Evaluation of Bearing Damages

Contents
1. Foreign particles:
1. scaring and embedding

2. Edge loading by incorrect shape and alignment

2.1. Unilateral edge loading
2.2. Diagonally opposed edge loading
2.3. Edge loading on both ends
2.4. Overloading of bearing center

3. Out-of-round housing bore

3.1. High oval bore
3.2. Wide oval bore

4. Wear
4.1. Wear in loaded area
4.2. Wear in the bearing center areck
4.3. Unworn areas near the bearing ends

5. Corrosion

6. Cavitation erosion
6.1. Oil flow cavitation beside grooves
6.2. Oil flow cavitation near oil groove runaut
6.3. Cavitation ciue to pressure fluctwation (partialiy grooved bearings)
6.4. Cavitativn due to vibration

7. Fatigue rupture
7.1. Fatigue of the electroplated overlay
7.2. Fatigue Of the lining material

8. Insufficient interference fit

8.1. Fretting corrosion an bearing back
8.2. Weld marks an bearing back
8.3. Rupture of the steel support shell

9. Incorrect assembly
9.1. Misaligned bearing cap
9.2. Improper matching of oil ducts
9.3. Deformation of shell under dowel pin
9.4. Locating lug misalignment

10. Failure mode analysis

 Evaluation of Bearing Damages

1. Foreign particles: Scoring and embedding

Appearance:
- Scratches in circumferential direction (Fig. 1)
- Indentations an the running surface with for(oign matter ornbedded in the ronter (Fig- 2)
Causes:
- Contaminated lubricating oil
- Inadequate cleaning of the engine parts prior to assembly (oil ducts of engine block, crankshaft, con rod,
…)
- Insufficient servicing of oil filter
 Evaluation of Bearing Damages

2. Edge loading by incorrect shape and alignment

General Appearance
- Shiny traces along bearing edges
- Excessive wear along edges
- Possibly rupture and smearing of overlay along edges.
2.1. Unilateral Edge Loading
Apperance :
- Shiny traces and excessive wear on one side of one or both bearing halves
Causes:
- Conical grinding of journal (a)
- Conical housing bore (b)
- Crankshaft fillet or axial clearance too large (c)
- Crankshaft not well balanced : tumbling (d)
Evaluation of Bearing Damages
 Evaluation of Bearing Damages

2.2. Diagonally opposed edge loading

Apperance :
- Excessive wear at the opposite end of the two bearing halves : in mild cases only in loaded area, then not
distinguishable from 2.1.
Causes :
- Misalignment of journal and/or housing bore (a)
- Deflections of housing
- Bent or twisted con. Rod (b)
 Evaluation of Bearing Damages

2.4. Overloading of bearing center

Appearance:
- Excessive wear in bearing center area, possibly cracks in the running surface clue to overloading. (Fig. 1)
- Dragging smearing of the overlay (Fig. 2)
Causes:
- Convex grinding Of journal, barrel shape (a)
- Concave housing bore: hourglass shape (b)
- Lubricating oil shortage
Evaluation of Bearing Damages
 Evaluation of Bearing Damages

3. Out-of-round housing bore

3. 1. High oval bore
Appearance:
- Heavy wear, smearing of overlay or overlay fatigue near the parting lines of the bearing
Causes:
- Deformation of the housing due to mechanical or thermal load.
- Bolt overtightening during housing bore rework
 Evaluation of Bearing Damages

3.2. Wide oval bore

Appearance:
- Area of excessive wear very narrow in circumferential direction, possibly accompanied by overlay smearing,
in extreme cases in both loaded arid unloaded half.
Causes:
- Excessive Plastic deformation (settling) of the housing mating faces or serrations.
- Bolt not adequately tightened during housing bore rework
 Evaluation of Bearing Damages

. Wear
4. 1. Wear in loaded area
Apperance :
- Wear over a wide area, mainly in most highly loaded zone
Causes:
- Normal wear after long running time.
- Oil starvation caused mixed friction between journal and bearing shell.
- Increased surface, roughness of the journal.
- Waviness or journal in circumferential direction
 Evaluation of Bearing Damages

4.2. Wear in the bearing center area

Appearance:
- Heavy, strip-shaped wear in the center area of the bearing
Cause:
- Oil hole of crankshalt inadequately blended.
 Evaluation of Bearing Damages

Appearance:
- Heavy, strip-shaped wear in the non-grooved shell (upper shell) in continuation of the oil groove of the
lower shell.
- In severe cases, fatigue rupture of the overlay
Causes:
- The lower side of the crankpin wears only locally where it contacts the bearing surface. A ridge remains in
its center. This causes overloading and local wear in the loaded region of the bearing.
 Evaluation of Bearing Damages

4.3. Unworn areas near the bearing ends

Appearance:
- No running traces in a narrow strip an one or both sides of the bearing.
- Possibly excessive wear next to these areas
Cause:
- Incorrect grinding Of journal width: undercuts too large (a, b)
 Evaluation of Bearing Damages

5. Corrosion
Appearance:
- Rough porous or velvety running Surface, most often darkened.
- Rernoval of overlay over wide areas with discoloured transition zones w In extreme cases, attacked lead
bronze
Causes:
- Chemically aggressive oil or additives.
- Contamination of the lubricating oil with alkaline (e.g.} antifreeze) or acidic substances.
- Aggressive combustion residues (heavy fuel Oil) in lubricating oil w Exceedingly long oil change intervals
- High water content of oil
 Evaluation of Bearing Damages

6. Cavitation erosion
Cavitation is generally caused by a local drop of the oil pressure below the vaporization pressure, leading to
the formation of ail bubbles. These bubbles collapse when carried Into a higher pressure region, initiating a shock
wave.
Cavitation is generally promoted by low oil pressure, by high oil temperatures. by the presence of substances
having a low boiling temperature (e.g. fuel) in the oil and by vibrations.
6. 1. Oil flow cavitation beside grooves
Appearance:
- Lance-shaped erosion with sharply defined fringes at the oil groove
Cause:
- Turbulance in the incoming oil flow, in particular in areas where flow direction in groove is opposite to pill
rotation
 Evaluation of Bearing Damages

6. 2. Oil flow cavitation near oil groove runout

Appearance:
- Mushroom shaped errosions after runout in pin rotation direction
- Possible errosion of groove edges.
Cause:
- Turbulance due to unfvorable transdition from groove to bearing surface.
 Evaluation of Bearing Damages

6. 3. Cavitation due to pressure fluctuation (partially grooved bearings)

Appearance:
- Kidney-shaped or circular errosions distinctly offset from groove runout in direction of rotation. Mostly
found at main bearing
Cause:
- Pressure wave in the oil hole of the cranlshaft because of altering oil flow direction
 Evaluation of Bearing Damages

6. 4. Cavitation due to vibration

Appearance:
- Punctual or kidney-shaped errosion of the overlay mainly at con. rod bearings (fig.1)
- At main bearings mostly lance-shaped errosion of the overlay at the upper shells. (fig.2)
Cause:
- Deflections of the con. rod large end because of the bearing load.
- Excessive bearing clearance
- Vibration of cycle rapid motion of pin.
 Evaluation of Bearing Damages

7.0. Fatigue Rupture

7.1. Fatigue of the electroplated overlay
Appearance:
- Fine cracks or a network of cracks in the overlay.
Cause:
- Local overloading due to high bearing forces, often in connection with high temperatures.
- Edge loading or increased mixed friction (e.g. high oval bore)
 Evaluation of Bearing Damages

7.2. Fatigue of the lining material

Appearance:
- Cracks, a net work of crack,”cobblestones”, in the material
- Parts of lining material broken out
Cause:
- Local overload because of generally high beating load
- Local overload by uneven loading
Mechanism:
- Fine cracks develop at first on the bearing surfaces (1)
- They propagate toward the steel support shell (2)
- Ultimately, parts of the lining material break out (3)
 Evaluation of Bearing Damages

8.0. Insufficient interference fit

8.1. Fretting corrosion on bearing back
Appearance:
- Dark, slightly rough areas on the bearing back and in the housing bore
- Steel surfaces attacked already
Cause:
- Insufficient crush height of the bearing shells caused by oversize housing bore
- Bolts not torqued according to specifications.
 Evaluation of Bearing Damages

8.2. Weld marks on bearing back

Appearance:
- Pitting on the bearing back and in housing bore, frequently near the parting lines
Cause:
- As 8.1., but more severly or after longer running time.
 Evaluation of Bearing Damages

8.3. Rupture 0f the steel support shell

Appearance:
- Broken steel support shell
- Frequently, concentric lines indicating a transient stop of rupture
Cause:
- Fretting corrosion and/or welding marks lead to increase notch effect
- Loose bearing shell
- Local areas of missing bearing back contact.
 Evaluation of Bearing Damages

9.0. Incorrect assembly

9.1. Misaligned bearing cap
Appearance:
- Excessive wear areas can be seen near the parting lines on diagonally opposite sides of upper and lower
bearing shell
Cause:
- Wrong bearing cap
- Bearing cap turned 180º
- Damaged cap guide
- Improper sequence of bolt torquing
 Evaluation of Bearing Damages

9.2. Improper matching of oil ducts

Appearance:
- Overheated running surface, bearing seizure
- Mirror image of housing bore visible on bearing back
Cause:
- Improper bearing installation: oil ducts blocked
 Evaluation of Bearing Damages

9.3. Deformation of shell under dowel pin

Appearance:
- Heavily wear and beginning of seizure on the running surfaces opposite the dowel pin. Marking of pin in
or beside slots on bearing back.
Cause:
- Dowel pin too long, material in pin hole
- Dowel pin misalignment
 Evaluation of Bearing Damages

9.4. Locating lug misalignment

Appearance:
- Deformed locating lug, heavy wear: possibly beginning of seizure in the running surface in lug area.
Cause:
- Locating lug misaligned with housing recess.
10.0. Failure mode analysis
Orientation guide to determine the cause of bearing damage
Function Characteristic Parameters to check
Operating conditions - particular load cases or application
Breakge of adjacent parts
Failure of piston

External Piston pin

Condition Piston pin bushing
Engine design, vibrations
Failure of lubrication - reason ?
Assembly / dirt in the system
Oil analysis, additives, oil aging
Single or multiple viscosity of oil
Viscosity
Viscosity
Water content
Foamimg
Oil treatment
Lubricant Impurifications Running surface and housing, transitions.evaluation of bearing set (cond rod, main)

Hot operation Standard temperature

condition Temperature under specific operating conditions
Cooling
performance Temperature measurement before failure
Overheating
Metallurgical analysis of the components

Mixed friction Running in / before stop / lubrication in advance

condition Specific apperance of bearing
Specific surface load
Pin orbital path / limits
Bearing design
(Engine's own) Vibration
Comparable engines

Installation Latest data from assembly test

situation Available geometric measurements
Bearing / load Installation situation
Housing
Condition of bearing back
Corrosion
Bearing Cavitation
Metallurgy
Cavitation
Pin
Metallurgy
Manufacturing records
Housing
Measurements of geometry, surface roughness. etc.
Manufacturing records
Quality Pin
Measurements of geometry, surface roughness. etc.
Manufacturing records
Bearing
Detailed geometry, including spread, crush height, well thickness, bearing
1) Relevant for the design and testing of new engines
2) Individual types of cavitations are not considered here in detail.
3) Probability on a scale of 1 (highly probable) to 5 (improbable) to assess the overall results and influences on the
bearing performance