Wear is caused by two solid materials rub against each other, removing pieces from one by some mechanical action. There are several different types of wear that can all lead to failure:
• Adhesive Wear
• Abrasive Wear
• Fretting Wear
• Erosive Wear
While these are not mutually exclusive, identifying the cause of wear particles is essential for preventing mechanical failures.
Often, signs of wear can be seen in the oil that lubricates the wearing parts. Particles flake off of the mechanism and end up in the lubrication between the parts. By examining the oil, manufacturers and mechanists can assess where the problem is originating from and take preventive steps to control potential failure.
Other times, wear can be seen as cracks in the surface of the metal pieces. This can cause immense failure potential in the mechanism, such as bearings, if it is not caught early and preventive steps taken. By analyzing the bearings, mechanics can either file down or replace bearings that could be a potential failure issue.
Since wear can manifest itself in several different ways, it is helpful to be able to identify several different types of wear directly on the shop floor. The Aspex Personal Scanning Electron Microscope (PSEM) with edx analysis can do just that, sizing and analyzing the particles quickly by using the Advanced Quality Control (AQC) software. The AQC not only provides manufacturers with a visual of the particles, but also with the elemental composition, allowing them to identify the source of the problem and take corrective action upstream.
Using the AQC software, automotive manufacturers have cut down on manufacturing and warranty failures, savings far out weighting the upfront cost of implementing the PSEM system. And, with the push towards critical cleanliness and higher-quality products, manufacturers have saved both time and money, reducing the failures and cutting down on product loses due to failures.
Understanding particle wear can be easier than fixing the issue, but it is definitely more advantageous than imminent failure caused by wear failure. Being able to predict wear failure, and then take preventive steps, is a crucial step in quality control programs. The Aspex PSEM with AQC software can identify microscopic wear particles quickly and accurately, directly on the manufacturing floor.
References:
Aspex, http://www.aspexcorp.com/industries/industrial-automation.html
Wikipedia, http://en.wikipedia.org/wiki/Wear
