Abstract
Condition monitoring of dynamic systems based on oil analysis is well known for closed-loop systems. The motivation for this work stemmed from repeating failures of Wankel engines. Failure analysis identified contact fatigue as the failure mechanism, but could not identify the cause. Thus, the objective of the work was to develop a method for condition monitoring of open-loop oil systems. A variety of analytical techniques was evaluated, including direct-reading ferrography, analytical ferrography combined with computational image analysis, atomic emission spectroscopy, and scanning electron microscopy combined with energy dispersive X-ray spectroscopy. Procedures for collection and separation of oil samples were developed. Analytical ferrography was found most useful in condition monitoring. Six engines were detected in their early failure stage. Those engines were disassembled, and contact fatigue failures in the bearing needles were observed. The quantitative image analysis allowed for a fairly objective rating of the wear level. The method developed in this work has already been implemented on a daily basis for monitoring the health of Wankel engines, with much success.
Similar content being viewed by others
References
Eliaz, N., Latanision, R.M.: Preventative maintenance and failure analysis of aircraft components. Corros. Rev. 25, 107–144 (2007)
Bowen, E.R., Westcott, V.C.: Wear Particle Atlas (Revised), vol. 1. Naval Air Engineering Center Contract number N00156-74-C01682, July (1976)
Maslach, J.K.: Ferrographic analysis of grease-lubricated systems: an analysis of greases in roller bearings. Lubr. Eng. 52, 662–666 (1996)
Toms, L.A.: Machinery Oil Analysis—Methods, Automation and Benefits, 2nd edn., pp. 106, 160. Coastal Skills, VA (1995)
Keith Mobley, R.: An Introduction to Predictive Maintenance, 2nd edn., p. 202. Butterworth-Heinemann, MA (2002)
Troyer, D., Fitch, J.: Oil Analysis—Basics, p. 67. Noria Corp., Tulsa, OK (2001)
Sheppard, K., Zagrai, A., Donskoy, D.: A non-linear acoustic, vibro-modulation technique for the detection and monitoring of contact-type defects, including those associated with corrosion. Corros. Rev. 25, 81–96 (2007)
Calvello, G., Olin, S., Hess, A., Frith, P.: PHM and corrosion control on the joint strike fighter. Corros. Rev. 25, 51–79 (2007)
Bovio, I., Lecce, L.: Health monitoring of aeronautical structures based upon vibration measurements and identification algorithms. Corros. Rev. 25, 27–37 (2007)
Cajani, M.: Ageing airframes and corrosion maintenance. Corros. Rev. 25, 263–274 (2007)
Ščekaturovienė, D., Višniakov, N.: Atomic emission spectrometric analysis in the assessment of wearing of vehicle engines. Mater. Sci. (Medžiagotyra) 10, 15–17 (2004)
Doyle, E.D., Atkin, M.L.: A review and case study of wear mechanisms and condition monitoring. In: Joint National Symposium 1985: The Influence of Aviation on Engineering and the Future of Aeronautics in Australia, p. 23, Preprints, The Institution of Engineers, Melbourne, Australia (1985)
Stecki, J.S., Kuhnell, B.T.: Condition monitoring of jet engines. Lubr. Eng. 41, 485–493 (1985)
Lukas, M., Anderson, D.P.: Analytical Tools to Detect and Quantify Large Wear Particles in Used Lubricating Oil. Spectro Inc., MA (2003)
Lockwood, F.E., Dalley, R.: Lubricant analysis. In: ASM Handbook Vol. 18: Friction, Lubrication, and Wear Technology, p. 302. ASM International, Materials Park, OH (1992)
Staff report, Ferrography: a tool for wear-particle analysis. Hydraulics & Pneumatics, November, pp. 59–61 (1986)
Seifert, W.W., Westcott, V.C.: A method for the study of wear particles in lubricating oil. Wear 21, 27–42 (1972)
Westcott, V.C.: Method and apparatus for segregating particulate matter. US Patent 4,047,814, 13 Sept 1977
Reda, A.A., Bowen, R., Westcott, V.C.: Characteristics of particles generated at the interface between sliding steel surfaces. Wear 34, 261–273 (1975)
Scott, D., Seifert, W.W., Westcott, V.C.: The particles of wear. Sci. Am. 230, 88–97 (1974)
Roylance, B.J.: Ferrography—then and now. Tribol. Intern 38, 857–862 (2005)
Stecki, J.S.: Failure prediction using ferrographic oil analysis techniques. In: Proceedings of the Conference on Lubrication, Friction and Wear in Engineering, p. 281. The Institution of Engineering, Melbourne, Australia (1980)
Merhib, C.P.: The on-line ferrograph. In: Proceedings of the Conference on Lubrication, Friction and Wear in Engineering, p. 277. The Institution of Engineering, Melbourne, Australia (1980)
Centers, P.W.: Laboratory evaluation of the on-line ferrograph. Wear 90, 1–9 (1983)
Holzhauer, W., Murray, S.F.: Continuous wear measurement by on-line ferrography. Wear 90, 11–19 (1983)
Barwell, F.T.: The role of particle analysis—a review of ferrography. In: Dowson, D., Taylor, C.M., Godet, M., Berthe, D. (eds.) Developments in Numerical and Experimental Methods Applied to Tribology, p. 3. Butterworths, London (1984)
Yan, L., Youbai, X., Fang, Z., Zhigang, Y.: Revision to the concept of equilibrium concentration of particles in lubrication system of machines. Wear 215, 205–210 (1998)
Zhang, P., Johnson, W.P., Rowland, R.: Bacterial tracking using ferrographic separation. Environ. Sci. Technol. 33, 2456–2460 (1999)
Zhang, P., Johnson, W.P.: Rapid selective ferrographic enumeration of bacteria. J. Magnetism Magnetic Mater. 194, 267–274 (1999)
Johnson, W.P., Zhang, P., Fuller, M.E., Scheibe, T.D., Mailloux, B.J., Onstott, T.C., Deflaun, M.F., Hubbard, S.S., Radtke, J., Kovacik, W.P., Holben, W.: Ferrographic tracking of bacterial transport in the field at the Narrow Channel Focus Area, Oyster, VA. Environ. Sci. Technol. 35, 182–191 (2001)
Meyer, D.M., Tillinghast, A., Hanumara, N.C., Franco, A.: Bio-ferrography to capture and separate polyethylene wear debris from Hip simulator fluid and compared with conventional filter method. J. Tribol. 128, 436–441 (2006)
Parkansky, N., Alterkop, B., Boxman, R.L., Leitus, G., Berkh, O., Barkay, Z., Rosenberg, Yu., Eliaz, N.: Magnetic properties of carbon nano-particles produced by a pulsed arc submerged in ethanol. Carbon 46, 215–219 (2008)
Ishay, J.S., Barkay, Z., Eliaz, N., Plotkin, M., Volynchick, S., Bergman, D.J.: Gravity orientation in social wasp comb cells (Vespinae) and the possible role of embedded minerals. Naturwissenschaften 95, 333–342 (2008)
West, K.C.: Energy Conversion, Brooks/Cole, p. 261. University of Tulsa (2000)
http://en.wikipedia.org/wiki/Wankel_engine. Accessed 3 May 2009
Raadnui, S.: Wear particle analysis—utilization of quantitative computer image analysis: a review. J. Tribol. Intern. 38, 871–878 (2005)
Russ, J.C.: Computer-Assisted Microscopy: The Measurement and Analysis of Images. Plenum Press, NY (1990)
Powel, G.W., Mahmoud, S.E.: ASM Handbook Vol. 11: Failure Analysis and Prevention, 9th edn., p. 586. ASM International, Materials Park, OH (1986)
Lawcock, R.: Rolling-contact fatigue of surface-densified gears. Intern. J. Powder Metall. 42, 17–29 (2006)
Zaretsky, E.V., Parker, R.J., Anderson, W.J., Reichard, D.W.: Bearing life and failure distribution as affected by actual component differential hardness. NASA Technical Note TN D-3101, Washington DC, November (1965)
ASTM E45-05e2: Standard Test Methods for Determining the Inclusion Content of Steel. ASTM International, West Conshohocken, PA
Acknowledgments
The authors are grateful to Mr. Kobi Basan and Mr. Konstantin Tartakovski for their significant contribution to the success of the project. We thank Mr. William Kopelovitch for his help in quantitative image analysis. We are also thankful to Prof. Isaac Garbar for his peer-review and professional advices.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Levi, O., Eliaz, N. Failure Analysis and Condition Monitoring of an Open-Loop Oil System Using Ferrography. Tribol Lett 36, 17–29 (2009). https://doi.org/10.1007/s11249-009-9454-2
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11249-009-9454-2