Leakage at interfaces: a comprehensive study based on Persson contact mechanics theory

TL;DR

This study develops a validated framework for predicting gas leakage at interfaces using Persson contact mechanics theory, combining experimental, numerical, and analytical methods to improve sealing system design.

Contribution

It introduces a comprehensive approach integrating surface characterization, FEM, and multiscale contact mechanics for accurate leakage prediction.

Findings

Good agreement between predicted and experimental leakage data.

Small changes in elastic modulus significantly affect leakage near percolation.

Framework offers practical guidance for sealing system design.

Abstract

We present a comprehensive study of gas leakage at interfaces based on Persson contact mechanics theory. A prototype syringe system consisting of a rubber stopper and a glass barrel is selected, where surface roughness is characterized using measurements from stylus profilometry and atomic force microscopy, and contact pressure distributions are obtained from Finite Element Method (FEM) calculations. Leakage prediction is performed using Multiscale Contact Mechanics (MCM) software. The predicted results show good agreement with experimental measurements under controlled dry conditions. Sensitivity analyses indicate that small variations in elastic modulus and contact pressure can significantly influence leakage, particularly near the percolation threshold. This work provides a generalized and validated framework for leakage prediction and offers practical guidance for the design of sealing systems in pharmaceutical and engineering applications.