Oil and Lubricant wear metals testing.

The determination of wear metals in used oil is a key diagnostic method used in Oil Condition Monitoring (OCM), Equipment Condition Monitoring (ECM), Condition Based Maintenance (CBM) programs.

Wear Metal Analysis in oils and lubricants allows maintenance to be scheduled efficiently, minimising the risk of damage to expensive plants and avoiding unscheduled downtime and maintenance, helping productivity and avoid costly repair or shut downs.

The Early stage of wear in oils and lubricants significantly improves the reliability of the machinery.

Hence – ATLAS – provides a comprehensive state-of-the-art Oil Testing & Lubricant Analysis Services. The objective is to spot any potential problems before they cause catastrophic failure.

Sources of Wear Metals in Analysis of Oils

The tables given below give an indication of the source of wear metals in the oil. Due to these wear metals, it is possible to identify the components that are wearing.

Wear Metals

Iron

Iron is the dominant and most common of the wear metals. It is found virtually in all equipment in some form or the other. As it is abundantly used it indicates that there are a lot of sources of wear in the machinery.

Due to this knowledge, the testing of this component allows the analyst to distinguish the source of the wear debris, like, cylinder rods vs. bearings.

Chromium

Chromium is used in machinery and equipment for its resistance to corrosion and for its great strength and hardness. Thus it is found in many systems operating under extreme and harsh conditions.

Copper

Commonly used as an alloy, it is extensively used because of its material properties like excellent electrical and thermal conductivity and is extremely ductile. It is used abundantly in bearing systems and heat exchangers.

Aluminium

Aluminium is prized in equipment because of it's high strength to weight ratio, also it has excellent corrosion resistance. Used as an alloy in combination with other elements it improves its wear and temperature resistance.

Tin

Tin is used as an alloying element along with copper and lead for sacrificial bearing liners.

Lead

A soft metal used for sacrificial wear surfaces such as journal bearings. Lead-based babbits are widely used.

Silver

Silver is highly prized as it has the highest electrical as well as thermal conductivity from all metals. It is an excellent bearing plate material, providing minimum friction. Due to its low contact resistance, it is susceptible to corrosive attack.

Cadmium

Cadmium is resistant to corrosion and as a result, it is used as a protective layer when deposited on other metals. Also used as an alloy with certain metals.

Vanadium

Used as an Alloy mainly with steel to increase the strength of steel considerably. Used in applications for axles, crankshaft and other critical components.

Titanium

The two most important properties of Titanium is corrosion resistance and the highest strength to weight ratio of any metal. Thus it is alloyed with Iron, Molybdenum, Vanadium, aluminium to produce strong lightweight alloys for aero-space, military and industrial use. Also used widely for manufacturing Titanium dioxide used in Paints, Coatings and Pigments.

Contaminant Metals

Silicon

A common contaminant found during lube oil analysis. Mainly due to ingested dirt (sand) which is a very hard crystalline material and is extremely abrasive to metal components. Also found due to Coolant / Anti-freeze and sealant wear.

Sodium

Corrosion inhibitor additive also indicates coolant leak into oil, can also be road Salt, Sea water, Ingested Dirt

Potassium

Usually not found in the oil but may be due to coolant leak if associated with Sodium and may be Magnesium.

Manganese

Manganese is important for Iron and Steel for its alloying properties as it increases their tensile strength when used. Also when used with Aluminium it increases its resistance against corrosion.

Additive Metals

Boron

Corrosion Inhibitor additive, Antiwear/Antioxidant additive, can indicate coolant leak, grease contamination

Magnesium

Detergent/dispersive additive can also be alloying element in steels

Calcium

Detergent/dispersant additive, Alkaline reserve additive for high sulphur fueled engines, can be grease contamination

Barium

Corrosion Inhibitors, Detergents, Rust inhibitors

Phosphorus

Antiwear, Corrosion inhibitors, Anti-oxidants additives, EP additives

Zinc

Antiwear, Corrosion inhibitors, Anti-oxidants, alloying element for bearings, thrust washers, galvanised cases

Testing of Metals in our Laboratory

Testing of the Metals comprising of Wear Metals, Contaminant Metals and Additive Metals is done in our laboratory.

Equipment used: ICP

Method of Testing: ASTM D5185: Standard Test Method for Determination of Wear Metals and Contaminants in Used Lubricating Oils or Used Hydraulic Fluids