UNIT 5

WEAR DEBRIS ANALYSIS

Particles in oil arise from a number of different sources. Contamination can enter the system
during maintenance, through breathers, during oil top offs, in the course of oil changes, and in
other ways. Wear particles are generated during machine operation. These wear particles can be
caused by contamination, improper lubrication, a change in operating conditions, and other
factors that may cause metal-to-metal contact.
We provide various levels of wear debris analysis, a process by which wear particles in a
lubricant are identified and used to assess the condition of equipment. As wear particle sizes and
quantities increase, so does the risk of failure due to wear. Wear debris testing evaluates particles
that may be too large to be detected in the standard metals test. This adds another dimension to
the information received from routine oil analysis testing.

Wear debris analysis identifies the properties:

Normal rubbing wear

Severe rubbing wear

Cutting wear / abrasives

Fatigue wear

Laminar wear

Fatigue spheres

Dark metallo-oxides

Red oxides (rust)

Corrosive wear

Ferrous metals-iron and iron alloys

Non-ferrous metals

Non-metallic particles

Friction polymers

Fibres

Contaminants, such as dirt, coal dust, fly ash, fibres, etc.

Routine wear debris can be provided with trending by Particle Quantifier(PQ). PQ measures the
relative level of ferrous wear debris in a sample and displays this as a PQ index. This index can
then be trended for useful wear monitoring.

Microscopic Particle Examination (MPE) provides Analytical Ferrography Analysis. MPE is a

comprehensive and detailed microscopic analysis of the solid particles that are captured in the oil
sample. The analysis begins by determining if metal particles are ferrous or non-ferrous. ALS
can also heat treat the particles to determine the metallurgical composition. Particles such as
fibres, corrosive wear, sand, dirt, and other elements are identified. Depending on the types of
particles, the quantities, and their respective sizes, ALS can determine the abnormal wear mode,
identify the likely component, detect the wear mechanism(s)generating the particles, and assess
the potential for failure. Detailed photographic images of the problem particles are included with
the report. Routine tests such as spectrochemical analysis, PQ, particle count or even
Laserview can trigger the need for the more comprehensive analysis provided by MPE.

Laserview is a streamlined, cost-effective wear debris analysis service used in combination

with traditional oil analysis as a trending tool and to pinpoint severe wear conditions. This test
data complements other oil analysis techniques by using laser imaging and advanced image
process software to classify, identify, and measure type of wear mechanism, particle size
distribution, rate and severity of wear processes, and ISO particle count.
Some of our laboratories employ Lasernet Fines instrumentation, which was developed by
Lockheed Martin with the Naval Research Laboratory for military application. Using direct
digital imaging, Lasernet Fines test results classify particles larger than 20 micron into cutting
wear, severe sliding wear, fatigue wear, and non-metallic material. The analysis economically
combines features of particle count determination with quantifying wear particle classification
for industrial, gear and drive-train components without subjective interpretation.
The test data complements other wear analysis techniques by using laser imaging and advanced
image processing software to identify and measure:

Type of wear mechanism

Rate and severity of wear processes
Wear particle size distribution
Particulate contamination and oil cleanliness

Filter Patch Test (FPT, filtergram, or patch test) is a common method for making a detailed
determination of wear occurrence, especially for non-ferrous materials, by examination of wear
particles through a microscope. A measured portion of used oil is filtered through a filter patch.
Trapped wear particles and debris are then visually examined microscopically for a qualitative
report. Observation will generally be accompanied by a photo of the filtered wear material on a
test report. The debris is assessed and the particles graded. The FPT can tell us a number of
things:

Is there abnormal wear taking place?

Is the wear ferrous or non-ferrous?
Is there any evidence of abrasive contaminants e.g. dirt?

Particle Quantifier Index (PQI): The Particle Quantifier is a magnetometer that measures the
mass of ferrous wear debris in a sample and displays this as a PQ Index. Test results are
quantitated as a relative number of ferrous materials within a sample; this can then be trended for
useful wear monitoring. PQI is a simple, cost-effective test that can easily be incorporated into
routine trending analysis.