Ferrography Analysis

FERROGRAPHY
ANALYSIS
INDENTIFICATION OF WEAR DEBRIS
FERROGRAPHY
Ferrography is one of the most advanced techniques in oil
analysis.
Oil is a magnetic fluid containing both ferrous and non ferrous
particles in it .
Ferrography applied this idea by using a high gradient magnetic
field to attract and hold the particles. The sample is loaded on a
slide which is kept in a slanting position on the magnet. The
ferrous particle get deposited at the upper part of the slide
where the magnetic field is strong. The heavier and non ferrous
particles flow down and get deposited at the bottom due to
gravity. The ferrogram prepared is later analyzed in the
microscope to identify the various ferrous wear debris and
contaminants.
PARTICLE IDENTIFICATION
WEAR DEBRIS CONTAMINANTS
Ferrous particles providing Non – ferrous particles

information about the machine
condition.
1.NORMAL RUBBING WEAR 1. ALUMINIUM
2. BEARING WEAR 2. COPPER
3. CUTTING WEAR 3. LEAD /TIN ALLOY
4.SPHERES
4.SILICA
5.CORROSIVE WEAR
6.STEEL WEAR 5.CARBON
7. SEVERE SLIDING WEAR 6.FIBRES
8. GEAR WEAR
9.BLACK OXIDE
10.RED OXIDE
11.FRICTIONAL POLYMERS
NORMAL RUBBING WEAR
• Caused to due to normal sliding motion in a machine. Rubbing wear

is considered primary wear as it will be produced if a machine is
being used.
• IDENTIFICATION –
• Seen as platelet like structure .
• Less than 15 micron in size.
NORMAL RUBBING WEAR
BEARING WEAR
• It is seen as a result of excessive rolling and sliding motion in a
machine.
• DESCRIPTION-
• It can be seen as chunks along with rubbing wear.
• Can be seen as shiny material having rough edges but they do not reflect
when light is passed through it.
• Can be seen in straw colour sometimes.
BEARING WEAR
Bearing wear having

Bearing wear seen along with sharp edges and metallic Bearing wear seen in
rubbing wear in very high in colour. straw colour.
quantities.
CUTTING WEAR
• It is generated as a result of one surface penetrating the other, like
any hard component becomes misaligned or fractured resulting in
hard sharp edge penetrating a soft surface.
• IDENTIFICATION-
• They are identified as c shaped or string like particles between rubbing
wear.
• Their average size ranges from 2- 5 micron width and 25 – 30 micron in
length.
CUTTING WEAR
SEVERE SLIDING WEAR
• It is caused due wear surface stress being too excessive due to load or
speed.
• IDENTIFICATION-
• Flat elongated particles with striations.
• Can be metallic or straw shaped in colour.
• Their size can range from 5 to 30 micron in size.
SEVERE SLIDING WEAR
CORROSIVE WEAR
Caused to excessive heat condition or additive depletion.
DESCRIPTION-
They are seen as heavy deposition of fine particles at the sides of the
ferrogram .
CORROSIVE WEAR
GEAR WEAR
They are of 2 types-
1.PITCH LINE FATIGUE
PARTICLE- distinguished by their
smooth surface and irregular shape.
2. SCUFFING AND SCORING

PARTICLES- caused by high load or
stress. Generally have rough surface
and even have striation on them .
Gear wear is mostly less than 20 PITCH LINE FATIGUE PARTICLE SCUFFING WEAR
micron in size.
SPHERE
Generated due to heat if there is
insufficient lubrication or if there
is depletion of extreme pressure
additives in high load or high stress
condition.
DESCRIPTION-
Spherical particles less than 5-10
micron in diameter .
BLACK OXIDE
• It is seen due to insufficient lubrication or effect of excessive heat
condition in the machine.
• IDENTIFICATION-
• Black coloured chunks or clusters seen along rubbing wear.
• Will be found at the upper part of the slide. It does not reflect when light
is passed.
BLACK OXIDES
RED OXIDE
• Mostly seen due to presence of moisture in the sample.
• DESCRIPTION-
• Seen as red or brown colored particles along rubbing wear having stony
texture.
• High chances of finding red oxides at the end of the slide as they are
paramagnetic in nature.
RED OXIDE
FRICTION POLYMER
Presence of friction
polymers indicates the
overstress on lubricant
in a critical contact.
DESCRIPTION-
They are seen as semi solid or
in emulsion forms .
STEEL WEAR
• .
• DESCRIPTION-They are abnormal wear having twisted or gnarled morphology. They are
detected by their temper colours after heat treatment is provided to the ferrogram
• Steel wear is seen in three forms-
• LOW ALLOY STEEL – Blue in colour. Many times many small particles are seen along with
rubbing wear but caution is only addressed when these particles are vey big with sharp edges.
• MEDIUM ALLOY STEEL- Mostly seen in straw colour.
• HIGH ALLOY STEEL- Mostly seen as yellowish to red in colour.
• Medium and high alloy steel are not seen as frequent as low alloy steel.
LOW ALLOY STEEL
Smaller particle of low alloy

steel seen along rubbing wear.
Larger particles with sharp edges seen indicating
abnormal wear
MEDIUM AND HIGH ALLOY STEEL
MEDIUM ALLOY HIGH ALLOY STEEL

STEEL
CAST IRON
They seen as a result of
abnormal wear or lack of
lubrication in the machine.
DESCRIPTION-
Predominantly distinguished
as straw coloured particles
even before heat treatment
is provided indicating that
they are heavily oxidized.
ALUMINIUM
They are white non ferrous
particles which are seen due
to pistons and aluminum
seals.
Sources can be-Pistons,
Bearings, Dirt, Gears,
Housing, Fuel Derivatives
Their size generally ranges

around 15- 20 micron.
COPPER
Seen in ferrogram due to
bearing cage failure /wear.
Sources can be-Bearing, Gears,Oil Coolers,
Pipe Works, Piston Rods,Glands
Distinguished by its red or bronze
Colour and shiny surface. They do
Not reflect when light is passed
through it.
LEAD AND TIN
• Mostly seen in samples where their additives are depleted.
• Sources can be-Bearings, Thrust Washers
• IDENTIFICATION-
• Can be seen as blackish chunks having blue or orange dots present on the
surface
• Can also be seen as metallic coloured chunks in some instances.
LEAD AND TIN
CARBON
• Presence of carbon on the slide is an indication for deposition of contaminants
in the sample.
• DESCRIPTION-
• They are non ferrous particles present at the lower region of the slide in the form
of dark non reflective particles.
• Their edges are not necessarily sharp.
• Many times the particles are present on top of rubbing wear and not along the
wear.
CARBON
The rubbing wear does not come in the focus of the lens
indicating the larger size of the carbon particle and that
they are on top of the rubbing wear.
SILICA
• Presence of silica indicates dust contamination in the sample.
DESCRIPTION-
• It is identified as particle seen at the lower part of the slide which reflect
when light is passed through them .
• They are seen in various colours from yellow, red or even pink.
• They are mostly seen in straw colour.
SILICA
FIBER
They are contaminant
particles present in oil seen
in clusters.
MOLYBDENUM DISULPHIDE
It is a semi metallic solid
lubricant used in machines
where high temperature and
load are anticipated.
DESCRIPTION-
It has grayish colour and it
blocks light when passed.

Ferrography Analysis

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FERROGRAPHY

WEAR DEBRIS CONTAMINANTS

Ferrous particles providing Non – ferrous particles

• Caused to due to normal sliding motion in a machine. Rubbing wear

Bearing wear having

2. SCUFFING AND SCORING

Smaller particle of low alloy

MEDIUM ALLOY HIGH ALLOY STEEL

Their size generally ranges

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