Bad design involving unrelieved angular transitions between surfaces ("sharp edges"); lack of lubrication on assembly; "forcing" things into place when resistance is encountered; wrong selection of O-ring size/thickness; wrong material for particular fluid; inadequate tightening, so that fluid leaks erode the O-ring; things vibrating loose; etc.
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In vino veritas; in cervisia carmen; in aqua E. coli.
GA. I hate to be picky but, I have had some O-rings that have failed from heat. Going from buna N to Viton cured early failures. I agree that it may have been incorrect application, but the OEM called for buna-N.
National O-ring;s catalog shows many ways O-rings fail. If the OP is having failures, the catalog is worth reading.
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