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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 Vernon C. Westcott is credited with inventing the ferrograph in the early
Analytical Ferrography can predict potential equipment failures and is an 1970s. Mr. Westcott passed away in September 2003 at the age of 84.
effective tool in determining the root cause of machine component failure. Initially, the ferrograph was used mainly by the military. Today, ferrography
Analytical Ferrography is a qualitative rather than quantitative analysis that is a fundamental tool of used fluids analysis and reliability maintenance.
provides digital imagery of the actual particles present. Powerful magnets
trap the ferrous particles, which are then placed on slides for microscopic Analytical Ferrography is among the most powerful diagnostic tools in
analysis. Particles are analyzed based on being metallic or non-metallic fluids analysis today. When implemented correctly it provides a tremendous
alloy via heat treatment, shape, size, color, and if possible, source. return on your fluids analysis dollars. Yet, it is frequently excluded from
fluids analysis programs because of its comparatively high price and a
Analytical Ferrography is one of the tools of fluids analysis in the group general misunderstanding of its value.
called Wear Debris Analysis (WDA) or Wear Particle Analysis (WPA). Other
WDA/WPA tests include Particle Count, Micropatch, Direct Reading In his article Wear Analysis, Mark Barnes states, Complete analytical
Ferrography, and the Particle Quantifier. ferrography is often referred to as the oil analysis equivalent of criminal
forensic science. The test method relies on a visual, microscopic evaluation
The technique of Wear Debris Analysis (Analytical Ferrography) is gaining of particles, extracted and deposited on a microscope slide called a
popularity in the field of Condition Based Maintenance System. WDA is a ferrogram. Based on an examination of the shape, color, edge detail, the
method of predicting health of equipment in a non-intrusive way, by the effects of a magnetic field and other diagnostic tests such as heat
study of worn particles. The continuous trending of wear rate monitors the treatment and the addition of chemical reagents, an assessment of the
performance of Machine/Machine components and provides early warning active wear mechanism can be made. This allows a skilled diagnostician to
and diagnosis. Oil condition monitoring can sense danger earlier than determine the root cause of a specific tribological problem.
Vibration technique. This technique holds good for both oil and grease
samples. While ferrographic analysis is an excellent tool when attempting to
diagnose an active wear problem, it too has its limitations. The test is a
Analytical Ferrography, with supporting physical and chemical tests, can qualitative test, which relies on the skill and knowledge of the ferrographic
help to determine: analyst. While this can have definite advantages, the interpretation is
The start of abnormal wear. somewhat subjective and requires detailed knowledge, not just of analytical
Root cause of wear/failure. chemistry, but also machine and tribological failures. Also, because of the
The component(s) that are wearing. time and skills required to perform the test, it is usually considered too
Usability of lubricant beyond its rated life. expensive for routine oil analysis. Nevertheless, used as an exception tool
when a wear problem is suspected based on other test results, complete
The particles contained in a lubricating fluid carry detailed and ferrographic analysis is one of the most enlightening of all wear analysis
important information about the condition of the machine components. This methods.
information can be deducted from:
Particle shape. The test procedure is lengthy and requires the skill of a well-trained
Particle composition. analyst. As such, there are significant costs in performing analytical
Particle size distribution. ferrography not present in other fluids analysis tests. But, if time is taken to
Particle concentration. fully understand what analytical ferrography can uncover, most agree that
the benefits significantly outweigh the costs and elect to automatically
When a fluid analysis report indicates a problem, it can be characterized incorporate it when an abnormal wear condition is encountered.
in two dimensions: ambiguity and importance. When the problem is As with all fluids analysis samples, I cannot overstress the importance of a
ambiguous and important, root cause analysis can be justified. For many properly taken sample of the fluid. Samples should be taken that are
reasons, fluids analysis is a powerful root cause tool, yet few take full representative of the conditions that are going on inside the equipment.
advantage of its capabilities. Despite the fact that hundreds of fluids Representative samples are dependent on the way the sample is taken and
analysis tests are available and useful to the analysis, few venture beyond the location where the sample is taken from. This is especially important
the 10 to 12 tests most common to used fluids analysis. when using Analytical Ferrography.
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
Figure 2. The Metal Alloy of the Particles Determines Whether They Line Up On or wear conditions.
Adjacent to the Magnetic Field.
After classifying the composition of particles the analyst then rates the Due to the method of sample preparation, Analytical Ferrography is
size of the particles using a micrometer scale on the microscope. Particles biased but not necessarily limited to ferrous particles. The test is non-
with a size of 30 microns or greater are given the rating of severe or quantitative and its effectiveness is critically dependent on the knowledge
abnormal. Severe wear is a definite sign of abnormal running conditions and experience of the analyst. Due to the analyst skills required and the
with the equipment being studied. 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
Often, the shape of a particle is another important clue to the origin of expensive tests, Analytical Ferrography can be an effective fluids analysis
the wear particles. Is the particle laminar or rough? Laminar particles are tool for most machine components.
signs of smashing or rolling found in bearings or areas with high pressure
or lateral contact. Does the particle have striations on the surface? References
Striations are a sign of sliding wear, perhaps generated in an area where 1. Wear Particle Atlas, published by Predict/DLI
scraping of metal surfaces occurs. Does the particle have a curved shape, 2. A Tribute to Vernon C. Westcott, Inventor of the Ferrograph, Teresa
similar to drill shavings? This would be categorized as cutting wear that Hansen, Noria Corporation, Practicing Oil Analysis magazine
can be caused by abrasive contaminants found in the machine. Is the 3. Analytical Ferrography - Make It Work For You, Michael Barrett and Matt
particle spherical in shape? To the analyst, these appear as dark balls with McMahon, Insight Services, Practicing Oil Analysis magazine
a white center. Spheres are generated in bearing fatigue cracks. An increase 4. Converting to Condition-Based Oil Changes - Part I, Raymond Thibault,
in quantity is indicative of spalling. According to Jim Fitch in his article ExxonMobil Lubricants & Petroleum Specialties Company, Practicing Oil
Today's Oil Detectives Have a New Bag of Tricks, The truth is, oil analysis Analysis magazine
is detective work, plain and simple. Todays detectives are empowered with a 5. Today's Oil Detectives Have a New Bag of Tricks, Jim Fitch, Practicing
growing bag of tricks but frankly, only a few of these tricks involve Oil Analysis magazine
traditional oil analysis. Lets take a closer look at whats involved in real oil 6. Tricks to Classifying Wear Metals and Other Used Oil Suspensions,
detective work. But before we do, remember that the primary job of the oil James C. Fitch, Practicing Oil Analysis magazine
analyst is not troubleshooting chronic machine problems but rather the 7. Wear Analysis, Mark Barnes, Practicing Oil Analysis magazine