What Causes Custom Hose Assemblies to Fail?

What Causes Custom Hose Assemblies to Fail?

August 30, 2021

In any hydraulic system, one of the most important components is the hydraulic hose. A hydraulic hose transports hydraulic fluid, often under pressure, throughout the hydraulic system. Because of the many different types of applications for them, hydraulic hoses can be custom made with unique specifications.

There are several different factors that go into hydraulic hose assembly, and taking everything into account is a surefire way to prevent hose failure. Before engaging in custom hydraulic hose fabrication, it would help to know why some custom hose assemblies fail—that’s what this article will cover.

Incompatible fluid

Using the right kind of fluid with the correct type of hose is of paramount importance. Failing to do this can lead to wearing away of the inside of the hose and, eventually, leakage. To prevent this, ensure that whatever fluid you’re using is compatible with all parts of the hydraulic hose system, from the inner tube to the O-rings.


While incompatible fluid can lead to inner wear of the hydraulic hose, abrasion refers to the wear and tear of the outside of the hose. Because of their applications, hydraulic hoses are often used in high-pressure and heated situations. These conditions, along with any chronic rubbing against components and other hoses, can lead to the exterior of the hose being scraped away, compromising its structural integrity. Try using hose covers or sleeves to mitigate this.

Heat aging

Though we briefly touched on this above, heat aging is the process of a hose being repeatedly exposed to extreme heat, causing it to wear out more quickly. Hydraulic hoses are made of rubber and plastics, and those materials can become less elastic and more brittle over time. This can eventually lead to cracks that can spread throughout the hose. Minimize heat exposure to hoses when possible, and try heat guards if it’s unavoidable.

Incorrect assembly

It’s imperative to exercise great care when performing hydraulic hose assembly. Hoses need to be secured properly, and the fittings must be seated deep enough to stop any weaknesses from developing in the hose. Proper assembly includes taking precautions during the hydraulic hose fabrication process, including making sure the hose is meticulously cleaned to prevent any harmful metal debris from getting into the hose and being circulated throughout the hydraulic system.

Tube erosion

Flow is extremely important in hydraulic hoses because proper flow can prevent erosion. The inside of the tube may erode if there’s a concentrated stream of fluid or contaminants flowing exclusively and constantly over a certain part of the tube. It’s critical to use the proper hose size and to not bend the hose too sharply, as this may adversely affect the flow of the hydraulic fluid. Using the correct fluid is important too, as we discussed above. You can reduce erosion by consulting various engineering manuals and flow nanograms and following their specifications for your particular hose.

Call for your hydraulic hose today

Now that you know some of the basics of hydraulic hose assembly and hydraulic hose fabrication, give us a call at Royal Brass Incorporated. We have everything you need for your custom hydraulic hose—from fittings to valves and everything in between.

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