Failure analysis and improvement measures of airplane actuator seals.

[Display omitted] • The failure reasons of reciprocating seal were analyzed by comprehensive tests. • Eight types of failure reasons and improvement measures were proposed. • Key points in seal design and assembly were put forward. • The failure analysis method makes the development of future seal products more effective. Hydraulic actuators are an important executive component of modern aircraft and are typically characterized by a reciprocating sealing form. Sealing failure affects the implementation of aircraft missions and flight safety. To determine the main cause for sealing failure of the ACGT-HP combined rod seal in an aircraft actuator, taking the new seal as the control group, compare and analyze the failure and non-failure combined rod seals under the same working conditions for approximately the same time. By means of microscopic examination, physical performance testing and chemical composition analysis, eight ACGT-HP seal failure reasons that act synergistically are summarized and preventive improvement measures are proposed. It is concluded that the main reason for the failure of the combined seal is that the wear of the seal is exacerbated by various inappropriate coupling factors, resulting in the rapid reduction of contact stress and seal failure. By putting forward the key points of seal design and assembly, a universal failure analysis method from macro to micro is found, which can be used for various types of combined seals to guide the design and application of the ACGT-HP seals. [ABSTRACT FROM AUTHOR]