BS ISO 3601-3.

7.2 Acceptance Criteria

O-rings that do not meet the surface finish quality acceptance criteria of clause 7 shall be rejected (i.e. free
from foreign matter and imperfections) which may be detrimental to the performance of the item.

8 Nitrile (Medium) Toroidal Sealing O-Rings for General Engineering Applications

This clause defines the system applications and specific requirements for the four rubber vulcanizates based
upon Medium Acrylonitrile Content (AC) Acrylonitrile-Butadiene rubber (NBR) used during the manufacture
of toroidal sealing O-rings to the requirements of this Def Stan.

8.1 System Applications

NBR O-rings supplied in accordance with the requirements of this Def Stan are suitable for the following
relevant applications:

a) mineral oil hydraulic and lubricating oils (-30°C to +120°C)

b) diesel fuels to Def Stan 91-4 (-30°C to +50°C)

c) water and water Glycols (-30°C to +120°C)

d) pneumatics (-30°C to +30°C)

8.2 Temperature Range Qualification

Nitrile (Medium) O-rings are suitable for operation within the temperature range quoted above but extended
use at either of the range extremes will shorten seal life and reduce sealing efficiency.

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8.3 Pressures and the Introduction of Anti-extrusion Rings

Nitrile (Medium) O-rings are suitable for use at pressures up to and in excess of 100 bar. For pressures
above 100 bar special attention shall be given to the design and dimensions of housing grooves particularly
with regard to dynamic applications. For both dynamic and static applications greater than 100 baranti-
extrusion back-up rings shall be used, see clause 13.

8.4 Preferred Range

The preferred range of Medium Nitrile (Medium AC NBR) O-rings is contained within Part 2 of this Def Stan.

8.5 Material Acceptance, Test and Tolerance Requirements

The material shall be type-accepted in accordance with clause 6. The test tolerances for Nitrile (Medium) O-
rings are specified within Tables 2 and 3.

8.6 Production Quality Control Test

The tests identified by asterisks within Table 2 and complying with clause 8.7, Table 3 shall be conducted to
verify production consistency of the type-accepted materials.

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Table 2 - Test Requirements – Medium Nitrile

Test Tolerances Method

+5 +5 +5 +3
Hardness (IRHD)* 60 70 80 90 see clause 6.7.1
-4 -4 -4 -4
Density (Mg/m3)* ± 0,02 ± 0,02 ± 0,02 ± 0,02 see clause 6.7.2
Minimum tensile strength (MPa)* 8,4 12,6 12,6 12,6
see clause 6.7.3
Minimum elongation at break (%)* 400 250 150 100
Compression set (% maximum)* 30 20 20 20 see clause 6.7.4@ 70°C
Volume change (% maximum) see clause 6.7.5
Volumetric method
1. Standard test fluid* 0 to +30 0 to +30 0 to +30 0 to +25
liquid B
22 hours @ 40°C

2. Service fluids: see clause 6.7.5

• OEP 80 28 days @ 80°C
• OX 40 -2 to +7 -2 to +7 -2 to +7 -2 to +7 28 days @ 40°C
• OM 33, OM 100 and OX 30 28 days @ 100°C
Resistance to low temperature:
°C at which rigidity modulus does see clause 6.7.6
-25 -20 -10 -10
not exceed 70 MPa
Adhesion to and corrosion of see clause 6.7.7
see section 6.7.7
metals 168 hours @ 70°C ±1°C
Dry heat air ageing:
Tensile strength maximum % see clause 6.7.8
-10 -10 -10 -10 168 hours at
change*
100°C ±1°C
Elongation at break maximum %
-30 -30 -30 -30
change*

Note: * These tests shall be performed to verify the production consistency of the type-accepted materials.

8.7 Routine Tests of Finished O-rings

Table 3 - Test Tolerances for Finished O-rings – Medium and High Nitrile

Test Tolerances Method

+5 +5 +5 +5
Apparent Hardness (IRHD) 60 70 80 90 see clause 6.7.1
-8 -8 -8 -8
3
Density (Mg/m ) ± 0,02 ± 0,02 ± 0,02 ± 0,02 see clause 6.7.2

Note: * Table 3 shows the routine tests that shall be carried out on samples of finished Medium and High Nitrile
O-rings to comply with requirements of clause 9.6.

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9 Nitrile (High) Toroidal Sealing O-Rings Applications

This section defines the system applications and specific requirements for the four synthetic rubber
vulcanizates of the High Acrylonitrile Content (AC) Acrylonitrile-Butadiene rubber (NBR) used during the
manufacture of toroidal sealing O-rings where resistance to organic liquids, such as Hydrocarbon fuels and
some synthetic oils is required.

9.1 Qualification of Application

Nitrile (High) O-rings are complementary to those covered within clause 8 and are only used in applications
where the oil resistance capability of the Nitrile (Medium) O-ring does not meet the requirements of the
intended application.

9.2 Pressures and the Introduction of Anti-extrusion Rings

Nitrile (High) O-rings are suitable for use at pressures up to and in excess of 100 bar. For pressures above
100 bar special attention shall be given to the design and dimensions of housing grooves particularly with
regard to dynamic applications. For both dynamic and static applications greater than 100 bar anti-extrusion
back-up rings shall be used, see clause 13.

9.3 Preferred Range

The preferred range of High Nitrile (High AC NBR) O-rings is contained within Part 2 of this Def Stan.

9.4 Material Acceptance, Test and Tolerance Requirements

The material shall be type-accepted in accordance with clause 6. The test tolerances for Nitrile (High) O-
rings are specified within Table 2 except that the volume change test requirements are specified within
Table 4.

9.5 Production Quality Control Test

The tests identified by asterisks within Tables 2 and 4 shall be conducted to verify production consistency of
the type-accepted materials.

9.6 Routine Test of Finished O-rings

For the finished routine test tolerances for samples of Nitrile (High) O-rings, see Table 3.

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Table 4 - Test Requirements – High Nitrile

Test Tolerances Method

Hardness (IRHD) 60 70 80 90 see clause 6.7.5
Volume change see clause 6.7.5
(% maximum)
Volumetric method
1. Standard test fluid* 0 to +20 0 to +20 0 to +20 0 to +20
liquid B
22 hours @ 40°C

2. Service fluids see clause 6.7.5

• OX 27, OX 38, OX
-2 to +7 -2 to +7 -2 to +7 -2 to+7 28 days @ 100°C
95
• Avgas Avtur, OX
40,Dieso, AVCAT, -2 to +10 -2 to +10 -2 to +10 -2 to +10 28 days @ 40°C
FSII
Dry heat air ageing:
Tensile strength maximum
-10 -10 -10 -10 see clause 6.7.8
% change*
168 hours at 100°C ±1°C
Elongation at break
-30 -30 -30 -30
maximum % change*

Note 1: * These tests shall be performed to verify the production consistency of type-accepted materials.
Note 2: The volume change test requirements shall be as specified within Table 4 and that the term ‘High Nitrile
(High AC NBR) applies in place of Medium Nitrile (Medium AC NBR).

10 Fluorocarbon Toroidal Sealing O-Ring Applications

This section defines the system applications and specific requirements for the rubber vulcanizate of the
Fluorocarbon type which is used during the manufacture of toroidal sealing O-rings to the overall
requirements of this Def Stan. These shall be used for applications where higher operating temperatures,
chemical compatibility or increased life requirements are unlikely to be satisfied by Nitrile materials.

10.1 Temperature Range

Fluorocarbon O-rings are generally suitable for applications in the temperature range of -20°C to +200°C.
They are more expensive than Nitrile O-rings and may not be suitable for low temperature cycling
applications.

10.2 Pressures and the Introduction of Anti-extrusion Rings

Fluorocarbon sealing O-rings are suitable for use at pressures up to and in excess of 100 bar. For pressures
above 100 bar special attention shall be given to the design and dimensions of housing grooves particularly
with regard to dynamic applications. For both dynamic and static applications greater than 100 bar anti-
extrusion back-up rings shall be used, see clause 13.

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10.3 Preferred Range

The preferred range of Fluorocarbon O-rings is contained within Part 2 of this Def Stan.

10.4 Material Acceptance, Test and Tolerance Requirements

The material shall be type-accepted in accordance with clause 6. The test tolerances for Fluorocarbon O-
rings are specified within Tables 5 and 6.

10.5 Oxygen Ageing Test

Four dumb-bell shaped test pieces as defined within 6.7.3 shall be suspended in an atmosphere of pure
oxygen, pressurised in a suitable vessel to 20 bar and maintained at a temperature of 70°C ±1°C for a
minimum period of twenty-one (21) days. The results of the tensile and elongation tests established in
accordance with 6.7.3 shall be reported as a percentage change from that pertaining before the ageing test.

10.6 Production Quality Control Test

The tests identified by asterisks within Table 5 and complying with clause 10.8, Table 6 shall be conducted
to verify production consistency of the type-accepted materials.

10.7 Colour Identification

The Fluorocarbon O-rings defined shall be coloured green. The colouring agent shall be compatible with the
polymer used. The coloured material shall satisfy the test requirements shown within Table 5.

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Table 5 – Test Requirements - Fluorocarbon

Test Tolerances Method

+5 +5 +5
Hardness (IRHD)* 70 80 90 see clause 6.7.1
-4 -4 -4
Density (Mg/m3)* within ±0,02 of agreed values see clause 6.7.2
Minimum tensile strength (MPa)* 11 11 11
see clause 6.7.3
Minimum elongation at break (%)* 150 120 100
Compression set (% maximum)* 15 15 15 see clause 6.7.4 @ 200°C
Volume change (% maximum)
see clause 6.7.5
Volumetric method liquid B
0 0 0
1. Standard test fluid* 168 hours @ 40°C
+10 +10 +10
2. Service fluids see clause 6.7.5
• OX 30, OM 33, OX 95 0 0 0 28 days @ 100°C
• Avtur, OX 40, Dieso,
+5 +5 +5 28 days @ 40°C
AVCAT, FSII
Resistance to low temperature:
°C at which rigidity modulus see clause 6.7.6
-15 -15 -15
doesnot exceed 70 MPa
Adhesion to and corrosion of
adhesion and corrosion see clause 6.7.7
metals
Dry heat air ageing:

Tensile strength elongation at

not to be reduced by more than 20% see clause 6.7.8
break*

Hardness change (IRHD) ±6 70 hours @ 250°C

Loss of weight (% maximum) 6
Oxygen Ageing:
Tensile strength elongation at
not to be reduced by more than 20% see clause 10.5
break

Note: * These tests shall be performed to verify the production consistency of the type-accepted materials.

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10.8 Routine Tests of Finished O-rings

Table 6 - Test Tolerances for Finished O-rings - Fluorocarbon

Test Tolerance Method

+5 +5 +5
ApparentHardness (IRHD)* 70 80 90 see clause 6.7.1
-4 -4 -4
3
Density (Mg/m )* ±0,02 of agreed value see clause 6.7.2

Note: * These tests shall be performed on samples of finished Fluorocarbon O-rings to comply with the
requirements within clause 6.

11 Hydrogenated Nitrile (Medium) Toroidal Sealing O-Rings for High Endurance

This section defines the system applications and specific requirements of this Def Stan for the three rubber
vulcanizates based upon peroxide cured Medium Acrylonitrile Content (AC) Hydrogenated Acrylonitrile-
Butadiene (HNBR) rubber used during the manufacture of toroidal sealing O-rings. HNBR vulcanizates allow
higher operating temperatures (up to a maximum of 150°C for intermittent use). They have an inherent
resistance to ozone attack, are tougher and more abrasion resistant than conventional Nitrile grades of
equivalent hardness.

11.1 System Applications

HNBR O-rings supplied in accordance with the requirements of this Def Stan have been proven in pneumatic
applications only. Although there is no reason to doubt the effectiveness of HNBR O-rings in other systems,
the user should verify the performance for the following relevant applications:

a) mineral oil hydraulic and lubricating oils (-30°C to +135°C)

b) diesel fuels to Def Stan 91-4 (-30°C to +50°C)

c) water and water Glycols (-30°C to +135°C)

d) pneumatics (-30°C to +30°C)

11.2 Temperature Range Qualification

O-rings are suitable for operation within the temperature range quoted within clause 11.1 but extended use
at either of the range extremes will shorten seal life and reduce sealing efficiency.

11.3 Pressures and the Introduction of Anti-extrusion Rings

O-rings are suitable for use at pressures up to and in excess of 100 bar. For pressures above 100 bar
special attention shall be given to the design and dimensions of housing grooves particularly with regard to
dynamic applications. For both dynamic and static applications greater than 100 bar anti-extrusion back-up
rings shall be used, see clause 13.

11.4 Preferred Range

The preferred range of Medium AC HNBR O-rings is contained within Part 2 of this Def Stan.

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11.5 Material Acceptance, Test and Tolerance Requirements

The test tolerances relating to this Def Stan for material acceptance are given within clause 6.4 and Table 7.
The materials shall be type-accepted in accordance with clause 6. Test tolerances for Hydrogenerated
Nitrile (Medium) O-rings are specified within Tables 7 and 8.

11.6 Production Quality Control Test

The tests identified by asterisks within Table 7 and complying with clause 11.8, Table 8 shall be conducted
to verify production consistency of the type-accepted materials.

11.7 Colour Identification

The HNBR O-rings defined within this Def Stan shall be colour coded with a white and red dash, or dot. The
colouring agent shall be compatible with the polymer used. The coloured material shall satisfy test
performed to verify product consistency.

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Table 7 - Test Requirements – Medium AC HNBR

Test Tolerances Method

+5 +5 +5
Method N
Hardness (IRHD)* 70 80 90
see clause 6.7.1
-4 -4 -4
Density (Mg/m3)* ± 0,02 ± 0,02 ± 0,02 see clause 6.7.2
Minimum tensile strength (MPa)* 20 25 27 see clause 6.7.3
Minimum elongation at break (%)* 250 230 180 see clause 6.7.3
see clause 6.7.4
Compression set (% maximum)* 25 25 25
24 hours @ 135°C
Volume change (% maximum) see clause 6.7.5
Volumetric method
Standard Test Fluids:
1. Liquid B* 0 to +50 0 to +50 0 to +50 22 hours @ 40°C
•
IRM 9033 0 to +30 0 to +30 0 to +25 28 days @ 150°C
2. Service Fluids:
• OEP 80 0 to +8 0 to +8 0 to +8 28 days @ 80°C
• OX 40 0 to +8 0 to +8 0 to +8 28 days @ 40°C
• OM 33, OM 100 and OX 30 0 to +8 0 to +8 0 to +8 28 days @100°C
Resistance to low temperature:
°C at which rigidity modulus does -20 -20 -20 see clause 6.7.6
not exceed 70 MPa
see clause 6.7.7
Adhesion to and corrosion of metals no adhesion or corrosion
168 hours @ 100°C ±2°C
Dry heat air-ageing:
Tensile strength maximum
-10 -10 -10 see clause 6.7.8
% change*
Elongation at break maximum %
-30 -30 -30 168 hours at 135°C ±2°C
change*

Note 1: * These tests shall be performed to verify the production consistency of the accepted material.
3
Note 2: Indicates significant differences from conventional Nitrile test conditions.

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11.8 Routine Testing of Finished O-rings

For the finished routine test tolerances of samples ofMedium AC HNBRandHigh HNBR O-rings see Table 8.

Table 8 - Test Requirements for Finished O-rings - Medium AC HNBR and High AC HNBR

Test Tolerances Method

70 80 90
ApparentHardness (IRHD) +5 +5 +5 see clause 6.7.1 Method CM
-4 -4 -4
3
Density (Mg/m ) ±0,02 ±0,02 ±0,02 see clause 6.7.2

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12 Hydrogenated Nitrile (High) Toroidal Sealing O-Rings for High Endurance

This clause defines the system applications and specific requirements of this Def Stan for the three rubber
vulcanizates based upon peroxide cured High Acrylonitrile Content (AC) Hydrogenated Acrylonitrile-
Butadiene (HNBR) rubber used during the manufacture of toroidal sealing O-rings where resistance to
organic liquids, such as Hydrocarbon fuels and some synthetic oils is required. HNBR vulcanizates can be
used where higher operating temperatures 135°C continuously and 150°C intermittently and increased
durability are required.

12.1 Qualification of Application

O-rings supplied in accordance with the requirements of clause 12 are complementary to those covered
within clause 11. They shall only be used where the oil resistance capability of the Medium AC HNBR O-
rings is inadequate for the intended application.

12.2 Temperature Range Qualification

O-rings supplied in accordance with the requirements of this clause 12 are suitable for operation within the
temperature range -30°C to 135°C with excursions to 150°C. However, extended use at either of the range
extremes will shorten seal life and reduce sealing efficiency.

12.3 Pressures and the Introduction of Anti-extrusion Rings

O-rings supplied in accordance with the requirements of this clause 12 are suitable for use at pressures up
to and in excess of 100 bar. For pressures above 100 bar special attention shall be given to the design and
dimensions of housing grooves particularly with regard to dynamic applications. For both dynamic and static
applications greater than 100 bar anti-extrusion back-up rings shall be used, see clause 13.

12.4 Preferred Range

The preferred range of High AC HNBR O-rings is contained within Part 2 of this Def Stan.

12.5 Material Acceptance, Test and Tolerance Requirements

a) The materials shall be type-accepted in accordance with clause 6. The test tolerances for
Hydrogenerated Nitrile (High) O-rings are specified within Tables 8 and 9.

b) In the event of a dispute concerning the in-service performance of material in contact with service
fuels, the Acceptance Scheme for volume change within Table 9 shall be re-applied at the discretion
of the MOD Design Authority.

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12.6 Production Quality Control Test

The tests identified by asterisks within Table 9 and complying with clause 12.8 shall be conducted to verify
consistency of the type-accepted materials.

Table 9 - Test Requirements – High AC HNBR

Test Tolerances Method

+5 +5 +5
Method N
Hardness (IRHD)* 70 80 90
see clause 6.7.1
-4 -4 -4
Minimum tensile strength (MPa)* 20 25 27 see clause 6.7.2
Minimum elongation at break (%)* 220 200 180 see clause 6.7.3
see clause 6.7.4
Compression set (% maximum)* 25 25 25
24 hours @ 135°C
Volume change (% maximum) see clause 6.7.5
Volumetric method
Standard Test Fluids:
1. Liquid B*
0 to +30 0 to +30 0 to +30 22 hours @ 40°C
•
IRM 9034
0 to +20 0 to +20 0 to +15 28 days @ 150°C
2. Service Fluids:
• OEP28, OX 95 0 to +15 0 to +15 0 to +15 28 days @ 100°C
• OX 38 0 to +8 0 to +8 0 to +8 28 days @ 100°C
• Avgas, Avtur and Dieso
0 to +25 0 to +25 0 to +25 28 days @ 40°C
AVCAT, FSII
• OX 40 -2 to +5 -2 to +5 -2 to +5 28 days @ 40°C
Resistance to low temperature: see clause 6.7.6 with the
°C at which rigidity modulus does exception of Liquid B
-15 -10 -5 and IRM 903
not exceed 70 MPa

Adhesion to and corrosion of see clause 6.7.7

no adhesion or corrosion
metals 168 hours @ 100°C ±2°C
Dry heat air-ageing:
Tensile strength maximum
-10 -10 -10 see clause 6.7.8
% change*
168 hours at 135°C ±2°C
Elongation at break maximum %
-30 -30 -30
change*

Density (Mg/m3) ±0,02 ±0,02 ±0,02 see clause 6.7.2

Note 1: * These tests shall be performed to verify the production consistency of the accepted materials.
4
Note 2: Indicates significant differences from conventional Nitrile test conditions.

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12.7 Colour Identification

The HNBR O-rings defined within this clause 12 shall be colour coded with a white and red dash, or dot.
The colouring agent shall be compatible with the polymer used. The coloured materials shall satisfy test
performed to verify product consistency.

12.8 Routine Testing of Finished O-rings

For the finished routine test tolerances of samples of Medium AC HNBR and High HNBR O-rings see
Table 8.

13 Anti-Extrusion Rings and Housings (Metric and Imperial)

The range of MOD (N) preferred thin back-up rings, complete with dimensions and NSN is given within Part
3 of this Def Stan.

a) BS 5106 specifies the metric range of spiral anti-extrusion rings, the shape and dimensions of housing
grooves to accommodate one or two spiral back-up rings compatible with metric O-rings to BS 4518.

b) No recognised standard exists for the shape and dimensions of housing grooves that accommodate
imperial thin back-up rings. Housing width, however, should be increased by the width (thickness) of
the anti-extrusion ring.

c) All back-up rings shall be suitable for use within the systems, and with the mediums, and temperatures
of the systems in which they shall be used.

14 Packaging
The conditions of packaging, the packaging materials to be used and the labelling, and marking of the
packaging are to comply with Def Stan 81-60.

14.1 Mandatory Individual Packaging Requirements

a) Each O-ring shall be cleaned and individually packaged to the Level P Package Requirements of Def
Stan 81-60, equivalent to NATO Level 4. Each item is to be retained in its individual package and the
total quantity under the order is to be collectively enclosed in an outer envelope or carton. Items that
are to be supported to prevent distortion are to meet the specified requirements contained within
Def Stan 81-60.

b) The outside of each individual is to be clearly marked with the following information:

1) NATO stock number

2) Material specification number of polymer description, or both

3) Hardness which may be combined with 2)

4) Date of cure

5) Life grouping, in accordance with the requirements BS 4F 68

6) Batch number or release and certification number

7) Manufacturer’s identity

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File Reference
The DStan file reference relating to work on this standard is D/DStan/69/2/337/1.

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When Defence Standards are incorporated into contracts users are responsible for their correct
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Defence Standards are revised as necessary by an up issue or amendment. It is important that users
of Defence Standards should ascertain that they are in possession of the latest issue or amendment.
Information on all Defence Standards can be found on the DStan Website www.dstan.mod.uk,
updated weekly and supplemented regularly by Standards in Defence News (SID News). Any person
who, when making use of a Defence Standard encounters an inaccuracy or ambiguity is encouraged
to notify UK Defence Standardization (DStan) without delay in order that the matter may be
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proceeding with any standards work.

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