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Chapter 2
Table 2-9: Wear-Failure Analysis

1. Identify the actual materials in the worn part, the environment, the abrasive, the wear debris, and the
lubricant.
2. Identify the mechanism or combination of mechanisms of wear: adhesive, abrasive, corrosive, surface
fatigue, or erosive.
3. Define the surface configuration of both the worn surface and the original surface.
4. Define the relative motions in the system, including direction and velocity.
5. Define the force or pressure between mating surfaces or between the worn surface and the wear
environment, both macroscopically and microscopically.
6. Define the wear rate.
7. Define the coefficient of friction.
8. Define the effectiveness and type of lubricant: oil, grease, surface film, naturally occurring oxide layer,
adsorbed film, or other.
9. Establish whether the observed wear is normal or abnormal for the particular application.
10. Devise a solution, if required.

Of course, we should never lose sight of the overwhelming advantages of defect

elimination by up front engineering efforts. An ounce of prevention is worth a pound
of cure.

Analyzing Wear Failures*

An accurate analysis of a wear failure depends largely upon three sources of evidence: the
worn surfaces, the operating environment, and the wear debris.
Surface damage can range from polished or burnished conditions to removal of a relatively
large volume of material. Examining the worn surface can provide much information,
including the amount of material removed, the type of damage or failure mode, and the
existence and character of surface films. Further, it will tell whether certain constituents
are being attacked preferentially, the direction of relative motion between a worn
surface and abrading particles, and whether abrading particles have become embedded in the
surface.

Environmental Conditions
The environment in which the failure takes place greatly affects the mechanism and rate of
metal removal, and detailed knowledge of these conditions should always be sought. For
*

Adapted by permission from course material published by the American Society of Metals, Metals Park,
Ohio 44073. For additional information on metallurgical service failures, refer to the 15-lesson course
Principles of Failure Analysis, available from the Metals Engineering Institute of the American Society for
Metals, Metals Park, Ohio 44073.