TECHNICAL BULLETIN
Analytical Ferrography and Micropatch Testing
Two common, advanced, in-service oil tests that use a
microscope to do qualitative analysis on samples are
micropatch and analytical ferrography. After performing
routine oil analysis, these advanced test methods may be
recommended in order to identify problems, but why should
you perform this testing?
Micropatch and analytical ferrography are typically performed
after standard testing indicates a problem, meaning a problem
warrants further investigation. These tests help data analysts
study particle wear on machine components by analyzing the
oil. It also can be used to predict and diagnose equipment
faults. For critical equipment, adding micropatch or analytical
ferrography could assist in catching issues before standard
oil analysis. A data analyst views a ferrogram slide with a micro-
scope to see particles, wear and contamination.
Analytical Ferrography
Analytical ferrography is the process of viewing a ferrogram, a
slide prepared to view under a microscope, and studying the
wear and contamination. A portion of the used oil is transferred
to a slide on which the ferrous (containing iron) objects in the oil
are collected. After proper agitation, a small amount of sample
is poured through a thistle tube across a glass slide suspended
over a powerful magnet. The oil, soot, dirt and other debris
are rinsed from the slide, leaving the ferrous wear visible when
viewed under a microscope.
Analyzing a ferrogram allows the analyst to see the different
types of wear mechanisms in the oil. It is not limited by the size
of wear particle, like some other types of testing, meaning that
Analytical ferrogram showing large fatigue,
large and small wear is easily identified. cutting and rubbing wear
As with any testing, there are limitations with this method. A
clean sample with very minimal ferrous wear (typically less than
10-15ppm of iron) will usually leave very little to analyze. Since
the magnet has nothing to pull out of the fluid without the
presence of ferrous material, the fluid will flow freely off of
the slide.
1 | Analytical Ferrography and Micropatch TB-0011-01
© 2019
TECHNICAL BULLETIN
Micropatch
A micropatch test is a similar process, but instead of catching only
ferrous material, a 0.8-micron filter patch collects all particulates
in the oil. This allows ferrous wear, non-ferrous wear, abrasives
and debris to be collected and then analyzed with the use of a
microscope.
This tool allows you to investigate high particle counts and small
amounts of bearing wear when there is minimal iron present. It can
help identify varnish in the oil as well as different types of abrasives
and debris, such as fibers and rust.
Unfortunately, darker fluids or fluids containing substantial debris
Micropatch showing ferrous wear, abrasives,
and wear are not ideal. Since the patch collects all contaminants oxides and copper alloy wear
and debris larger than 0.8-micron, it can be difficult for the analyst
to determine the cause of wear. Therefore, a micropatch is ideal
for clean systems and is not appropriate for diesel engine samples,
unleaded gasoline engine samples or dark gear oils.
When should ferrography or micropatch be performed?
Ideally, mission-critical components would receive this testing on
a regular basis to identify trends, much like standard oil analysis.
Since these methods are qualitative and visual tests, an analyst
may identify precursors to failure modes. This includes signs such
as metallic spheres (which point to early signs of fatigue) or thermal
discoloration (signs of excessive heat in localized areas), which
would not be able to be detected in routine elemental analysis.
If you are seeing high levels of copper or lead in your engine
or gearbox samples, analytical ferrography can help determine
whether these particles are wear or just the soft metals
leaching into the oil. Micropatch testing is great for identifying
contamination issues and investigating non-ferrous wear.
Highly contaminated ferrography slide
As with all testing, there will always be limitations. In some cases,
the samples can be so laden with particles that diagnosis can be
difficult. In severely contaminated samples, the stacking of these
particles can literally bury some of the important information.
If you’d like to learn more about this testing, contact a data analyst.
2 | Analytical Ferrography and Micropatch TB-0011-01
© 2019
