Understanding Bearing

Failure Modes
Bearings are essential components in a wide range of machinery, from
simple household appliances to complex industrial equipment.
Understanding the different failure modes that can affect bearings is
crucial for maintaining the reliability and longevity of these critical
components. The International Organization for Standardization (ISO)
has established the ISO 15243 standard, which outlines six primary
classifications of bearing failure modes. By exploring these failure modes
in detail, engineers and maintenance professionals can develop
strategies to mitigate the risks and prolong the lifespan of their bearings.

by Davood
4 ISO - Classification for bearing failure modes, ISO 15243:2004

5.1 Fatigue --.--- 5.1.2 Subsurface initiated fatigue

5.1.3 Surface initiated fatigue --

5.2 Wear --.--- 5.2.2 Abrasive wear

5.2.3 Adhesive wear

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5.3 Corrosion --- 5.3.2 Moisture corrosion

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5.3.3 Frictional corrosion 5.3.3.2 Fretting corrosion

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5.4.2 Excessive voltage____ 5.3.3.3 False Brinelling

5.4.3 Current leakage

5.5 Plastic deformation ----��- 5.5.2 Overload

5.5.3 Indentation from debris

5.5.4 Indentation by handling

5 .6 Fracture/cracking --.--- 5.6.2 Forced fracture

5.6.3 Fatigue fracture

5.6.4 Thermal cracking

Rolling Contact Fatigue
Cyclic Stress 1
Rolling contact fatigue is the most
common type of bearing failure and is
caused by the cyclic stresses that 2 Subsurface Cracking
develop within the bearing's raceway As the cyclic stresses continue, the
or rolling elements. These stresses can cracks will gradually grow and spread,
initiate and propagate cracks beneath compromising the structural integrity
the surface, leading to the eventual of the bearing. This subsurface
flaking or spalling of the bearing cracking is a key indicator of rolling
material. contact fatigue and can eventually
lead to the complete failure of the
bearing.
Spalling and Flaking 3
The final stage of rolling contact
fatigue is the visible manifestation of
the subsurface cracks, resulting in the
spalling or flaking of the bearing
surface. This damage can accelerate
the failure of the bearing and lead to
the need for replacement or repair.
5 Failure mode descriptions
Failure mode 5.1: Fatigue
5.1.2 Subsurface initiated fatigue 5.1.3 Surface initiated fatigue

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Wear and Its Manifestations
Abrasive Wear Adhesive Wear Fretting Wear

Abrasive wear is caused by Adhesive wear occurs when Fretting wear is caused by
the introduction of hard the bearing surfaces weld small, vibratory motions
particles into the bearing, together under high pressure between the bearing
which can scratch and grind and shearing forces, leading surfaces, leading to the
away the bearing surfaces. to the gradual removal of gradual removal of material.
This type of wear is typically material. This can be This can be a particular issue
associated with exacerbated by inadequate in applications where there
contaminated lubricants or lubrication or misalignment are tight clearances or where
harsh operating within the bearing. the bearing is subject to
environments. oscillatory loads.
Failure mode 5.2: Wear

5.2.2 Abrasive wear

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Corrosion: A Chemical Attack

1 Pitting 2 Etching
Corrosion can cause pitting on the The chemical attack from corrosive agents
bearing surfaces, creating small can also lead to the etching of the bearing
indentations that can accelerate the surfaces, compromising the structural
failure of the bearing. integrity of the material.

3 Softening 4 Discoloration
In some cases, corrosion can cause the Visible discoloration of the bearing
bearing material to soften, making it more surfaces is a common indicator of
susceptible to wear and deformation corrosive attack, signaling the need for
under load. further inspection and potential
remediation.
Failure mode 5.3: Corrosion

5.3.2 Moisture corrosion

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FaHure mode 5.3: Corrosion

5.3.3 Frictional corrosion

5.3.3.2 Fretting corrosion

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Failure mode 5.3: Corrosion

5.3.3 Frictional corrosion

5.3.3.3 False Brinelling

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Electrical Erosion: The Impact of Stray
Currents
Pitting Melting Disintegration
Electrical erosion can cause The passage of electrical In extreme cases, electrical
pitting on the bearing current through the erosion can lead to the
surfaces, creating small bearing can also lead to the complete disintegration of
indentations that can lead melting of the bearing the bearing surfaces,
to further damage and material, causing severe resulting in the
eventual failure. damage and catastrophic failure of the
compromising the bearing.
bearing's functionality.
Failure mode 5.4: Electric erosion

5.4.2 Excessive voltage 5.4.3 Current leakage

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Plastic Deformation: When the Load is Too
High

Brinelling Smearing Cracking

Plastic deformation can Under high loads, the In severe cases, the high
cause brinelling, which is the bearing material can also loads can cause the bearing
formation of indentations in become "smeared," or rings or rolling elements to
the bearing raceway due to displaced, resulting in a loss crack, leading to a
excessive loads. This can of dimensional accuracy and catastrophic failure of the
compromise the smooth potential failure. bearing.
operation of the bearing and
lead to further damage.
Failure mode 5.5: Plastic deformation

5.5.2 Overload

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Failure mode 5.5: Plastic deformation

5.5.3 Indentation from debris

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Failure mode 5.5: Plastic deformation

5.5.4 Indentation by handling

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Cracking and Fracture: Sudden Failure

Overload Fatigue Stresses

Sudden overloads can cause cracks to Cumulative fatigue stresses over time can also
propagate through the bearing material, cause cracks to develop and spread, resulting in
leading to catastrophic failure. the eventual fracture of the bearing.
Failure mode 5.6: Fracture

5.6.2 Forced fracture 5.6.3 Fatigue fracture

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Failure mode 5.6: Fracture

5.6.4 Thermal cracking

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Other: Discolouration

Overheating Chemical

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Preventing Bearing Failures
Proper Lubrication Ensure adequate lubrication to prevent wear
and corrosion.

Contamination Control Implement measures to keep contaminants

out of the bearing environment to avoid
abrasive wear.

Monitoring and Inspection Regularly inspect bearings for signs of wear,

corrosion, or deformation to catch issues
early.

Alignment and Load Distribution Ensure proper alignment and load

distribution to prevent excessive stress and
deformation.

By understanding the various bearing failure modes and implementing appropriate preventive
measures, engineers and maintenance professionals can significantly improve the reliability and
lifespan of critical machinery components.