What causes machine components to fail? What are the most prevalent failure mechanisms, and how can you avoid them? Continue reading to learn how to spot components in various phases of progressive failure, as well as the tools you may use to diagnose and fix them. FMEA Process for Lubrication Failures
The most common failure modes in lubricated machines include abrasion, corrosion, fatigue, adhesion, cavitation, erosion, electrical discharge, and deposition.
Abrasion
Hard particles that are too big to flow through a lubricant-lubricated surface cut into another moving surface, causing abrasion. A surge in the circulation system, a faulty breather, or even a faulty engine might cause it to happen.
CBM Tool: Oil Analysis
Corrosion
Corrosion occurs when a substance such as moisture, oxygen, or acids attacks metal and changes its chemical properties. Shear readily removes the resultant oxide, exposing new metal for long-term oxidation. Process contamination, a coolant leak, or a faulty desiccant breather are some of the possible sources of corrosion.
CBM Tool: Oil analysis
Fatigue
Rolling contact failure occurs often in roller bearings and gears, resulting in material fatigue fractures and spalling. You can reduce fatigue by minimizing dynamic loads from imbalance, misalignment, and resonance, as well as by lowering static loads and performing other maintenance measures.
CBM Tool: Vibration Analysis, Ultrasound, Infrared Inspection, Oil Analysis
Lack of Lubrication
When the lubricant coating meant to decrease friction and separate a roller from a race or a journal from a shaft fails due to lack of lubrication, metal-to-metal contact occurs. You can prevent this mechanism by using the correct lubricant at the proper level and operating the machine at the appropriate speed and load.
CBM Tool: Ultrasound Monitoring
Deposition
Any varnish buildup on a control valve can cause it to block and stick, while fibrous material buildup on a fan can produce unbalance and pose a fire hazard. By recognizing, understanding, and resolving the unique accumulation process, this failure mechanism can be avoided.
CBM Tool: Oil analysis
Misalignment
Misalignment occurs when the driven shaft’s (motor) centerline of rotation does not align with the pump’s centerline. However, the tolerance built into the couplings only indicates how much misalignment the coupling can handle while still transferring power.
CBM Tool: Vibration Analysis
Tension, Compression, and Shear
From incipient to catastrophic failure modes, shear force is almost always a contributing element. Mechanical systems are made to last a long time and do work by applying tension and compression. Shear is a frequent failure element in abrasion, corrosion, fatigue, adhesion, cavitation, erosion, and electrical discharge failure processes.
Tools for Detecting Failure
To detect early signs of equipment failure, industry professionals rely on predictive maintenance tools such as:
- Vibration analysis – monitors rotating machinery for abnormal movement or imbalance
- Oil analysis – checks lubricant condition to detect wear, contamination, or degradation
- Acoustics – listens for unusual sounds indicating mechanical issues
- Infrared or thermal imaging (thermography) – identifies abnormal heat patterns in machinery
- Motor circuit analysis – assesses electrical performance and potential faults
Using these tools helps organizations perform more efficient maintenance, reduce downtime, save costs, and enhance workplace safety.
Thermographic and Infrared Analysis
Specifically, infrared technology allows the creation of temperature maps even from a distance. Consequently, it is particularly useful for monitoring heating systems. Furthermore, thermographic examinations can detect bearing conditions as well as assess a motor’s electrical state. Therefore, this technology provides a comprehensive way to identify potential issues before they lead to failures. Additionally, it helps prevent downtime while improving safety. Ultimately, adopting this approach helps extend equipment lifespan and reduce unexpected breakdowns.
Applications of infrared thermography include:
- Monitoring a motor’s electrical and mechanical characteristics
- Inspecting bearings for abnormal friction and checking refractory insulation
- Detecting levels of gas, liquids, and sludge
The primary goal of infrared thermography is to confirm normal operation and identify anomalous heat patterns in machinery. For asset managers responsible for condition monitoring, this tool is invaluable for spotting potential issues before they escalate.
Oil Analysis
Consequently, it is particularly useful for monitoring heating systems. In addition, thermographic examinations can detect bearing conditions as well as assess a motor’s electrical state. Thus, this technology provides a comprehensive way to identify potential issues before they lead to failures. Furthermore, by using infrared inspections regularly, maintenance teams can prevent costly downtime. Similarly, it helps ensure system efficiency while improving safety.
By analyzing oil, professionals can detect:
- Abrasion and corrosion
- Adhesion and cavitation
- Erosion
- Electrical discharge
- Deposition
Oil analysis is particularly effective in predicting potential breakdowns by identifying the specific particles and contaminants that indicate wear or damage mechanisms.
Vibration Analysis
Vibration analysis is ideal for rotating machinery, including compressors, pumps, and engines. A sensor is attached to detect movement or acceleration, converting mechanical vibrations into electrical impulses for analysis.
According to the US National Electrical and Mechanical Engineering Institute (NETEI) in Washington, D.C., vibration analysis can identify failure modes such as:
- Broken gears
- Operation outside system parameters
- Electrical faults
- Belt problems
- Cracked shafts
Additional advantages of vibration analysis include:
- Proven reliability
- Easy detection of potential failures
- Accessibility of data via the internet
- Quick setup of portable data collection routes
Beyond detecting bearing failures, vibration analysis has a broad range of applications across mechanical systems.
Is Predictive Maintenance a Solution for All?
Predictive maintenance cannot prevent all failures. Machines have a finite lifespan, and failures will inevitably occur. What predictive maintenance offers is awareness and preparedness, which leads to:
- Higher levels of safety
- Cost savings
- Better maintenance planning
By understanding the condition of your equipment, predictive maintenance allows organizations to act before a minor issue becomes a major problem.