Elastomers in Aerospace, Space & Military Applications

High-performance elastomers including FKM, FFKM, and silicone used in aerospace, space, and military applications requiring extreme environment resistance and MIL-SPEC compliance.

Introduction to Aerospace and Military Elastomers

The aerospace, space, and military sectors represent the most demanding environments for elastomer sealing solutions. From jet engine fuel systems operating at extreme temperatures to satellite components exposed to the vacuum of space, elastomer materials must deliver uncompromising performance where failure is not an option. These industries require materials that can withstand temperature extremes from cryogenic lows of -60 degrees Celsius to continuous highs exceeding 300 degrees Celsius, aggressive fuels and hydraulic fluids, high-altitude ozone exposure, and the rigors of vibration and mechanical stress.

Military specifications (MIL-SPEC) and aerospace material standards (AMS) define strict requirements for elastomer materials used in defense and aviation applications. Meeting these standards requires not only the right material chemistry but also precise manufacturing controls, batch traceability, and comprehensive testing protocols. Tereefek Solutions supplies elastomer products that meet these exacting requirements for aerospace and defense customers worldwide.

High-Performance Elastomer Materials

FKM (Fluoroelastomers / Viton)

FKM fluoroelastomers are the workhorses of aerospace sealing, offering an exceptional combination of chemical resistance, high-temperature performance, and mechanical durability. In aerospace applications, FKM seals are found throughout fuel systems, hydraulic circuits, and engine accessories. Key aerospace-relevant properties include:

  • Continuous service temperature up to 200 degrees Celsius with peaks to 250 degrees Celsius
  • Outstanding resistance to jet fuels (JP-4, JP-5, JP-8, Jet A), hydraulic fluids (MIL-PRF-5606, MIL-PRF-83282, Skydrol), and lubricating oils
  • Excellent resistance to ozone, oxygen, and weathering at high altitudes
  • Low permeability to gases, critical for pressurized systems
  • Compliance with AMS 7259, AMS 7276, and other aerospace material specifications
  • Available in compounds meeting MIL-R-83248 and AMS-R-83485 requirements

FFKM (Perfluoroelastomers / Kalrez)

FFKM represents the ultimate in chemical and thermal resistance for aerospace applications. Where standard FKM reaches its limits, FFKM continues to perform. These materials are specified for the most critical sealing points in rocket propulsion systems, satellite components, and advanced military platforms. FFKM offers:

  • Continuous service temperatures exceeding 300 degrees Celsius
  • Near-universal chemical resistance, including aggressive rocket propellants and oxidizers
  • Extremely low outgassing rates, critical for space applications (meets ASTM E595 requirements)
  • Plasma and radiation resistance for satellite and space station components
  • Long-term reliability in sealed, inaccessible locations

Silicone (VMQ) and Fluorosilicone (FVMQ)

Silicone elastomers provide the widest temperature range of any common elastomer family, making them invaluable for aerospace applications requiring performance from -60 degrees Celsius to +230 degrees Celsius. Fluorosilicone (FVMQ) combines the temperature range of silicone with improved fuel and oil resistance, making it ideal for aircraft fuel system seals and connectors. Military specifications such as MIL-R-25988 define requirements for fluorosilicone seals used in fuel-wetted applications.

Aerospace Sealing Applications

Elastomer seals are found throughout every aircraft and spacecraft system. In aircraft engines, FKM O-rings and gaskets seal fuel nozzles, oil sumps, and hydraulic actuators. The engine nacelle environment subjects seals to extreme heat from the engine core while simultaneously exposing them to cold ambient temperatures at cruising altitude. Landing gear hydraulic systems rely on precision-molded FKM and polyurethane seals to maintain hydraulic pressure under shock loads and temperature cycling.

Flight control systems use elastomer seals in hydraulic actuators that move ailerons, rudders, elevators, and flaps. These seals must maintain zero-leak performance under high pressures while accommodating rapid pressure reversals and vibration. Environmental control systems (ECS) that pressurize and condition cabin air use EPDM and silicone seals for duct connections and valve seats.

Military and Defense Requirements

Military elastomer applications extend beyond aircraft to include ground vehicles, naval vessels, missiles, and soldier equipment. MIL-SPEC standards ensure consistent material quality and performance across all defense applications. Common military specifications for elastomer seals include:

  • MIL-PRF-28800 (general-purpose O-rings and seals)
  • MIL-R-83248 (fluorocarbon elastomer O-rings for fuel and hydraulic systems)
  • MIL-DTL-83528 (silicone rubber, electrically conductive gaskets for EMI shielding)
  • AMS 7259, 7271, 7276 (aerospace material specifications for FKM compounds)
  • AS568 standard O-ring sizes for interchangeability

Chemical, biological, radiological, and nuclear (CBRN) protective equipment relies on elastomer seals in gas masks, protective suits, and decontamination systems. These seals must resist warfare agents while maintaining flexibility and sealing integrity in combat conditions.

Space Environment Challenges

Space applications present unique challenges for elastomer materials. The vacuum of space, combined with extreme temperature cycling (from -150 degrees Celsius in shadow to +150 degrees Celsius in direct sunlight), atomic oxygen erosion in low Earth orbit, and radiation exposure, severely limits material options. Outgassing is a critical concern, as volatile compounds released by elastomers can condense on optical surfaces, solar panels, and sensitive electronics. Materials must meet NASA outgassing requirements per ASTM E595 (less than 1.0% TML and less than 0.1% CVCM).

FFKM and specially formulated silicone compounds are the primary choices for space applications. These materials maintain their sealing properties through thousands of thermal cycles while exhibiting minimal outgassing and radiation degradation.

Tereefek Solutions: Aerospace and Defense Elastomer Expertise

Tereefek Solutions supplies a comprehensive range of aerospace and military-grade elastomer products, including FKM, FFKM, silicone, and fluorosilicone seals in standard AS568 and metric sizes. Our products meet applicable MIL-SPEC and AMS requirements, with full material traceability and certification documentation available. Whether you need standard O-rings for aircraft maintenance or custom-molded seals for a new defense platform, our technical team has the expertise to support your most demanding applications. Contact us to discuss your aerospace and military sealing requirements.