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1. Introduction
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all type of bearings, gears or coupling (if lubricated in path). Analytical ferrography is among
the most powerful diagnostic tools in oil analysis in tribology. When implemented correctly it
provides tremendous information on machine under operation. Yet, it is frequently excluded
from oil analysis programs because of its comparatively high price and a general is
understanding of its value. The test procedure is lengthy and requires the skill of a trained
analyst. As such, there are significant costs in performing analytical ferrography not present
in other oil analysis tests. But, if time is taken to fully understand what analytical ferrography
uncovers, most agree that the benefits significantly outweigh the costs and elect to
automatically incorporate it when abnormal wear is encountered. Additionally, a lub system
performance may be improved through proper filtrations of oil. Clean oil lubrication is
always more effective. Adopting approach of oil replacement is expensive. A rapid
centrifuged and/ or magnetic separator cleaning system helps cost cutting and disposal of
used oil, as well. Ferrography also helps improving filtration efficiency and frequency for oil
cleaning systems.
B. Methodology: Determination of oil is collected from a four stroke – two wheeler engine
(Honda CBZ). The condition of the oil is, it is used oil after running 1750km of bike after
putting a fresh oil Quantity taken 100 ml. Test performed in CHOKSI lab Indore.
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CHAPTER-2
Literature survey
There are six basics wear particle types generated through the wear process. These
include metallic particles that comprise of Normal Rubbing Wear, Cutting Wear Particles,
Spherical Particles, Severe Sliding particles, Bearing Wear Particle (Fatigue Spall Particles,
Laminar Particles) and Gear Wear (Pitch Line Fatigue Particles, Scuffing or Scoring
Particles) There do also exist sand and dirt particles responsible to generate wear particles in
the system. The particles are classified to determine the type of wear and its source. White
nonferrous particles, often aluminium or chromium, appear as bright white particles. They are
deposited randomly across the slide surface with larger particles getting collected against the
chains of ferrous particles. The chains of ferrous particles typically act as a filter, collecting
contaminants, copper particles and Babbitt. Copper particles usually appear as bright yellow
particles but the surface may change to verdigris after heat treatment. These also will be
randomly deposited across the slide surface with larger particles resting at the entry point of
the slide and gradually getting smaller towards the exit point of the slide. Babbitt particles
consisting of tin and lead, Babbitt particles appear gray, sometimes with speckling before the
heat treatment.
After heat treatment of the slide, these particles still appear mostly gray, but with
spots of blue and red on the mottled surface of the object. Also, after heat treatment these
particles tend to decrease in size. Again, these nonferrous particles appear randomly on the
slide, not in chains with ferrous particles. Contaminants are usually dirt (silica), and other
particulates which do not change in appearance after heat treatment. They can appear as
white crystals and are easily identified by the transmitted light source, that is, they are
somewhat transparent. Contaminants appear randomly on the slide and are commonly dyked
by the chains of ferrous particles. Fibres, typically from filters or outside contamination, they
are long strings that allow the transmitted light to shine through. Sometimes these particles
can act as a filter, collecting other particles. They can appear anywhere on the ferrogram,
however they tend to be washed towards the exit end. Ferrous particles can be broken down
to five different categories, high alloy, low alloy, dark metallic oxides, cast iron and red
oxides. Ferrous particles are identified using the reflected light source on the microscope.
Transmitted light will be totally blocked by the particle. High Alloy Steel - particles are
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found in chains on the slide and appear gray-white. The distinguishing factor in the
identification between high alloy and white nonferrous is position on the slide. If it is white
and appears in a chain, it’s deemed to be high alloy. Otherwise, it’s considered white
nonferrous. Low Alloy Steel - particles are also found in chains and appear gray-white but
they change color after heat treatment. After heat treatment they usually appear as blue
particles but can also appear pink or red. Dark Metallic Oxides - deposit in chains and appear
dark gray to black. The degree of darkness is indicative of the amount of oxidation. Cast Iron
- particles appear gray before heat treatment and a straw yellow after the heat treatment. They
are incorporated in chains amongst the other ferrous particles. Red Oxides (Rust) - polarized
light readily identifies red oxides. Sometimes they can be found in chains with the other
ferrous particles and sometimes they are randomly deposited on the slide surface. A large
amount of small red oxides on the exit end of the slide is generally considered to be a sign of
corrosive wear. It usually appears to the analyst as a “beach” of red sand. Following are the
images of few wear particles.
2.1 Experiment
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After classifying the composition of particles the analyst then rates the size of the particles
using a micrometer scale on the microscope. Particles having size of 30 microns or greater
are given the rating of “severe” or “abnormal.” Severe wear is a definite sign of abnormal
running conditions with the equipment being studied.
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CHAPTER-3
Discussion
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The health status is a single parameter which gives the unit a level of threat. (Health
status is a parameter between 1 -5 with 1 being a healthy machine and 5 being a
machine which is imminently threatened with failure.)
6. Repeat the procedure at a decided time interval. Wear debris analysis is a relatively
simple procedure not requiring a high skills level to perform.
Since the early days of 1986 debris analysis has become a widespread and generally accepted
technique of condition monitoring. Examples of some of the successes achieved with debris
analysis are:
Failure prevention in diesel engines used in haul trucks.
Failure prevention in long wall mining and continuous miner gearboxes.
Failure prediction on a large selection of both surface and underground mining
equipment used in the gold mining industry.
Contamination control in surface gold mining process equipment.
Grease and oil selection through comparative lubricant trials.
Condition monitoring of critical coal milling gearboxes in the power generation industry.
Failure investigations of critical bearings in ball mills used in the gold mining industry.
New Developments in Debris Analysis:- There have been two innovative local
developments of debris monitoring. These are Contamination Control. A simple technique for
monitoring and reporting on levels of solid contamination within a system has been
developed. Previously monitoring of contamination to the accepted codes has either been
time consuming or required an expensive investment in equipment. Now users are able to set
contamination limits for their equipment and simply monitor whether they are within these
limits.
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3.2 Types Of Wear Particles
There are six basic particles type generated through the wear process. These include
ferrous and non-ferrous particles and comprise of:
1. Normal Rubbing Wear: Rubbing wear particles are generated because of normal
sliding wear in a machine and result from exploitation of particles of the shear mixed
layer. Rubbing wear particles consists of flat platelets, generally 5 microns or smaller,
although they might range up to 15 microns depending upon equipment associations.
There should be little or no visible texturing of the surface and thickness should be 1
micron or less
2. Cutting Wear Particles: Cutting wear particles are generated as result of one surface
penetrating another. There are two ways of generating this effect. A relatively hard
component can become misaligned or fractured resulting in hard, sharp edge penetrating
a soft surface. The particle generated this way is coarse and large, averaging 2-5 microns
wide and 25-100 microns long. Hard abrasive particles in the lubrication, either as
contaminants such as sand or wear debris from another part of this system, may become
embedded in soft wear surface (two body abrasion) such as Lead/Tin alloy bearing. The
abrasive particles protrude from the soft wear surface and penetrating the opposing wear
surface. The maximum size of cutting wear particles generated in this way is proportional
to the size of abrasive particles in the lubricant. Very fine wire-like particles can be
generated with thickness as low as 25 microns. Cutting wear particles are abnormal.
Their presence and quantity should be carefully monitored. If the majority of the cutting
particles in a system are a few micrometers long and a fraction of micrometers wide the
presence of particulate contaminants should be suspected. If a system shows increased
quantity of large (50 microns long) cutting wear particles, a component failure is
potentially imminent.
3. Spherical Particles: These particles are generated in the bearing cracks. If generates
their presence gives an improved warning of impending trouble as they are detectable
before any spalling occurs. Rolling fatigue generates few spheres over 5 microns in
diameter while the sphere generated by welding, grinding and corrosion are frequently
over 10 microns in diameter.
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Fig 3 Spherical Particles
4. Severe Sliding: Severe sliding wear particles are identified by parallel on their surfaces.
They are generally larger than 15 microns, with the length-to-width thickness ratio falling
between 5-30 microns. Severe sliding wear particles sometimes show evidence of temper
colours, which may change the appearance of the particle after heat treatment.
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Fatigue spherical particles formed within bearing fatigue cracks range in size from 1
to 10 microns. A marked increase in spherical particles indicates possible equipment distress.
Lubricating oil used in engine may possibly include concentration of such elements as
iron chromium, copper, lead, tin, antimony, borated silver, silicon.
5. Lead Bearings, bushings Iron concentration usually rises as a consequence of higher wear
rate of cylinder liners or piston rings (or of piston where these are of ferrous materials). A
common cause is that of piston rings stuck in their grooves with consequent blow-by of
combustion gases and burning of the oil film adding to scuffing and piston seizure. Iron and
silicon together in high concentration suggests linear and ring wear from dust in the intake
air. This could be caused by inefficient or chocked air filters. Air filter filled relatively low in
the body of a vehicle may choke and allow direct to enter.
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Inspection and sampling intervals for intermittent monitoring methods such as debris
collection and lubricant sampling. This time interval will depend on the application but
fortnightly or monthly is probably a reasonable choice for an industrial application in the
absence of more precise guidance. Debris collection and lubricant sampling can also indicate
the nature of the wear problem and engineers carrying out monitoring need to be given a
regular feedback of information on the accuracy of their diagnosis. A scattering of black
particle fragments (whiskers) is seen. An unacceptable coating is visible. This indicates
abnormal wear. A sample of lubricant is extracted from a machine and analyzed for wear
debris contamination.
There are two most widely used methods and they are:
1. Spectrometric oil analysis program (SOAP)
2. Ferrography
These methods are normally used to monitor the conditions of components lubricated
by a circulating oil system. Two main lubricating sample analysis methods are:
1. Analysis of the sample to determine the concentration of the chemical elements it
contains.
2. Analysis of the sample to determine the amount, size and shape of contaminant
particles contained in it.
Soap
It is a maintenance tool which is used to check the condition of the oil lubricated
mechanical systems (Examples: Motors, Gear boxes, Hydraulic systems). The systems can be
kept under surveillance without dismantling them. Abnormally worn compounds can be
localized and replaced before a catastrophic failure occurs. The quantity and type of wear
metals in sample of lubricating oil is determined. The quantity can indicate something about
the magnitude of the wear and the type of wear metals can reveal which component is
wearing out.
Emission Spectroscopy An emission spectrometer is an optical instrument where the
sample is burned is in a spark between two electrodes. The energy is absorbed by the
metal in the sample, and they emit light with wavelengths, which are characteristic
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For each element in the sample. The intensity of light is proportional to the
concentration of the metal in the sample.
Atomic Absorption Spectroscopy In this, the sample is burned in a gas flame, where
the metal compounds are transferred into atoms that can absorb light at wavelengths,
which can characteristic for each metal. If one wishes e.g. to determine the quantity
of fuel copper, then light with a wavelength characteristic for copper is send through
the flame, where the copper atoms absorb a part of light . The quantity of absorbed
light is proportional with the quantity of copper in the sample. Only particle under
certain size can be measured, which is of the order of 0-10Â Âμm. With emission
spectroscopy somewhat larger particles can be measured.
Limitations
Users of the SOAP claim that they find that a large proportion of the defects which
would lead to the breakdown. This method provides no indication of: Large particles (E.g.
bearings can breakdown due to few large particles) Defects which occurs quickly (E.g. due to
the lack of lubricating oil or due to bearings which burn up) Defects where no wear metals
are formed.(E.g. breakdown due to metal fatigue).
3.5 Ferrography:
It is a technique which is based upon the systematic collection of oil samples from oil-
lubricated machines. The method identifies, isolate and classify wear particles from machine
parts. A magnetic field is used to sort the wear particles in the flowing oil. This technique
was used successfully to monitor the condition of military aircraft engines, gear boxes and
transmissions. Three of the major types of equipments used in wear particle analysis are the
Direct Reading (DR) ferrography, the analytical ferrograph system and Ferrogram scanner.
Registration of the quantity of large and small wear particles is used to monitor the
development of process between checks. Abnormal wear is revealed when there is a change
in distribution of the particles called wear index of the oil.
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With the flowing oil. The density i.e. the concentration of particles at a single location on the
ferrogram is measured with a optical densitometer by allowing light to pass through it.
1. DR Ferrography This is a quick method for which direct reading of the index SD
can be achieved in about 5 minutes. In this apparatus, a controlled flow of oil passes through
a calibrated glass tube which is mounted in a specially designed magnetic field. The
separation causes the particles to be sorted by the size of the bottom of the tube. The
apparatus uses photocells to convert the measured light intensities attained by passing light to
the tube to electric signals. The measured region of the apparatus is 0 -190 DR units, where
maximum value is 190 DR corresponding to the cases where the bottom of the tube is
completely covered with metal particles.
2. The Analytical Ferrograph additional information about a wear sample can be
obtained with the Analytical Ferrograph system, instruments that can provide a permanent
record of the sample, as well as analytical information. The Ferrogram is an important
predictive tool, since it provides an identification of the characteristic wear pattern of specific
pieces of equipment. After the particles have deposited on the Ferrogram, a wash is used to
flush away the oil or water-based lubricant. After the wash fluid evaporates, the wear
particles remain permanently attached to the glass substrate and are ready for microscopic
examination. Ferrogram Maker Instrument Wear-Debris analysis made easy The EDAX
Eagle Micro-Probe EDXRF system provides a fast and simple method for the component
identification of wear-debris particles .
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Fig 6 Babbitt particle
High alloy steel EDAX has led the way in the development and supply of elemental
analysis instrumentation based on the method of energy-dispersive (X-ray) spectrometry
(EDS). The EDS method utilizes the simple spectral information produced as a result of
electron transitions deep within an atom. These X-ray spectra (so called because of their
energy/ wavelength) obtained from a sample under investigation within a suitable analysis
instrument, provide unique information about the type and quantity of the elements present.
EDAX introduced the first commercially available EDS system for electron
microscopy applications The EDS technique is a familiar elemental analysis attachment to a
scanning electron microscope (SEM) where electrons are used as the primary energy source
to excite the X-ray spectra. SEM-EDS methods are used for wear-particle analysis for both
their morphological and compositional properties, and are particularly useful where the study
of very small particles (approximately five microns or less) is necessary. On the other hand,
the radiation output from an X-ray tube may also be employed as an energy source. The
resultant benefits for systems using an X-ray energy source include greatly simplified
specimen handling/presentation needs, less sophisticated instrumentation, simpler and faster
operation and lower cost. Such a standalone system is called an energy-dispersive X-ray
fluorescence spectrometer (EDXRF), of which the EDAX Eagle is a specialized example. the
EDS technique is a familiar elemental analysis attachment to a scanning electron microscope
Ease of analysis:- The magnetic plugs are degreased prior to the transfer of the debris on to a
clear sticky tape (the traditional method used for debris archiving and/or optical examination)
Without the need for any further sample preparation, the tape/debris is presented to the
spectrometer for analysis where, in typically less than two minutes, its analysis may be
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Obtained. Also the measured spectrum can be compared (using spectral pattern-recognition
methods) to stored reference spectra of the monitored assembly's component parts and hence
to identify the component that has worn or been damaged.
4. Applications
1. It is used in situation s where breakdowns are catastrophic or expensive.
2. It is widely used in the military services.
3. In US, it is used by the Air force, Navy and the Army.
4. It is used for many civil aviation companies.
RESULTS
The Result of this analysis is found that the wear debris in oil is dark brown in colour
which shows the presence of Dark metallic oxides.
5. Conclusion
The wear debris monitoring method access the nature of the particles generated when
components wear. They can
indicate exact nature of the machine problem
indicate the amount of debris present
indicate the size distribution of debris
indicate the physical form of debris
application of chemical analysis of debris
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6. References
[1] Moreton, G and Yardley, E D - The Use Of Wear Debris Analysis to Monitor Gear
Transmissions Under ground. Proc. of the Conf. on Condition Monitoring, 1984, p491.
[2] Lester M F and Brooks A - Debris Testing Progress and Further Developments. Proc. of
the Conf. on Condition Monitoring 1987
[3] Fogel A G and Wright G J - Case Study: The Application of wear Debris Analysis for
Monitoring Under ground Continuous Coal Miners. Conf. Proc. of “Tribology 86".
[4] Fogel A G and Wright G J - Refining Wear Debris Monitoring as a useful Applied
Technology in Maintenance Management. Conf. Proc. of “Tribology 88".
[7] Reference:http://seminarprojects.com/thread-wear-debris-analysis-full-
report#ixzz2af9kpj3p.
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