Wear Metals Testing for Oils and Lubricants
Oil and Lubricant wear metals testing.
The determination of wear metals in used oil is a key diagnostic method used in Oil Condition Monitoring (OCM), Equipment Condition Monitoring (ECM), Condition Based Maintenance (CBM) programs.
Wear Metal Analysis in oils and lubricants allows maintenance to be scheduled efficiently, minimising the risk of damage to expensive plants and avoiding unscheduled downtime and maintenance, helping productivity and avoid costly repair or shut downs.
The Early stage of wear in oils and lubricants significantly improves the reliability of the machinery.
Hence – ATLAS – provides a comprehensive state-of-the-art Oil Testing & Lubricant Analysis Services. The objective is to spot any potential problems before they cause catastrophic failure.
SOURCES OF WEAR METALS IN ANALYSIS OF OILS
The tables given below give an indication of the source of wear metals in the oil. Due to these wear metals, it is possible to identify the components that are wearing.
WEAR METALS
IRON
Iron is the dominant and most common of the wear metals. It is found virtually in all equipment in some form or the other. As it is abundantly used it indicates that there are a lot of sources of wear in the machinery.
Due to this knowledge, the testing of this component allows the analyst to distinguish the source of the wear debris, like, cylinder rods vs. bearings.
| ENGINE | Cylinders, Blocks, Gears, Crankshaft, Piston Rings, Camshaft, Valve Train, Oil Pump, Liners | |
|---|---|---|
| TRANSMISSION | Gears, Discs, Housing, Bearings, Brake Bands, Shift Spools, Pumps, PTO-Power Take Off | |
| HYDRAULIC SYSTEM | Pump / Motor Vanes, Gears, Pistons, Cylinder Boxes & Rods, Bearings, Valves, Pump Housing | |
| GEAR SYSTEM | Gear, Shafts, Bearings | |
| COMPRESSORS | Crankshaft Block, Housing, Screws, Bearings, Shaft, Oil Pump, Piston Rings, Cylinders | |
| TURBINE | Shafts, Gears, Bearings, Valves |
CHROMIUM
Chromium is used in machinery and equipment for its resistance to corrosion and for its great strength and hardness. Thus it is found in many systems operating under extreme and harsh conditions.
| ENGINE | Rings, Roller / Taper, Bearings, Liners, Exhaust Valves, Water Treatment | |
|---|---|---|
| TRANSMISSION | Roller / Taper, Bearings, Water Treatment (Oil Cooler) | |
| HYDRAULIC SYSTEM | Rods, Spools, Roller / Taper, Bearings | |
| GEAR SYSTEM | Roller / Taper, Bearings | |
| COMPRESSORS | Rings, Roller / Taper, Bearings, Water Treatment (Oil Cooler) | |
| TURBINE | Shafts, Bearings |
COPPER
Commonly used as an alloy, it is extensively used because of its material properties like excellent electrical and thermal conductivity and is extremely ductile. It is used abundantly in bearing systems and heat exchangers.
| ENGINE | Wrist Pin Bushings, Valve Train, Bushings, Cam Bushings, Bearings (Near Failure), Oil Cooler, Thrust Washers, Governor, Oil Pump, Oil Additives. | |
|---|---|---|
| TRANSMISSION | Clutches, Steering Discs, Bushings / Thrust Washers, Oil Cooler | |
| HYDRAULIC SYSTEM | Pump Thrust Plates, Pump Pistons, Cylinders, Guides, Bushings, Oil Cooler | |
| GEAR SYSTEM | Bushings, Thrust Washers | |
| COMPRESSORS | Wear Plates, Bushings, Wrist Pin Bushings, Bearings, Thrust Washers | |
| TURBINE | Bearings, Bushings, Thrust Plates, Cooler Core Tubing |
ALUMINIUM
Aluminium is prized in equipment because of it's high strength to weight ratio, also it has excellent corrosion resistance. Used as an alloy in combination with other elements it improves its wear and temperature resistance.
| ENGINE | Pistons, Bearings, Bushings, Blocks, Housings, Oil Pump Bushings, Blowers, Thrust Bearings | |
|---|---|---|
| TRANSMISSION | Pumps, Clutches, Thrust Washer, Bushings | |
| HYDRAULIC SYSTEM | Pump / Motor, Housing, Cylinder | |
| GEAR SYSTEM | Thrust Washers, Oil Pump, Bushings, Some Greases | |
| COMPRESSORS | Rotors, Pistons, Bearings, Thrust Washers, Block Housing | |
| TURBINE | Thrust, Heat Exchanger Core, Aluminum Oxides from Silica (Dirt) |
TIN
Tin is used as an alloying element along with copper and lead for sacrificial bearing liners.
| ENGINE | Pistons (Overlay), Bearings (Overlay), Bushings | |
|---|---|---|
| TRANSMISSION | Roller / Taper, Bearings, Water Treatment (Oil Cooler) | |
| HYDRAULIC SYSTEM | Rods, Spools, Roller / Taper, Bearings | |
| GEAR SYSTEM | Roller / Taper, Bearings | |
| COMPRESSORS | Rings, Roller / Taper, Bearings, Water Treatment (Oil Cooler) | |
| TURBINE | Bearings (Babbit), Bushings, Solder from Tin |
LEAD
A soft metal used for sacrificial wear surfaces such as journal bearings. Lead-based babbits are widely used.
| ENGINE | Bearings, Gasoline, Octane Improver, Oil Additives | |
|---|---|---|
| TRANSMISSION | Oil Additives | |
| HYDRAULIC SYSTEM | Not Found | |
| GEAR SYSTEM | Oil Additives | |
| COMPRESSORS | Bearings | |
| TURBINE | Bearings, Bushings (Babbit) |
SILVER
Silver is highly prized as it has the highest electrical as well as thermal conductivity from all metals. It is an excellent bearing plate material, providing minimum friction. Due to its low contact resistance, it is susceptible to corrosive attack.
| ENGINE | Wrist Pin Bushings, Solder From Cooler Core Joints | |
|---|---|---|
| TRANSMISSION | Needle Bearings (Traces), Solder From Oil Cooler Core Joints | |
| HYDRAULIC SYSTEM | Solder, Trace Element | |
| GEAR SYSTEM | Not Found | |
| COMPRESSORS | Solder, Trace Element | |
| TURBINE | Solder, Trace Element |
CADMIUM
Cadmium is resistant to corrosion and as a result, it is used as a protective layer when deposited on other metals. Also used as an alloy with certain metals.
| ENGINE | Enviornmental Contaminant | |
|---|---|---|
| TRANSMISSION | Alloy Metal, Enviornmental Contaminant | |
| HYDRAULIC SYSTEM | Alloy from Bearings, Enviornmental Contaminant | |
| GEAR SYSTEM | Alloy Metal, Enviornmental Contaminant | |
| COMPRESSORS | Alloy Metal, Enviornmental Contaminant | |
| TURBINE | Alloy Metal, Enviornmental Contaminant |
VANADIUM
Used as an Alloy mainly with steel to increase the strength of steel considerably. Used in applications for axles, crankshaft and other critical components.
| ENGINE | Alloy Metal, Contaminant in Marine Bunker Fuels | |
|---|---|---|
| TRANSMISSION | NOT FOUND | |
| HYDRAULIC SYSTEM | Alloy Metal | |
| GEAR SYSTEM | NOT FOUND | |
| COMPRESSORS | Alloy Metal | |
| TURBINE | Alloy Metal |
TITANIUM
The two most important properties of Titanium is corrosion resistance and the highest strength to weight ratio of any metal. Thus it is alloyed with Iron, Molybdenum, Vanadium, aluminium to produce strong lightweight alloys for aero-space, military and industrial use. Also used widely for manufacturing Titanium dioxide used in Paints, Coatings and Pigments.
| ENGINE | Valves, Piston Pins, Bearings, Shafts | |
|---|---|---|
| TRANSMISSION | Shafts, Gears, Bearings, Paint or Coatings | |
| HYDRAULIC SYSTEM | Valves, Piston Pins, Bearings, Shafts | |
| GEAR SYSTEM | Shafts, Gears, Bearings, Paint or Coatings | |
| COMPRESSORS | Shafts, Gears, Bearings, Paint or Coatings | |
| TURBINE | Shafts, Gears, Bearings, Paint or Coatings |
CONTAMINANT METALS
SILICON
A common contaminant found during lube oil analysis. Mainly due to ingested dirt (sand) which is a very hard crystalline material and is extremely abrasive to metal components. Also found due to Coolant / Anti-freeze and sealant wear.
| ENGINE | Anti-Foam Additive, Ingested Dirt, Coolant Leak, Silicates from Antifreeze | |
|---|---|---|
| TRANSMISSION | Disc Lining, Brake Shoes, Ingested Dirt, Silicates from Antifreeze | |
| HYDRAULIC SYSTEM | Ingested Dirt, Elastomeric Seals, Silicates from Antifreeze | |
| GEAR SYSTEM | Ingested Dirt, Silicone Sealant, Anti-Foam Additive, Silicates from Antifreeze | |
| COMPRESSORS | Ingested Dirt, Silicone Sealant, Silicates from Antifreeze | |
| TURBINE | Ingested Dirt, Silicone Sealant, Defoamant Additive, Silicates from Antifreeze |
SODIUM
Corrosion inhibitor additive also indicates coolant leak into oil, can also be road Salt, Sea water, Ingested Dirt
| ENGINE | Oil Additive, Anti-Freeze, Salt, Ingested Dirt, Molybdates from some Coolants | |
|---|---|---|
| TRANSMISSION | Oil Additive, Anti-Freeze, Salt, Ingested Dirt | |
| HYDRAULIC SYSTEM | Oil Additive, Anti-Freeze, Ingested Dirt | |
| GEAR SYSTEM | Oil Additive, Ingested Dirt | |
| COMPRESSORS | Oil Additive, Anti-Freeze, Ingested Dirt | |
| TURBINE | Oil Additive, Anti-Freeze, Ingested Dirt |
POTASSIUM
Usually not found in the oil but may be due to coolant leak if associated with Sodium and may be Magnesium.
| ENGINE | Anti-Freeze, Solder Flux, Head Coatings, Pot-Ash | |
|---|---|---|
| TRANSMISSION | Anti-Freeze, Solder Flux, Head Coatings, Pot-Ash | |
| HYDRAULIC SYSTEM | Airbourne Environmental Contaminant, Anti-Freeze, Solder Flux | |
| GEAR SYSTEM | Additive from Potassium or, Sodium Borate Gear Oil, Environmental Contaminant, Solder Flux | |
| COMPRESSORS | Airbourne Environmental Contaminant, Anti-Freeze, Solder Flux, Gas Contaminant | |
| TURBINE | Airbourne Environmental Contaminant, Anti-Freeze , Solder Flux, Gas Contaminant |
MANGANESE
Manganese is important for Iron and Steel for its alloying properties as it increases their tensile strength when used. Also when used with Aluminium it increases its resistance against corrosion.
| ENGINE | Steel Alloy Metal in Gears, Some Shafts | |
|---|---|---|
| TRANSMISSION | Steel Alloy Metal in Gears, Some Shafts | |
| HYDRAULIC SYSTEM | Steel Alloy Metal in Gears, Some Shafts, Bearings | |
| GEAR SYSTEM | Steel Alloy Metal in Gears, Some Shafts, Bearings | |
| COMPRESSORS | Steel Alloy Metal in Gears, Some Shafts, Bearings | |
| TURBINE | Steel Alloy Metal in Gears, Some Shafts, Bearings |
ADDITIVE METALS
BORON
Corrosion Inhibitor additive, Antiwear/Antioxidant additive, can indicate coolant leak, grease contamination
| ENGINE | Additive common in Engine Oils and, Gear Oils, Indicates Coolant Leak | |
|---|---|---|
| TRANSMISSION | Additive common in Engine Oils and, Gear Oils, Indicates Coolant Leak | |
| HYDRAULIC SYSTEM | Additive common in Engine Oils and, Gear Oils, Indicates Coolant Leak | |
| GEAR SYSTEM | Additive common in Engine Oils and, Gear Oils, Indicates Coolant Leak | |
| COMPRESSORS | Additive common in Engine Oils and, Gear Oils, Indicates Coolant Leak | |
| TURBINE | Additive common in Engine Oils and, Gear Oils, Indicates Coolant Leak |
MAGNESIUM
Detergent/dispersive additive can also be alloying element in steels
| ENGINE | Detergent / Dispersant Additive, Alloy Element in Steels, Environmental Contaminant | |
|---|---|---|
| TRANSMISSION | Detergent / Dispersant Additive, Alloy Element in Steels, Environmental Contaminant | |
| HYDRAULIC SYSTEM | Detergent / Dispersant Additive, Alloy Element in Steels, Environmental Contaminant | |
| GEAR SYSTEM | Detergent / Dispersant Additive, Alloy Element in Steels, Environmental Contaminant | |
| COMPRESSORS | Detergent / Dispersant Additive, Alloy Element in Steels, Environmental Contaminant | |
| TURBINE | Detergent / Dispersant Additive, Alloy Element in Steels, Environmental Contaminant |
CALCIUM
Detergent/dispersant additive, Alkaline reserve additive for high sulphur fueled engines, can be grease contamination
| ENGINE | Detergent / Dispersant Additive, Calcium from Water Contamination, Alkaline Reserve Additive | |
|---|---|---|
| TRANSMISSION | Detergent / Dispersant Additive, Calcium from Water Contamination, Alkaline Reserve Additive | |
| HYDRAULIC SYSTEM | Detergent / Dispersant Additive, Calcium from Water Contamination, Alkaline Reserve Additive | |
| GEAR SYSTEM | Detergent / Dispersant Additive, Calcium from Water Contamination, Alkaline Reserve Additive | |
| COMPRESSORS | Detergent / Dispersant Additive, Calcium from Water Contamination, Alkaline Reserve Additive | |
| TURBINE | Detergent / Dispersant Additive, Calcium from Water Contamination, Alkaline Reserve Additive |
BARIUM
Corrosion Inhibitors, Detergents, Rust inhibitors
| ENGINE | Not Found, Contaminant in Drilling Applications | |
|---|---|---|
| TRANSMISSION | Demulsifying Agent in some, Transmission Oils, Contaminant in Drilling Applications | |
| HYDRAULIC SYSTEM | Demulsifying Agent in some, Transmission Oils, Contaminant in Drilling Applications | |
| GEAR SYSTEM | Demulsifying Agent in some, Transmission Oils, Contaminant in Drilling Applications | |
| COMPRESSORS | Demulsifying Agent, Contaminant in Drilling Applications, Additive common in Compressor, Oils and some Transmission, Fluids and Gear Oils | |
| TURBINE | Demulsifying Agent, Contaminant in Drilling Applications, Additive common in Compressor, Oils and some Transmission, Fluids and Gear Oils |
PHOSPHORUS
Antiwear, Corrosion inhibitors, Anti-oxidants additives, EP additives
| ENGINE | Anti-Wear Additive ZDDP, (Zinc Dialkyl-DithioPhosphate), Phosphate Ester, Phosphate Inhibitor found in Coolants | |
|---|---|---|
| TRANSMISSION | Anti-Wear Additive ZDDP, (Zinc Dialkyl-DithioPhosphate), Phosphate Ester, Phosphate Inhibitor found in Coolants | |
| HYDRAULIC SYSTEM | Anti-Wear Additive ZDDP, (Zinc Dialkyl-DithioPhosphate), Phosphate Ester, Phosphate Inhibitor found in Coolants | |
| GEAR SYSTEM | Anti-Wear Additive ZDDP, (Zinc Dialkyl-DithioPhosphate), Phosphate Ester, Phosphate Inhibitor found in Coolants | |
| COMPRESSORS | EP Additive, Anti-Wear Additive ZDDP, (Zinc Dialkyl-DithioPhosphate), Phosphate Ester, Phosphate Inhibitor found in Coolants | |
| TURBINE | EP Additive, Anti-Wear Additive ZDDP, (Zinc Dialkyl-DithioPhosphate), Phosphate Ester, Phosphate Inhibitor found in Coolants |
ZINC
Antiwear, Corrosion inhibitors, Anti-oxidants, alloying element for bearings, thrust washers, galvanised cases
| ENGINE | Alloy in Brass, Anti-Wear Additive ZDDP, (Zinc Dialkyl-DithioPhosphate), Galvanized Steel from Filter Cannisters | |
|---|---|---|
| TRANSMISSION | Alloy in Brass, Anti-Wear Additive ZDDP, (Zinc Dialkyl-DithioPhosphate), Galvanized Steel from Filter Cannisters | |
| HYDRAULIC SYSTEM | Alloy in Brass, Anti-Wear Additive ZDDP, (Zinc Dialkyl-DithioPhosphate), Galvanized Steel from Filter Cannisters | |
| GEAR SYSTEM | Alloy in Brass, Anti-Wear Additive ZDDP, (Zinc Dialkyl-DithioPhosphate), Galvanized Steel from Filter Cannisters | |
| COMPRESSORS | Alloy in Brass, Anti-Wear Additive ZDDP, (Zinc Dialkyl-DithioPhosphate), Galvanized Steel from Filter Cannisters | |
| TURBINE | Alloy in Brass, Anti-Wear Additive ZDDP, (Zinc Dialkyl-DithioPhosphate), Galvanized Steel from Filter Cannisters |
TESTING OF METALS IN OUR LABORATORY
Testing of the Metals comprising of WEAR METALS, CONTAMINANT METALS and ADDITIVE METALS is done in our laboratory.
Equipment used: ICP
Method of Testing: ASTM D5185: Standard Test Method for Determination of Wear Metals and Contaminants in Used Lubricating Oils or Used Hydraulic Fluids