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Page 1 of 17
ppm
of
wear
metals
using
Atomic
Absorption
Spectrometer.
The
images
below
are
from
machines
that
appear
to
be
in
an
Page 2 of 17
Below
shows
the
normal
Lubricating
Film
Thickness
in
each
application
in
operating
conditions.
Particles larger than the lubrication film thickness become Three Body Contact Contaminate Particles
as
the
lubricant
flow
forces
them
through
the
load
zone,
easily
penetrating
the
lubricating
film,
0.4 to 1
Micron
Ball Bearings
0.4 to 0.7
Micron
Journal Bearings
0.5 to 25
Microns
Hydrostatic Bearings
5 to 100
Microns
Gears
0.1 to 1
Micron
Dynamic Seal
0.05 to 0.5
Micron
0.5 to 5
Microns
0.5 to 5
Microns
5 to 13
Microns
0.5 to 1
Micron
5 to 40
Microns
0.5 to 5
Microns
130 to 450
Microns
18 to 63
Microns
1 to 4
Microns
Actuators
130 to 450
Microns
Human Hair
70 to 100
Microns
Page 3 of 17
Abrasion
Fatigue
Three-body
rolling
load bearing surfaces.
roughens
and
Erosion
Particles
suspended
in
high
velocity
and wearing away load bearing surfaces.
fluid
impact
Striction
during
Fouling
Of
Corrosion
Attack
by
water
or
during oxidation of fluids.
nozzles,
contact
flow
passages,
aggressive
oil
galleries,
chemicals
microdents
component
surfaces,
fracturing
against
the
feed
such
from
down
lines,
as
surface,
periods
heat
organic
cutting
cause
exchangers.
Acids
as
contaminate
catalysed
chemicals
or
water,
and
formed
reactions,
depleting
Page 4 of 17
Page 5 of 17
Sliding Wear occurs when the lubricants film strength has been insufficient in
providing separation between two wear surfaces, allowing metal to metal contact.
Its like the glacier sliding down the hill, it bulldozers along the surface
tearing everything off in its path. Severe sliding wear generates extreme heat,
in some cases over 1000C in the load zone. How many times you have seen
a large gearbox showing gear case temperatures above 100C?
How much energy would it take to heat the gearbox to this temperature?
How much energy is being wasted by tearing off metal, which could be
turned into production?
To generate this heat, the machine is tearing off of 50 to 200 micron
chunks of metal and releasing them into the lubricant flow. This forces
the metal chunks through the rolling elements of the machine causing
secondary wear. Gear faces subject to high temperatures over time,
anneal the gear tooth surfaces, softening them promoting further wear.
Here are examples of Sliding Wear Particles 500X-600X Sized 40-200 Microns.
Page 6 of 17
Cutting
Silica
Wear
(Sand),
Particles
or
are
other
hard
caused
by
hard
contaminants,
or
contamination,
an
acute
usually
angle
of
metal to metal contact that has occurred between the machines components.
The distinctive curled swarf, shapes of Cutting Wear Particles, show a hard
contaminate has penetrated the lubricating film, gouging out the metal.
Cutting Wear is an abnormal wear mode. Cutting Wear Particles results
in machinery damage and should corrected as soon as possible.
Filtergram Analysis identifies all wear mode types present, then recommends
changes and monitors the immediate effect of the changes to ensure success.
Page 7 of 17
2 Body Fatigue Wear chunks occur when the machines cyclic application
of the stress, is in excess of the design value.
The machine has been overloaded, past the capabilities of the metals surface,
slightly collapsing the metals sub-surface creating a crack or dent.
Repetitive bruising in this area further fractures the metals sub-surface causing
the area to eventually spall out. This creates the familiar deep pitting and scaring
damage observed on load bearing surfaces. Spheres are usually generated in
these areas.
2 Body Fatigue Wear Particles are flat platelets with a major dimension to
thickness ratio of approximately 10:1, a smooth surface and a random
irregularly shaped circumference.
These spalling metal particles are carried by the oil flow through other load
zones, snowballing the effect and further damaging load-bearing surfaces.
Damage will continue to this machine until the contamination is completely
removed
Filtergram Analysis identifies all wear mode types present, then recommends
changes and monitors the immediate effect of the changes to ensure success.
Page 8 of 17
3 Body Fatigue Wear Chunks are wear metal Particles that began when
a foreign body was forced through the load zone creating a micro crack or dent.
Repetitive bruising in this area fractures the metals surface, causing the area to
eventually spall out. This creates the familiar loss of hardened surface, scaring
and light pitting damage observed on load bearing surfaces.
These spalling metal particles are carried by the oil flow through other load
zones, snowballing the effect and further damaging load-bearing surfaces.
Damage will continue to this machine until the contamination is completely
removed.
Filtergram Analysis identifies all wear mode types present, then recommends
changes and monitors the immediate effect of the changes to ensure success. If
not corrected this wear mode will escalate in Scuffing Wear and eventual failure.
Three Body Wear
Scuffing Wear
Page 9 of 17
Page 10 of 17
Red Iron Oxide Particles are easily formed when water is present in the
system, or has been in the system in the past.
If heavy amounts of large Red Iron Oxide Particles are found in the sample, this
will indicate the presents of water in the system.
Red Iron Oxide particles vary in colour and size with the amount of water present.
The presence of other minerals, in the water and the size of the crystals, all have
an effect on the way the Red Oxide Particles form. Below are several different
forms of Red Iron Oxide Particles, the effect of the formation of these particles
on the metal surfaces causes severe surface corrosion damage and subsequent
loss of load carrying surface area, this is catalysed by the formation of the Red
Iron Oxide Particles.
Filtergram Analysis identifies all wear mode types present then recommends
changes and monitors the immediate effect of the changes to ensure success.
Page 11 of 15
Dark Metallo & Black Oxide Particles are formed when machine is being over
driven beyond the capability of the lubricant. The heat and pressure generated
causes lubricant starvation. When Red Iron Oxide (rust), is forced through the
load zone it polymerises and forms Dark Metallo-Oxide and Black Oxide
Particles. Water is not present when Black Oxide Particles and Dark MetalloOxides are formed. There are many forms of Iron Oxides FeO, Fe2O3 and
Fe3O4.
To rectify this wear mode the lubricant should be up graded to a product more
suitable to the machines operating environment. It is not unusual to see particles
oxidised to varying degrees of colour , from straw through to blue purple.
Filtergram Analysis identifies all wear mode types present then recommends
changes and monitors the immediate effect of the changes to ensure success.
Page 12 of 15
Laminar Wear is a secondary wear mode, which is the end result of all wear
modes being forced through the load zone by the lubricant flow. Their passage
damages load bearing surfaces, forming large rolled out particles that contain
all wear modes created earlier. The machines rolling elements roll the abnormal
Wear Metal Particles flat, to the distinctive length to thickness 30:1 ratio.
Typical operating lubrication film clearance in Industrial Ball Bearing, Roller
Bearing and Meshing Gear Sets are of 0.1 to 1-Micron clearance. When spalls or
breakages occur, or foreign contaminates are introduced to the lubrication
system, the foreign particles could be 100s of microns in size, the human hair is
60 to 100 microns in diameter. The lubricant flow forces these huge foreign
particles, through the machines rolling gears and bearings causing extensive
damage to the machines running surfaces.
As these chunks of metal, up to 500 microns in size, are forced through the
bearings and gears, with a maximum clearance of 1 micron, they crush and mill
down forming the 0 to 15 microns sized abnormal wear metals that register when
an Atomic Absorption Spectrometer test is preformed. Most people have
trended the wear rate using the Atomic Absorption Spectrometer from the
local Caterpillar Agent or Fuel Company. The problem with this type of
analysis is wear particles are required to be milled down by the
machines rolling elements to the small size of 0-10 microns before they
register in the test. Particles bigger than 10-micron increase the particle
count but cannot be identified. This means this the Atomic Absorption
Spectrometer often only registers the introduction of a contaminant 2 to 3
months after the event. Undetected contaminates cause extensive damage to
the machines wear surfaces, shortening their life by cracking and denting the
surface in the end forming other abnormal wear metals shown ahead. Filtergram
Analysis identifies all wear mode types present, then recommends changes and
monitors the immediate effect of the changes to ensure success.
Damage will continue to the machine until the contamination is completely
removed.
Mainlube Superior Maintenance Lubricants Pty Ltd
Page 13 of 17
Note: See how as the time extends the particles are broken up smaller.
Page 14 of 17
Range Number 24
indicates
80,000 to 160,000
Range Number 23
indicates
40,000 to 80,000
Range Number 22
indicates
20,000 to 40,000
Range Number 21
indicates
10,000 to 20,000
Range Number 20
indicates
5,000 to 10,000
Range Number 19
indicates
2,500 to 5,000
Range Number 18
indicates
1,300 to 2,500
Range Number 17
indicates
640 to1,300
Range Number 16
indicates
320 to 640
Range Number 15
indicates
160 to 320
Range Number 14
indicates
80 to 160
Range Number 13
indicates
40 to 80
Range Number 12
indicates
20 to 40
Range Number 11
indicates
10 to 20
Range Number 10
indicates
5 to 10
Range Number 9
indicates
2.5 to 5
Range Number 8
indicates
1.3 to 2.5
Range Number 7
indicates
0.64 to 1.3
Range Number 6
indicates
0.32 to 0.64
Range Number 5
indicates
0.16 to 0.32
Range Number 4
indicates
0.08 to 0.16
Range Number 3
indicates
0.04 to 0.08
Range Number 2
indicates
0.02 to 0.04
Range Number 1
indicates
0.01 to 0.02
Page 15of 17
The ISO Solid Contaminant Code ISO 4406 is the single most wide spread system for representing contaminant
levels in Hydraulic or Lube Oil Systems.
ISO 4406 uses 2 range numbers, the first one representing particle counts above 5 microns and the second one
represent particles counts above 15 microns.
The first range number is separated for the second range number by a slash, (eg 15/12) From the chart, the particle
count ranges correspond to each adjacent range.
A typical ISO Code for a hydraulic system is ISO 16/13.
By checking the Range Chart we can see that
Range Number 16 means there are between 320 and 640 particles per ml of oil bigger than 5 microns.
And
Range Number 13 means there are between 40 and 80 particles per ml of oil bigger than 15 microns included in this
first total of between 320 and 640 particles per ml of oil.
This equates to approximately I milligram of dirt per litre of fluid or 1 ppm.
A Vickers Chart of Recommended Cleanliness Codes uses the Pal or Vickers System, same as this ISO 4406
Systems Range Numbers. Vickers being a leading Hydraulic Equipment Manufacturer developed this system to
prevent unnecessary wear in hydraulic systems.
The difference between the Vickers System and ISO 4406 is that Vickers also consider particles 2 microns and
greater, this range is recorded by adding another set of numbers in front for the number of particles greater than 2
microns. eg 18/15/12, or;
(1300 to 2500 particles >2 microns/ 160 to 320 particles >5 microns/ 20 to 40 particles >15 microns).
At all times the first Range Number will indicate the total number of particles of all sizes per ml of lubricant, the
subsequent Range Numbers indicate the sizing of the particles in this first total
Both systems without the previous pages chart offer limited information until the system has been learnt and
understood. Once this is accomplished the user will notice any unusual Range Number changes and be very accurate
with early detection and correction of abnormal wear modes.
Page 16 of 17
Test No.
___/___/___
NOTE: TO ENSURE PROCESSING OF THIS SAMPLE ALL APPLICATION DETAILS MUST BE COMPLETED
CUSTOMER NAME, ADDRESS, PH & FAX.
_________________________________________________________________________________________________
_________________________________________________________________________________________________
_________________________________________________________________________________________________
Attention :
Phone :
Fax :
NOTE: TO ENSURE PROCESSING OF THIS SAMPLE ALL APPLICATION DETAILS MUST BE COMPLETED
APPLICATION DETAILS
Unit, Vehicle, Plant, Rego,
Id, Number, Name, etc:______________________________________ Equipment Make :_________________________
Equipm ent Model:____________________ Total Machine Hours/Kms:_____________ Hours/Kms on Oil:______________
Lubricant Brand,
Machine Location :___________________________ Type, & SAE :___________________________________________
Filter Changed: Yes / No.
Top Up Ltrs : ______________. Oil Changed: Yes / No. OIL QUANTITY _________Litres
HP/kW _______________
Compressor;
Vacuum
Pump;
Heat
Transfer
System;
Page 17 of 17