Lifetime Extension Report: Progress on the SAVY-4000 Lifetime Extension Program
The 3-year accelerated aging study of the SAVY-4000 O-ring shows very little evidence of significant degradation to samples subjected to aggressive elevated temperature and radiation conditions. Whole container thermal aging studies followed by helium leakage testing and compression set measurements were used to establish an estimate for a failure criterion for O-ring compression set of ≥65 %. The whole container aging studies further show that the air flow and efficiency functions of the filter do not degrade significantly after thermal aging. However, the degradation of the water-resistant function leads to water penetration failure after four months at 210°C, but does not cause failure after 10 months at 120°C (130°C is the maximum operating temperature for the PTFE membrane). The thermal aging data for O-ring compression set do not meet the assumptions of standard time-temperature superposition analysis for accelerated aging studies. Instead, the data suggest that multiple degradation mechanisms are operative, with a reversible mechanism operative at low aging temperatures and an irreversible mechanism dominating at high aging temperatures. To distinguish between these mechanisms, we have measured compression set after allowing the sample to physically relax, thereby minimizing the effect of the reversible mechanism. The resulting data were analyzed using two distinct mathematical methods to obtain a lifetime estimate based on chemical degradation alone. Both methods support a lifetime estimate of greater than 150 years at 80°C. Although the role of the reversible mechanism is not fully understood, it is clear that the contribution to the total compression set is small in comparison to that due to the chemical degradation mechanism. To better understand the chemical degradation mechanism, thermally aged O-ring samples have been characterized by Fourier Transform Infrared (FTIR), Electron Paramagnetic Resonance (EPR), Gel Permeation Chromatography (GPC), and Differential Scanning Calorimetry (DSC). These experiments detect no significant O-ring degradation below 80°C. Furthermore, durometer measurements indicate that there is no significant change in O-ring hardness at all aging conditions examined. Therefore, our current conservative lifetime estimate for the O-ring and the filter is 10 years at 80°C. In FY17, we will continue to probe the chemical degradation mechanism using oxygen consumption measurements under accelerated aging conditions to reveal temperatures at which oxidation occurs, along with any differences in oxidation rate at the low vs. high aging temperatures. We will also refine the failure criteria and finalize the radiation/thermal synergistic studies to determine a final design lifetime.