PTFE has great mechanical properties:
- Auto-ignition temperature of >427°C
- A super low heat of combustion at just 4,200–7,100 J/g
- One of the lowest dynamic friction coefficients of all materials at just 0.01 to 0.04 (obviously heavily dependent on the coupled material)
- One of the lowest static friction coefficients of all materials at just 0.08 (obviously heavily dependent on the coupled material)
- A virtually unlimited shelf life. Elastomers such as NBR, EPDM, or FKM will have to be discarded after a few years or a decade on the shelf.
- Most elastomers used in SCUBA will swell ever so slightly over time, depending on the lubricants used. The reason is that they absorb moisture/lubricants over time. While this is of no interest to the user, the engineer must take this into account. PTFE does not swell at all.
- It is inert to almost all chemicals (hardly relevant for SCUBA).
- Awesome dielectric properties, with around 60 kV/mm (hardly relevant for SCUBA).
However, it also has some disadvantages:
- It has a very high hardness rating of 55 Shore. While this sounds low on the surface, this is on the "D" hardness scale, compared to elastomers like NBR or FKM, which are classed on the "A" hardness scale. This high hardness of PTFE means that it is less effective at sealing things. The soft elastomers deform easily to seal parts, but the harder PTFE does a poorer job at this. Oftentimes, things that get sealed via a PTFE O-ring require precision machining.
- PTFE is a polymer that does not belong to the elastomers. This means that once it deforms under pressure, it will stay that way. Think of it like an ordinary O-ring suffering from extreme compression set, but PTFE suffers this compression set instantly.
- It costs an arm and a leg, at least compared to "ordinary" elastomers.
From the above, it should become clear that PTFE is not a go-to material for all types of O-rings.
It is currently the best choice available with regards to oxygen compatibility, even leaving FKM in the dust by a wide margin. Its low coefficient of friction means that moving parts can work much more efficiently than they otherwise would with a comparable elastomer. However, the instant compression set and poor sealing capabilities make this material a non-starter for some parts.
To give a few examples, my go-to O-ring for sealing oxygen cylinders with a 3/4"-16 UNF inlet is a 3.6 mm x 19.0 mm PTFE O-ring, such as
this. As I get oxygen cylinders only once a decade, I found that FKM O-rings, under certain circumstances, failed prematurely.
I had a discussion with the guys from Deep6 a while ago, as they use another clever alternative. They use an O-ring that has an
FKM core encapsulated in a PTFE layer. They use this O-ring on the barrel of the seat. The incredibly low coefficient of friction of the outer layer of PTFE means that the seat will move effortlessly, which in turn improves the performance of the first stage compared to a standard NBR or FKM O-ring. This also negates the need for a back-up ring.
This approach has the downside of not being the cheapest, and unfortunately, manufacturers are limited in how small they can manufacture these FKM-PTFE encapsulated O-rings. Here’s me hoping that this approach will be refined in the future down to the size of O-rings such as 1.0 mm x 2.2 mm. If this were to happen, I can dream of a manufacturer choosing one of these PTFE-encapsulated O-rings for their poppet in a balanced second stage. The O-rings on a balanced second-stage barrel are one of the limiting factors with regards to performance, as NBR, EPDM, or FKM introduce friction.