Analytical Ferrography for Root Cause Analysis and Failure Prevention

WALT HUYSMAN, (CLS, OMA) POLARIS LABORATORIES, LLC

Abstract
There are many tests available for used fluids analysis. Some tests are qualitative while others are quantitative in scope. One test often overlooked is
Analytical Ferrography. Complete Analytical Ferrography is often referred to as the oil analysis equivalent of criminal forensic science. The test method relies
on a visual, microscopic evaluation of particles, extracted and deposited on a microscope slide called a Ferrogram. Based on an examination of the shape,
color, edge detail, the effects of a magnetic field and other diagnostic tests such as heat treatment and the addition of chemical reagents, an assessment of
the active wear mechanism can be made.

Analytical Ferrography, when performed with other analysis tests, is capable of determining the Root Cause of failure, which can lead to failure prevention.
Analytical Ferrography utilizes microscopic analysis to identify the composition of the material present. This technology will differentiate the type of material
contained within the sample and determine the wearing component from which it was generated. This test method is used to determine characteristics of a
machine by evaluating the particle type, size, concentration, distribution, and morphology. This allows a skilled diagnostician to determine the root cause of a
specific tribological problem.

INTRODUCTION
Analytical Ferrography can predict potential equipment failures and is an
effective tool in determining the root cause of machine component failure.
Analytical Ferrography is a qualitative rather than quantitative analysis that
provides digital imagery of the actual particles present. Powerful magnets
trap the ferrous particles, which are then placed on slides for microscopic
analysis. Particles are analyzed based on being metallic or non-metallic
alloy via heat treatment, shape, size, color, and if possible, source.
Analytical Ferrography is one of the tools of fluids analysis in the group
called Wear Debris Analysis (WDA) or Wear Particle Analysis (WPA). Other
WDA/WPA tests include Particle Count, Micropatch, Direct Reading
Ferrography, and the Particle Quantifier.
The technique of Wear Debris Analysis (Analytical Ferrography) is gaining
popularity in the field of Condition Based Maintenance System. WDA is a
method of predicting health of equipment in a non-intrusive way, by the
study of worn particles. The continuous trending of wear rate monitors the
performance of Machine/Machine components and provides early warning
and diagnosis. Oil condition monitoring can sense danger earlier than
Vibration technique. This technique holds good for both oil and grease
samples.
Analytical Ferrography, with supporting physical and chemical tests, can
help to determine:
The start of abnormal wear.
Root cause of wear/failure.
The component(s) that are wearing.
Usability of lubricant beyond its rated life.
The particles contained in a lubricating fluid carry detailed and
important information about the condition of the machine components. This
information can be deducted from:
Particle shape.
Particle composition.
Particle size distribution.
Particle concentration.
When a fluid analysis report indicates a problem, it can be characterized
in two dimensions: ambiguity and importance. When the problem is
ambiguous and important, root cause analysis can be justified. For many
reasons, fluids analysis is a powerful root cause tool, yet few take full
advantage of its capabilities. Despite the fact that hundreds of fluids
analysis tests are available and useful to the analysis, few venture beyond
the 10 to 12 tests most common to used fluids analysis.
Vernon C. Westcott is credited with inventing the ferrograph in the early
1970s. Mr. Westcott passed away in September 2003 at the age of 84.
Initially, the ferrograph was used mainly by the military. Today, ferrography
is a fundamental tool of used fluids analysis and reliability maintenance.
Analytical Ferrography is among the most powerful diagnostic tools in
fluids analysis today. When implemented correctly it provides a tremendous
return on your fluids analysis dollars. Yet, it is frequently excluded from
fluids analysis programs because of its comparatively high price and a
general misunderstanding of its value.
In his article Wear Analysis, Mark Barnes states, Complete analytical
ferrography is often referred to as the oil analysis equivalent of criminal
forensic science. The test method relies on a visual, microscopic evaluation
of particles, extracted and deposited on a microscope slide called a
ferrogram. Based on an examination of the shape, color, edge detail, the
effects of a magnetic field and other diagnostic tests such as heat
treatment and the addition of chemical reagents, an assessment of the
active wear mechanism can be made. This allows a skilled diagnostician to
determine the root cause of a specific tribological problem.
While ferrographic analysis is an excellent tool when attempting to
diagnose an active wear problem, it too has its limitations. The test is a
qualitative test, which relies on the skill and knowledge of the ferrographic
analyst. While this can have definite advantages, the interpretation is
somewhat subjective and requires detailed knowledge, not just of analytical
chemistry, but also machine and tribological failures. Also, because of the
time and skills required to perform the test, it is usually considered too
expensive for routine oil analysis. Nevertheless, used as an exception tool
when a wear problem is suspected based on other test results, complete
ferrographic analysis is one of the most enlightening of all wear analysis
methods.
The test procedure is lengthy and requires the skill of a well-trained
analyst. As such, there are significant costs in performing analytical
ferrography not present in other fluids analysis tests. But, if time is taken to
fully understand what analytical ferrography can uncover, most agree that
the benefits significantly outweigh the costs and elect to automatically
incorporate it when an abnormal wear condition is encountered.
As with all fluids analysis samples, I cannot overstress the importance of a
properly taken sample of the fluid. Samples should be taken that are
representative of the conditions that are going on inside the equipment.
Representative samples are dependent on the way the sample is taken and
the location where the sample is taken from. This is especially important
when using Analytical Ferrography.

48 LUBRICATION EXCELLENCE 2005 CONFERENCE PROCEEDINGS

 Another critical factor in fluids analysis and Analytical Ferrography in
particular, is the need of the customer to provide as detailed as possible the
specific information about the machine/component from which the sample
was taken. This includes lubricant information, component manufacturer,
model and type of component. The more detailed the machine/component
information, the better the diagnosis of the test results.
To perform analytical ferrography, the solid debris suspended in a
lubricant is separated and systematically deposited onto a glass slide. The
slide is examined under a microscope to distinguish particle size,
concentration, composition, morphology and surface condition of the ferrous
and non-ferrous wear particles.
This detailed examination, in effect, uncovers the mystery behind an
abnormal wear condition by pinpointing component wear, how it was
generated and often, the root cause.
Analytical ferrography begins with the magnetic separation of machine
wear debris from the lubricating fluid in which it is suspended using a
ferrogram slide maker. The lubricating fluid sample is diluted for improved
particle precipitation and adhesion. The diluted sample flows down a
specially designed glass slide called a ferrogram. The ferrogram rests on a
magnetic cylinder, which attracts ferrous particles out of the oil (Figure 1).
Due to the magnetic field, the ferrous particles align themselves in
chains along the length of the slide with the largest particles being
deposited at the entry point. Nonferrous particles and contaminants,
unaffected by the magnetic field, travel downstream and are randomly
deposited across the length of the slide. The deposited ferrous particles
serve as a dyke in the removal of nonferrous particles. The absence of
ferrous particles substantially reduces the effectiveness with which
nonferrous particles are removed.
After the particles are deposited on the ferrogram, a wash is used to
remove any remaining lubricant. The wash quickly evaporates and the
particles are permanently attached to the slide. The ferrogram is now ready
for optical examination using a bichromatic microscope.
Figure 1. Ferrogram Slide Maker Separates Particles from the Oil.
The ferrogram is examined under a polarized bichromatic microscope
equipped with a digital camera. The microscope uses both reflected (top)
and transmitted (bottom) light to distinguish the size, shape, composition
and surface condition of ferrous and nonferrous particles (Figure 4). The
particles are classified to determine the type of wear and its source.
Particle composition is first broken down into six categories: white
nonferrous, copper, Babbitt, contaminants, fibers and ferrous wear. In order
to aid the identification of composition, the analyst will heat-treat the slide
for two minutes at 600F.
White nonferrous particles, often aluminum or chromium, appear as
bright white particles both before and after heat treatment of the slide.
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 both before
and after heat treatment 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 that 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.
Fibers, typically from filters or outside contamination, are long strings
that allow the transmitted light to shine through. They can appear in a
variety of colors and usually do not change in appearance after heat
treatment. 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. Large ferrous
particles will be deposited on the entry end of the slide and often clump on
top of the other. 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 found in chains on the slide and appear
gray-white before and after heat treatment. 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, its deemed to be high
alloy. Otherwise, its considered white nonferrous. The frequency of high
alloy on ferrograms is rare.
Low Alloy Steel - particles are also found in chains and appear gray-
white before heat treatment but then change color after heat treatment.
After heat treatment they usually appear as blue particles but can also
be pink or red.
Dark Metallic Oxides - deposit in chains and appear dark gray to black
both before and after heat treatment. 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.
LUBRICATION EXCELLENCE 2005 CONFERENCE PROCEEDINGS 49
 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.
Figure 2. The Metal Alloy of the Particles Determines Whether They Line Up On or
Adjacent to the Magnetic Field.
After classifying the composition of particles the analyst then rates the
size of the particles using a micrometer scale on the microscope. Particles
with a 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.
Often, the shape of a particle is another important clue to the origin of
the wear particles. Is the particle laminar or rough? Laminar particles are
signs of smashing or rolling found in bearings or areas with high pressure
or lateral contact. Does the particle have striations on the surface?
Striations are a sign of sliding wear, perhaps generated in an area where
scraping of metal surfaces occurs. Does the particle have a curved shape,
similar to drill shavings? This would be categorized as cutting wear that
can be caused by abrasive contaminants found in the machine. Is the
particle spherical in shape? To the analyst, these appear as dark balls with
a white center. Spheres are generated in bearing fatigue cracks. An increase
in quantity is indicative of spalling. According to Jim Fitch in his article
Today's Oil Detectives Have a New Bag of Tricks, The truth is, oil analysis
is detective work, plain and simple. Todays detectives are empowered with a
growing bag of tricks but frankly, only a few of these tricks involve
traditional oil analysis. Lets take a closer look at whats involved in real oil
detective work. But before we do, remember that the primary job of the oil
analyst is not troubleshooting chronic machine problems but rather the
50 LUBRICATION EXCELLENCE 2005 CONFERENCE PROCEEDINGS
activity of machine health management, that is, maintaining and
controlling machine wellness. Proactive maintenance is always where the
big payoff is found. Still, even the best proactive maintenance programs
cant completely rid machines of random failures and occasional abnormal
wear conditions. It is in these cases when the oil detective earns his keep.
A problem is still a problem whether it is detected early or kept out of
sight. Out of sight may be of momentary convenience, but for process-
critical machines, problem penalties can grow if not corrected early.
Compounding and/or chain-reaction failures can cost millions of dollars or
even ones life. Youve seen it before - the worse things get, the faster they
get worse.
By the time a problem has been detected and localized, the cause of the
problem is often discovered as well, but not always. A suspect cause
(misalignment, degraded oil, etc.) may need further confirmation or there
may be two or more causes working in concert. Knowing the true root cause
is vital to prescribing a remedy that works. Slowing the rate of progress
may, in many cases, be the best response, enabling complete correction at
the next scheduled outage.
Defining the wear mode is where the real strength in microscopic Wear
Particle Analysis (Analytical Ferrography) lies. Properly sampled lubricants
often contain particles of unique shape and size that characterize how they
were created. The skillful eye of a well-trained wear particle microscopist
can be invaluable.
CONCLUSIONS
In the hands of a skilled analyst, Analytical Ferrography is capable of
detecting active machine wear and can often provide a root cause based on
the morphology of the wear particles. Used in conjunction with treatments of
the ferrogram like heating and chemicals, it can pinpoint the root cause of
specific wear problems. The advantage of Analytical Ferrography is that the
source, cause and scope of equipment wear can easily be determined. The
analysis determines both the type and metallurgy of the wear particle,
allowing the analyst to see inside operating equipment to identify abnormal
wear conditions.
Due to the method of sample preparation, Analytical Ferrography is
biased but not necessarily limited to ferrous particles. The test is non-
quantitative and its effectiveness is critically dependent on the knowledge
and experience of the analyst. Due to the analyst skills required and the
time the analysis takes, it can be fairly expensive compared with other test
methods. Used as an exception test based on results from other less
expensive tests, Analytical Ferrography can be an effective fluids analysis
tool for most machine components.
References
1. Wear Particle Atlas, published by Predict/DLI
2. A Tribute to Vernon C. Westcott, Inventor of the Ferrograph, Teresa
Hansen, Noria Corporation, Practicing Oil Analysis magazine
3. Analytical Ferrography - Make It Work For You, Michael Barrett and Matt
McMahon, Insight Services, Practicing Oil Analysis magazine
4. Converting to Condition-Based Oil Changes - Part I, Raymond Thibault,
ExxonMobil Lubricants & Petroleum Specialties Company, Practicing Oil
Analysis magazine
5. Today's Oil Detectives Have a New Bag of Tricks, Jim Fitch, Practicing
Oil Analysis magazine
6. Tricks to Classifying Wear Metals and Other Used Oil Suspensions,
James C. Fitch, Practicing Oil Analysis magazine
7. Wear Analysis, Mark Barnes, Practicing Oil Analysis magazine