Wear Particle Analysis – Identifying Failing Components – Before They Fail

Wear particle analysis can be used for both wear analysis and contaminant analysis.

MAI engineers have developed an analytical process that identifies specific components which are failing by wear – before they fail. And while the machines or systems they are part of are still in service.

This revolutionary approach identifies the alloy group of wear particles, the number of particles of each alloy type, their size, and their shape. Particles ranging in size from millimeters to sub-micron can be analyzed. Using this data, specific parts or components that are wearing more rapidly than predicted, can be identified.

Both metal and non-metal wear particles are characterized. As a result, failing organic components such as polymer, elastomer or ceramic seals can be identified, as well as metal parts such as bearings, bushings, pistons, cylinders and any other part functioning in relative movement to another.

The immediate benefit of wear particle analysis is the opportunity to replace prematurely wearing parts by a planned process that minimizes or eliminates down time. Replacement of wearing parts may also be coordinated with scheduled maintenance, depending on the rate of wear.

Long term benefits include the identification of improvement opportunities through redesign or specification revisions for longer service life. Parts that do not conform to current specification, and may have slipped through your quality system, may also be identified before they fail.

Wear failure can be avoided in brearing failure, bushing failure, pisron failure, cylinder failure and seal failure by wear particle analysis.

Wear particle analysis also provides the value of confirmation that no unexpected wear is occurring and the machine or system is operating efficiently. Analyses at defined intervals are also an effective tool for monitoring the long term performance of optimized systems and machines.

Wear particle analysis is ideally suited to evaluating wear in fluid systems such as lubrication systems, hydraulics, heat exchangers, and fluid product processing.

Wear particle analysis gives you the advantage of identifying wear failures before they occur. MAI engineers will provide all the guidance you need to collect samples for wear particle analysis from systems in the field or pre-production development test programs.