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S·O·S Wear Rate Analysis

Prevent problems and reduce costs by knowing wear rates

Wear rate analysis is an integral part of the Finning (Canada) fluid analysis program that helps you maintain equipment performance and maximize availability. Through regularly scheduled testing of oil samples from your engine, hydraulics and powertrain systems, wear rate analysis detects metal particles caused by component wear. By monitoring trends in the type and quantity of particles, you can get early warning of problems before major damage occurs.

Understanding wear metals

Every oil-washed system—engines, hydraulics, transmissions, and final drives— produces wear metals in everyday operation. If wear accelerates, the concentration of wear metal particles increases, signaling a problem. Wear rate analysis allows you to find problems before they result in major repairs or machine failure.

Wear rate analysis can detect particles that range up to about 5 to 8 microns in size. Wear metal concentrations are expressed in parts-per-million (or ppm). The Finning (Canada) fluid analysis program tests for the following wear metals: copper, iron, chromium, lead, tin, aluminum, molybdenum, silver, nickel and titanium. Most of these wear metals are found in machines and engines. Certain elements in a sample may be from the oil additive package rather than from wear within the system. Skilled dealer interpreters can tell the difference between normal elements and those that indicate abnormal wear. Oil additive elements typically are calcium, magnesium, zinc, boron and barium. Phosphorus, vanadium and sulfur are present naturally in crude oils. Sulfur is present naturally in some fuels and sulfur compounds are sometimes added as anti-corrosion agents in gear lubricants and as anti-oxidants in lubricating oil. Phosphorus can be present as an antiwear additive in some lubricants.

Contaminant elements like sodium and potassium can indicate coolant contamination, silicon normally accompanied with aluminum, dirt entry.

Silicon/aluminum ratio in dirt varies by location

The primary constituents of dirt are minerals containing silicon and aluminum. The ratio of these two elements varies widely from place to place. Clay soils contain nearly as much aluminum as silicon. This is one reason why local interpretation of your sample results is important. We are familiar with the soils in your area, giving us the best understanding of the combinations of elements in your samples.

Trending wear metals in your equipment

Two identical machines under identical conditions may generate wear particles at different rates. Our Fluid Analysis interpreters have access to a large database of samples for comparison with samples from your equipment. However, your own machines provide the best guidelines for appropriate levels of wear metals in each compartment and that’s why trending is an essential part of wear rate analysis. After three samples have been taken from a particular compartment, a trend for each wear metal is established. Our interpreters then compare subsequent samples to this trend line to quickly spot deviations as well as monitor gradual changes in concentration levels. This attention to trends also assists with life cycle analysis, helping you optimize productivity.

The technology behind Wear Rate Analysis

We use an emission spectrometer (ICP) to perform wear rate (elemental) analysis. The spectrometer determines wear elements and silicon in a sample by subjecting the oil to very high temperatures. At these temperatures, the elements in the sample are “atomized,” with each emitting a different wavelength of light energy. An optical system measures and records the light energy and calculates the results in parts-per-million (ppm) for each element.

How much is a ppm? Take one aspirin, crush into powder, divide into 225 equal parts, drop one part into a liter of liquid and you now have a ppm.


Combinations of Classic Wear Elements

ENGINES-TOP END

Primary Element Secondary Element Potential Wear Probable Problem Area/Causes
Silicon (dirt) Iron, Chrome, Aluminum Liners, Rings, Pistons Air Induction System/Filter Dirt Contamination
Iron Chrome, Aluminum Liners, Rings, Pistons Abnormal Operating Temps., Oil Degradation, Fuel and/or Coolant Contamination, Stuck/Broken Rings
Chrome Molybdenum, Aluminum Rings, Pistons Blowby, Oil Consumption, Oil Degradation
Iron -- Liners, Gears, Valve Train, Crankshaft Abnormal Operating Temps., Lack of Lubrication, Contamination, Storage (Rust)

ENGINES-BOTTOM END

Primary Element Secondary Element Potential Wear Probable Problem Area/Causes
Silicon (Dirt) Lead, Aluminum Bearings Dirt Contamination
Lead Aluminum Bearings Lack of Lubrication, Coolant Contamination, Fuel Contamination

HYDRAULICS

Primary Element Secondary Element Potential Wear Probable Problem Area/Causes
Silicon (Dirt) Molybdenum, Aluminum Cylinders, Rods Dirt Contamination
Copper Iron Hydraulic Pumps Oil Degradation, Contamination

TRANSMISSIONS

Primary Element Secondary Element Potential Wear Probable Problem Area/Causes
Aluminum Iron, Copper Torque Converter Oil Degradation, Lack of Lubrication, Contamination
Copper Iron Sintered Bronze Disk Oil Degradation, Lack of Lubrication, Contamination

FINAL DRIVES

Primary Element Secondary Element Potential Wear Probable Problem Area/Causes
Silicon (Dirt) Iron, Aluminum Gears Dirt Contamination, Clay Soils Contamination
Iron Sodium, Chrome Gears, Bearings Water Entry, Preload Loss

Pinpointing the causes and effects of component wear

By comparing infrared (oil condition) test results with wear metal buildup, we can pinpoint probable causes of elevated wear metals. The chart above illustrates some of the most common wear metals, their source(s), and the potential problems they indicate in oil-lubricated systems.

Spectrometry can detect dirt contamination, as well as wear metals. Silicon is the most common element indicating dirt entry, although some clay soils also produce increased aluminum readings.

Monitoring your components

When Finning (Canada) fluid analysis identifies an increase in the concentration of one or more metals, it can point to the wearing component most likely causing the increase and, often, the probable cause. For example, a sudden increase in copper and iron in a hydraulic oil sample would probably indicate a problem with the hydraulic pump caused by either oil degradation or contamination (see chart, above).

Silicon/aluminum ratio in dirt varies by location

The primary constituents of dirt are minerals containing silicon and aluminum. The ratio of these two elements varies widely from place to place. Clay soils contain nearly as much aluminum as silicon. This is one reason why local interpretation of your sample results is important. We are familiar with the soils in your area, giving us the best understanding of the combinations of elements in your samples.