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Ball bearings in gas turbine have played a critical role in supporting heavy radial loads but with higher failure rates and repair costs. Therefore, the purpose of this study is to introduce and study a method for their failure analysis with an actual industrial example to guarantee operation reliability and safety.

Spectrometric oil analysis was used as an early abnormal wear indicator, based on which emergent in-use oil replacement was carried out to reduce the wear rate. However, with wear deterioration, further wear failure investigation was conducted by LaserNet Fines and ferrography to detect the imminent wear failure. Finally, with the assistance of elemental analysis of the typical wear particles, the root cause and worn components were determined by scanning electronic microscope and energy-dispersive X-ray spectroscopy.

The results have shown that an extraneous source led to wear failure, which later caused overheat between the outer bearing ring and ball. It is in accordance with visual inspection of the disassembled engine.

This method has specified the occasion under which the suitable measurement can be taken. It can achieve the rapid wear condition assessment allowing for root cause and worn parts identification. In addition, wear rate reduction by change of oil can be efficient for most of the time to avoid premature disassemble, especially with the possibility of contamination. It has provided experience to address similar industry-level practical wear failure analysis problems.