Damage analyses

When components fail prematurely, every hour counts. Our systematic damage analysis not only clarifies the "what", but above all the "why". The analysis process begins with careful documentation of the damage condition - photographically and metrologically. We then examine the component using a wide range of methods: visual inspection identifies macroscopic damage patterns, microscopic analyses show wear mechanisms in detail, hardness measurements reveal material changes, chemical analyses clarify material composition and contamination. The interpretation is carried out by experienced tribology engineers who draw on numerous analyzed cases of damage. We reconstruct the load history and identify the chain of causes - from the primary cause through consequential damage to the final failure. The result is a detailed damage report with clear recommendations for action to prevent damage.

Wear has many faces - and each requires a different counter-strategy. Our analyses differentiate precisely between the various types of wear: abrasive wear caused by hard particles leaves characteristic grooves and furrows. Adhesive wear is characterized by material transfer and cold welding. Surface disintegration begins with microcracks under the surface. Tribochemical reactions create reaction layers. Erosion by particles or cavitation has its own characteristics. We identify not only the dominant wear mechanism, but also mixed forms and interactions. High-resolution microscopy visualizes traces of wear down to the nanometer range. EDX analyses show element distributions and material transfer. Profilometry quantifies wear volume and surface changes. We derive targeted countermeasures from the type of wear: Hardness increase against abrasion, coatings against adhesion, lubricant optimization against mixed friction. This turns the analysis into a concrete improvement plan.

Lubricant failure is often the hidden cause of component damage. Our analyses reveal why the lubricant has not fulfilled its function. Thermal overload is manifested by coking, resinification or polymerization. Oxidation leads to acid formation and an increase in viscosity. Water contamination causes corrosion and additive failure. Particle contamination leads to abrasive wear. Incompatibilities in lubricant mixtures can lead to precipitation. We analyze lubricant samples from the damaged area using state-of-the-art methods: FTIR spectroscopy identifies chemical changes, viscosity measurements show rheological degradation, element analysis detects wear metals and contamination. Particle analysis distinguishes between external impurities and internal wear. Water content and acid number quantify degradation. We use the results to determine whether the lubricant was incorrectly selected, the relubrication intervals were too long or external influences led to failure.

Rolling bearings are critical machine elements - their failure can have catastrophic consequences. Our bearing analyses identify the causes of damage and help to prevent consequential damage. Classic fatigue damage manifests itself as pitting or flaking, starting below the surface at points of maximum shear stress. We differentiate between normal material fatigue and premature failure due to overload, misalignment or vibrations. Standstill marks (false brinelling) are caused by micro-movements. Current passage causes characteristic rippling. Lack of lubrication leads to overheating with tempering colors and structural changes. Our analyses cover all bearing components: Raceways, rolling elements, cages and seals. We reconstruct load distribution and kinematics, measure hardness curves and residual stresses, and analyze lubricant residues. The damage patterns allow conclusions to be drawn about operating conditions and show potential for optimization in design, assembly and maintenance.

Corrosion and tribology are often inextricably linked. Frictional corrosion is caused by relative movements under vibration. Crevice corrosion occurs in narrow joints. Contact corrosion between different metals is promoted by electrolytes. Our analyses identify corrosion types and mechanisms: pitting, surface corrosion, intercrystalline corrosion or stress corrosion cracking have characteristic appearances. We examine corrosion products using XRD and determine their composition. Electrochemical measurements clarify corrosion potentials. We reconstruct the environmental conditions - humidity, temperature, pH value, chloride content - from deposits and corrosion products. The interaction between corrosion and mechanical stress is particularly important: corrosion scars act as notches, mechanical stress destroys protective passive layers. Our recommendations include material selection, surface treatment, cathodic protection and optimized lubricants with corrosion inhibitors.

Overheating leaves clear traces in tribological systems. Tempering colors on steel surfaces show temperature curves. Structural changes such as recrystallization or grain growth indicate temperature peaks. Melting phenomena on contact surfaces are evidence of extreme overloading. The causes of thermal overload are manifold: Insufficient lubrication leads to mixed friction with high heat development. Overloading or excessive speeds generate more frictional heat than can be dissipated. Blocked cooling systems or insulating deposits prevent heat dissipation. We quantify heat sources and sinks, calculate temperature fields and develop cooling concepts. The lubricant selection is optimized for high-temperature resistance.