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HET4 > Failure and Fluid Analysis > Flashcards

Failure and Fluid Analysis Flashcards

1
Q

How is fluid analysis best utilized

A

as a major part of predictive maintenance

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2
Q

what is the most effective application of fluid analysis

A

involves the scheduled testing of fluids , recording results , and chartering data for a particular piece of equipment with its own specific operating conditions and environment

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3
Q

the data obtained from regular testing can provide what general information

A

. wear rates of internal components
. rate of product deterioration and additive depletion
. the amount and type of external contamination

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4
Q

what is spot checking when referring to fluid samples

A

a one time look into the system with no reference or comparison data to highlight any recent changes to operating conditions

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5
Q

what is the break-in-period

A

this is the period where new components mate and wear with other components after assembly and small particles smaller than can be seen by the naked eye float into the system

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6
Q

after assembling a new component and the oil sample taken reads a high ppm of wear particles . what might be the issue

A

this is the break in period of the new component and the ppm should taper off to a normal level after a period of time

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7
Q

what might indicate a reason for concern and possible intervention when reading a fluid sample

A

any deviation of wear particles

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8
Q

a common method of oil sampling is to sample between services when dealing with large oil sumps and extended oil change periods . what can this data be used to determine

A

the optimum oil change durations and intervals between servicing

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9
Q

what are the three major areas a oil analysis report will provide information on

A

. Deterioration of the oil itself , either physical properties or additives
. the amount of PPM and type of wear particles in the oil
. the presence of foreign contamination

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10
Q

why is it important to take a oil sample from a warm and operating system

A

because the contamination in the system will be in suspension

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11
Q

what is viscosity

A

resistance to flow

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12
Q

what might cause a increase in an oils viscosity

A

. contamination by a product with a higher viscosity
. thickening of the oil base due to contamination during operation , high operating temperatures
. extended drain intervals

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13
Q

why is water usually found in oil

A

because it is a by-product of combustion and is always present as condensation

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14
Q

what will water in the oil system cause

A

rust of components - creation of acids - become a catalyst in chemical reactions between additives in the oil

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15
Q

in applications other than engines what would be the cause of solids such as varnish , sludge and soot being found in the oil sample

A

high operating temperatures or outside contamination

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16
Q

if sodium and boron are obtained in an engine sample what would be the cause

A

antifreeze has entered the system and O-rings , coolers , gaskets and seals between the systems becomes the possible source of the leak

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17
Q

if the oil sample has a high FLASH PIONT what might be the cause

A

most commonly fuel is in the oil this could be caused by Incomplete combustion , over fueling from faulty fuel system or poor service practices

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18
Q

what will the acid number provide in a oil sample

A

information regarding the accumulation of combustion products and their reaction with various metallic surfaces or additive packages

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19
Q

as the acid number increases so does the

A

rate of corrosive damage to wear surfaces

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20
Q

Tin

A

used as a sacrificial overlay of moving parts to facilitate wear in . also found in solders and in Babbitt metals used in friction type bearings

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21
Q

Lead

A

is a component in ,metal used in friction type bearings , found in solders , oil additives , gaskets and anti seize compounds

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22
Q

Copper

A

used as an overlay on bearings , used in bushings , cooling coils , bearing cages and shaft surfaces may be copper treated , sealants , anti seize

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23
Q

Aluminium

A

commonly the main component in pistons , supercharger and turbocharger blades , bearings , engine blocks , gear boxes and other housings , filtering and reclaiming systems , grease

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24
Q

Silicon

A

dust , dirt , sand . when found in conjunction with high iron or other metals it becomes a reliable indicator of premature wear and or dirt contamination

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25
Q

chromium

A

main component of chrome surfacing and several hardening processes , especially stainless steel

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26
Q

Silver

A

found in solder and is used as a coating on some bearings . gears and bushings

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27
Q

zinc

A

Zinc is a major component in brass and is also found in bronze some solders , Extreme pressure agents in oils and grease commonly contain zinc

28
Q

magnesium

A

found in steel alloys , as additives in oils and some gear box housings

29
Q

Nickel

A

is used in the hardening process of stainless steels and can indicate shaft , gear , and or frictionless roller bearing wear

30
Q

Sodium

A

common in most antifreezes . when found in combination with boron it indicates antifreeze is present

31
Q

barium

A

used as an additive in oil, grease and some commercial fuel additives

32
Q

calcium

A

mainly used as an additive in petroleum products

33
Q

Vanadium

A

can be found as the result of specialized hardening processes

34
Q

phosphorus

A

a component in additive packages such as detergents, anti wear and extreme pressure

35
Q

Molybdenum

A

used as hardening and anti-corrosion treatment of steel compounds

36
Q

boron

A

is a component in antifreeze, when found in conjunction with sodium an antifreeze leak is indicated

37
Q

Manganese

A

used as a sacrificial coating on many new metal parts

38
Q

can all fluids used in mechanical systems be analyzed

A

yes , fluids whether taken from engines, transmissions, rear axle housings, hydraulics, cooling systems, exhaust or any other system will yield valuable results

39
Q

poor engine combustion and or low combustion temperatures yield excess hydrocarbons in the exhaust . this excess of hydrocarbons can be the result of

A

restricted air supply to the engine or faulty fuel system components

40
Q

how is a fatigue fracture formed

A

over time after several loading cycles and within normal specifications

41
Q

what are the identifying features of a fatigue fracture

A

initial fracture site then slow progression of fracture growth leading up to the final break and resulting shear lip

42
Q

how are brittle fractures formed

A

when a part suddenly breaks as a result of shock or impact load

43
Q

what are the identifying features of a brittle fracture

A

rough fracture surface with none or very little deformation . the break will look very jagged in nature

44
Q

how are ductile fractures formed

A

by a single application of high shear stress

45
Q

what are the identifying features of a ductile fracture

A

the surface will reveal plastic deformation as the molecules slipped past each other during the shearing process . this will change the shape of the component and large shear lips will form

46
Q

what are some of the ways wear can be classified

A

. type of stress
. the movement of the parts
. the damage to the wear surfaces

47
Q

what are the categories of visible wear

A

Adhesive wear - Abrasive wear - Surface fatigue wear - Brinelling ( true and false ) - Corrosive wear - Erosive wear

48
Q

what is Adhesive wear

A

the formation and separation of atomic surface bonds at the molecular level

49
Q

how is Adhesive wear formed

A

when two moving surfaces make contact without sufficient lubrication and/or cooling . the resulting friction can raise pinpoint temperatures high enough to momentarily weld these small peaks together which are then pulled apart as the surfaces continue to move

50
Q

what is abrasive wear

A

scraping stress created by particles caught between two moving surfaces

51
Q

what a some identifying features of Abrasive wear

A

Scratches, cuts and gouges appear on the surface without the evidence of hot spots

52
Q

what is surface fatigue wear

A

when load is applied and released at high pressure point areas such as cam lobes or rolling surfaces in bearings

53
Q

what are some of the identifying features of surface fatigue

A

surface cracks and pitting

54
Q

what are the classifications of brinelling

A

true and false brinelling

55
Q

what is true brinelling

A

tiny indentations on the bearing race . typically occurs high on the outer race or in the valley of the bearing raceway

56
Q

what is one possible cause of true brinelling

A

improper removal or installation of a bearing caused by shock loading or impact also incorrect preloading can cause this

57
Q

what is false brinelling

A

material wear or removal caused overtime from vibration without lubrication

58
Q

what type of surface wear would be found in the trunnions of a universal joint with a working angle of 0 degrees

A

false brinelling

59
Q

how is false brinelling managed in universal joints

A

with bearing creep

60
Q

what is corrosive wear

A

a chemical or electrochemical reaction between surfaces and surrounding mediums

61
Q

how can corrosive wear be identified

A

by rusting and scaling producing observable damage as pitting with irregular holes

62
Q

what is Erosive wear

A

caused by the removal of material from a surface by high velocity particles in a fast moving fluid or by cavitation

63
Q

how can you tell the difference between cavitation or fast moving fluid Erosive wear

A

high velocity fluids will appear dull and shot peened . cavitation will appear as pits and notches with laser precision

64
Q

how is a tension failure formed

A

stress placed on a component that tend to elongate the component

65
Q

where would tension stress be most common

A

used in connecting components or those used to transfer pulling forces, chains, cables, bolts and some brackets

66
Q

a brake related to tension is always characterized by

A

an increase in longitudinal dimension of the member and a reduction of the cross sectional dimension near the fracture

67
Q

where would compression distortion normally occur

A

at 90 degrees to the lines of force

HET4 (31 decks)

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