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org International Engineering Research Journal (IERJ), Volume 3 Issue 3 Page 5318-5321, 2019 ISSN 2395-1621

ISSN 2395-1621
Wear Particle Analysis Using
Ferrography
#1
Miss. Yogita N. Patil, #2Prof. Dr. R.R. Navthar

1
yogita.patil9@yahoo.com
2
ravi_navthar@rediffmail.com

#1
P.G. research Scholar at Department of Mechanical Engineering
#2
Professor at Department of Mechanical Engineering

Dr. Vithalrao Vikhe Patil College Of Engineering, Vilad Ghat, Ahmednagar, India -414111,
Savitribai Phule Pune University, Pune-411041

ABSTRACT ARTICLE INFO

The Ferrographic analysis of wear particles contained in used lubricant oil samples Article History
that collected from the engines and gearboxes of a Hero Honda Splendor bike.
Received: 4th May 2019
Ferrography analysis and elemental analysis have been employed to selection the
material information about the physical point of used oil and the wear condition of Received in revised form :
the parts from gearbox and main engine. The application of wear particle analysis
4th May 2019
and ferrography in particular is an effective means to identify and respond to
maintenance needs of bike engine. Accepted: 06th May 2019
Published online :
Keywords: Lubricant oil, ferrographic analysis, wears particles, elemental analysis. 11th May 2019

I. INTRODUCTION densitometer by allowing light to pass through it. The wear

index SA = AL2-AS2 is obtained by the comparison of the
Ferrography is a wear particle analysis utilizing density AL of the large particles and the density AS of the
diagnostic and predictive techniques to evaluate the on- small particles.
line condition of interacting lubricated or fluid powered
parts or components. The use of Ferrography to assess a
system’s condition is to avoid time consuming and
potentially damaging hardware teardown and other
destructive or interfering inspections. Ferrography can
analyze a system’s fluid to determine the type of wear it is
experiencing and hence, predict the type of system failure
and when the failure may occur. Ferrography can provide an
established and easily performed inspection method for
determining the health of a system and providing an early
failure detection method. Ferrographic analysis
encompasses wear (metallic and non-metallic), contaminant
(crystals, water, and organic and inorganic compounds), and
lubricant (friction polymers) monitoring.
Fig1.1. Ferrograpy [4]
1.1 Ferrograph analysis apparatus
1.2 Types of ferrograph instruments
The particles are separated on a serve object glass where
Two basic types of ferrograph instruments are used to
due to its displacement in a special magnetic field (with a
assess the wear particles.
very high field gradiation) causes the particle should be
sorted according to size. The largest particles are unload
first while smaller ones travel farther with the flowing oil.  Direct reading ferrograph System
The density i.e. the attentiveness of particles at a single  Analytical Ferrograph system
location on the ferrogram is measured with a optical

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1.2.1 Direct reading ferrograph System 2. The FM Ferrograph, which accurately prepares
ferrograms, or slides on which wear particles have been
The direct reading ferrograph, shown in Fig1.2.1.1, deposited
measures the concentration of wear particles in a 3. The PASSPORT SOFTWARE system for data
lubrication oil or hydraulic fluid. The particles are subjected management and reporting.
to a powerful, magnetic gradient field and are separated by
order of decreasing size. 1. Ferroscope
The ferroscope is a three-power bi-chromatic
microscope with a CCPC camera for recording digital
images. Under magnifications of 100X, 500X, and 1000X,
the ferroscope utilizes both transmitted and reflected light
sources with red, green, and polarizing filters to distinguish
the size, composition, shape, and surface of both metallic
and non metallic wear particles.

2. Ferrogram maker
The FM ferrogram maker, shown in Fig. 1.2.2.1, is
designed with two independent stations to permit two
samples to be prepared at the same time. Each station
includes a holder that accurately positions a slide at a slight
incline over the machine assembly.

Fig 1.2.1.1 Direct Reading Ferrography System [1]

Particles 5 μm and larger are confined to the entry end of the

deposition field, as shown in Fig. 1.2.1.2. The particle sizes
become progressively smaller along the deposition path.

Fig 1.2.2.1 The FM-Ill Ferrograph, An Instrument In The

Analytical Ferrograph System, Prepares Ferrograms For
Analysis [1]
Ferrograms, as depicted in Fig 1.2.2.1 can be
Figure 1.2.1.2 In A Direct Reading Ferrograph, Wear prepared automatically, semi-automatically, or manually at
Particles In An Oil Or Fluid Are Deposited Subject To A the operator’s option. In the automatic mode, the oil sample
Magnetic Gradient And Are Separated By Decreasing Size. is deposited on the glass slide at a carefully controlled rate.
[1]
At the end of the sample discharge cycle, the wash cycle is
Particle attentiveness are sensed at two locations—at the automatically initiated, and an audio and visual signal
entry deposit and at a point approximately 4 mm further indicates when the ferrogram is complete. A sample of used
down the tube. Based on the calculation of the density of fluid, which can be a lubricant pre preparation, a hydraulic
large particles, DL, and the density of small particles, DS, fluid, or an aqueous solution, is prepared by diluting with
we can derive values for wear particle concentrations and tetrachloroethylene (actisol) as a fixer to improve particle
the percentages of large particles. With these measurements, precipitation and adhesion.
machine wear baselines can be established, and trends in
wear condition can be monitored. This system direct
ferrograph readings serve to alert maintenance personnel to
an abnormal trend in wear.

1.2.2 Analytical ferrography system

When direct ferrograph readings indicate abnormal
wear, analytical ferrographic techniques can be used to
study the wear pattern. The purpose is to pinpoint the
difficulty and identify the nature of potential machine
problems. Analytical ferrograph system includes: Figure.1.2.2.2 Ferrograms are prepared by depositing an
oil sample on a glass slide. Showing particles lined up in
1. A ferroscope for measurement and analysis strings, the sample on the left was taken at close to the
entry deposit, at 50 mm

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PASSPORT SOFTWARE SYSTEM investigations indicate the kind of lubricating oil base stock
and its improvement way, as well as type of engine and its
The Passport Software features the Passport system for service conditions as very important factors affecting the
enhanced data management, comparative analysis, and engine oil performance depreciation.
reporting. As shown in Fig. 1.2.2.3, the system features a Yuesen Wang, Xingyu Liang, GequnShu, LihuiDong
video camera that projects the image through a personal (2015) [7]Lubricating oil contributes to both small and large
computer to a high resolution video monitor. size particles. However, conclusion that large particles
mainly from the unburned organic and metallic additive
fraction should be further verified in future works. The
combustion ratio of oil determines its influence. Low
combustion ratio donate to lose aggregate structure, while
high ratio contributes to compact one. Oil-related particles
have larger collection size than neat diesel particles, which
may be caused by the unburned organic and metallic ash
fraction in particles.
Chandan Kumar, Dr. Manoj Kumar (2016) [8] stated that
Ferrography is a method for analyzing the particles present
in fluids that indicate mechanical wear. Ferrography supply
Fig 1.2.2.3 The PASSPORT Analytical System [1] Microscopic Examination and Analysis of Debris (particles)
found in lubricating oils. These particles contain of metallic
II. LITERATURE REVIEW
andnon metallic matter. The metallic particle in a wear
The aim of the literature review was to get the condition that separates different size and shapes of metallic
detail about the approach of methodology adopted in dust from components like all type of bearings, gears or
carrying out wear particle analysis using Ferrography. coupling (if lubricated in path). Non - metallic particle
contains of dirt, sand or corroded metallic particle.
Raymond .J.Dalley (1990) [1] stated that a ferrographics Analytical ferrography is among the most powerful
analysis of wear particles starts with the magnetic separation
determination tools in oil analysis in tribology. When
of machine wear debris from the lubricating, grease, or
hydraulic media in which it becomes suspended. execute correctly it provides tremendous information on
R. Gligorijevic, J. Jevtic and D. J. Borak (2006) [2] stated machine under operation. Yet, it is frequently excluded from
that the reduction of harmful pollutant emissions as well as oil analysis programs because of its comparatively high cost
CO2 emissions emanating from motor vehicles will beof and a general misunderstanding of its value. Performance
considerable interest in the coming decades. Emissions may be upgrade through proper filtration of oil. Clean oil
legislation will be the guiding principle in the lubrication is always more effective. Adopting approach of
developmentof new technologies and vehicles.
N.Govindarajan& R. Gnanamoorthy (2008) [3] states that oil replacement is expensive. A rapid centrifuged and/ or
failure analysis of the rolling sliding contact fatique magnetic separator cleaning structure helps cost cutting and
specimens tested at the different contact stress and slide roll disposal of used oil, as well. Ferrography also helps upgrade
ratio are carried out .Severe running in wear particles are filtration efficiency and frequency for oil cleaning systems.
ferrogram prepared in the sintered materials while the The objective of their work was to present the ferrographic
concentration of the wear particles is less in the wrought analysis of wear particles contained in used lubricant oil
steels
samples that collected from the engine of dumper, A heavy
O. Levi Æ N. Eliaz (2009) [4]A sensitive, reliable procedure
was developed for condition monitoring of an open-loop oil vehicle that normally used in coal mines. The supplication
system, based mainly on Analytical Ferrographythis is the of wear particle analysis and ferrography in particular is an
first demonstration in the literature of the use of Analytical effective means to identify and respond to maintenance
Ferrography for health monitoring of an open-loop oil needs of Engines and machineries.
system. The method is already used on adaily basis. PRABIR KUMAR BANDYOPADHYAY,RAM BALAK
M.C. Isaa, N.H.N. Yusoffa, HasrilNaina, MohdSubhi CHOUDHARY ,RAVIRANJAN PRASAD (2017) [9]
DinYatia, M.M. Muhammada,IrwanMohd Nora (2013) States that Wear particle analysis provides that earliest
[5]
The observed morphology of wear particles using warming of component failure in the lubricant path .The
ferrographic analysis, particularly in the iron-containing analysis can pinpoint the specific failing elements ,saving on
debris, indicate the involvement of two types of wear both the cost of repairs and downtime associated with
mechanisms, namely normal rubbing wear which generates equipment maintenance. Continuous monitoring through
very small iron particles in the range of 1–15 µm or less, diagnostic techniques is helpful for prevention of failure of
and abrasive wear, which is caused by particles with size of machine.
15–50 µm. Thepresence of abnormal wear particles will A.K. SINHA, V.N. KONDA, M.D. SOMAN PILLAI
cause the lubrication system to not work efficiently and at &V.S. SRINIVASAN [10] studied the Ferrography as a
the same timedestroy parts of the metallic components. diagnostic predictive maintenance tool that is available to
ZbigniewStepien, Wieslawa Urzedowska, Jan alert problems early in rotatory and reciprocating machinery.
Czerwinski (2014) [6] the results obtained in these The particle of abnormal and accelerated wear generated by

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 www.ierjournal.org International Engineering Research Journal (IERJ), Volume 3 Issue 3 Page 5318-5321, 2019 ISSN 2395-1621

each of the mechanism can easily be recognized by their [8] CHANDAN KUMAR, DR. MANOJ KUMAR, ―WEAR
shape, size and texture appearance. Thus, wear particle DEBRIS ANALYSIS USING FERROGRAPHY‖,
analysis can avoid failures and can also pinpoint the root International journalof resent trends in engineering
cause of problem. It was capable of indicating the rate of &research ,2016,Pg.No-2455-1457.
wear, severity of wear, type of wear and location of wear for
the equipment well in advance. Their work will provide an [9] PRABIR KUMAR BANDYOPADHYAY,RAM
overall view on the application of ferrography for BALAK CHOUDHARY ,RAVI RANJAN PRASAD, ―
identifying primary modes of failure in critical equipments
Application of oil condition monitoring techniques for
of Indian Nuclear Power Plants. The trending of particle
quantification (PQ) index was found suitable for trend improving critical equipment availability in steel
analysis of the wear process. The normal, alarming and plant’’,tribologyonline,April 2017,Pg.No 37-41.
severe levels of wear in terms of PQ index were being
established. Their aim was realized on the strength of [10]A.K. SINHA, V.N. KONDA, M.D. SOMAN PILLAI
extensive experimental work on oil samples drawn &V.S. SRINIVASAN,―Fault Diagnosis Through Wear
periodically/regularly from machine. Particle Analysis (Ferrography) In Indian Phwrs And Bwrs‖
Pg. No .415 -425
III. CONCLUSION

The study about Ferrography today has advanced as one

of the premier predictive maintenance tools. Ferrography
can be valuable in helping to determine the maintenance
needs for machinery by identifying the specific conditions
of machine wear.

REFERENCES

[1]RAYMOND J. DALLEY, ―An overview of ferrography

and its use in maintenance,‖ Proceedings from the Wear
Particle Analysis Division of Predict, High Pointe Corporate,
Cleveland, Ohio, 1990.

[2] NIKOLAOS P. KYRTATOS, ―The International

Council on Combustion Engines Conseil International des
Machines à Combustion, April 2004, Pg .No.1-60.

[3] R. GLIGORIJEVIC, J. JEVTIC AND D. J. BORAK,

―Engine oil contribution to diesel exhaust emissions‖,
JOURNAL OF SYNTHETIC LUBRICATION, 2006 ,
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[4]N.GOVINDARAJAN & R. GNANAMOORTHY,

―Ferrography-A procedure for measuring wear rate,‖
Proceedings from Indian journal of engineering &materials
sciences ,vol-15, October 2008 , Pg No 377-381.

[5] O. LEVI Æ N. ELIAZ, ―Failure Analysis and Condition

Monitoring of an Open-Loop Oil System Using
Ferrography‖,April 2009.Pg No-17-29.

[6]M.C. ISAA*, N.H.N. YUSOFFA, HASRIL NAINA,

MOHD SUBHI DIN YATIA, M.M. MUHAMMADA,
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marine ship‖, The Malaysian International Tribology
Conference 2013, MITC2013,Pg No. 345 – 351.

[7] YUESEN WANG, XINGYU LIANG*, GEQUN SHU,

LIHUI DONG, ―Impact of Lubricating Oil on Morphology
of Particles from a Diesel Engine‖, The 7th International
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2393.

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