Learning from FTIR-Based Characterization of Ring Failure in a Damaged Cylinder

Abstract Hydraulic cylinders are critical components in oil sands mining excavators, converting hydraulic energy into linear motion for precise control of lifting, digging, and other operations. Sealing and guiding rings play essential roles in ensuring proper cylinder function and preventing fluid leakage. One of the bucket curl hydraulic cylinders equipped with a newly installed ring set experienced functional failure after only 240 hours of service - significantly shorter than expected. In contrast, parallel cylinders continued operating normally, suggesting that the failure was likely related to issues with the installed rings. Three failed ring components from the damaged cylinder were collected for failure analysis. Fourier Transform Infrared Spectroscopy (FTIR) in attenuated total reflectance (ATR) mode was employed to investigate potential causes such as material degradation, use of incorrect materials, or other contributing factors. A new ring set sourced from the original equipment manufacturer was used for comparison. The investigation revealed difficulties in component identification, as the ring set contained 19 pieces from 12 different items, none of which were individually labeled. Despite installation by a specialized third-party contractor, the findings suggest that the failed rings were misidentified, potentially leading to improper application. This failure highlights the critical importance of clear component labeling, proper material verification, and traceability in complex assembly tasks. It also reinforces the value of FTIR analysis as a rapid and non-destructive tool for identifying polymeric materials and supporting root cause determination in field failures.