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The importance of anal yzing journal repairs
The importance of anal yzing journal repairs
Why to analyze journals for repairs To determine if fits have been pr eviously repaired. Why
Why to analyze journals for repairs
To determine if fits have been pr eviously repaired.
Why was the fit was previously repaired.
To determine proper way to repair journal if needed.
To aid in the quoting process if repair is required.
To help educate customer if there are any issues.
To help determine structural integrity of journal.
To prevent catastrophic failures from occurring.
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Types of journal repairs to be analyzed Ther mal sprayed fits - metal spray - brass
Types of journal repairs to be analyzed
Ther mal sprayed fits
-
metal spray
-
brass spray
Electroplated fits
-
nickel
Sleeved fits
Welded split sleeves
Welded fits
Ground b earing fits
Uniqu e re pairs
-
copper
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Visual clues a fit has been repaired. Odd colored fit. Irregular step on back of taper
Visual clues a fit has been repaired.
Odd colored fit.
Irregular step on back of taper fit.
Widened thread relief.
Swirled polishing marks.
Hydraulic assist groove modified.
Hydraulic assist hole modified.
Hydraulic assist groove, and or hole edges – chipping,
or porosity .
Porous seam lines on fit, by leading edge, and by
hydraulic assist groove.
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Edges of fit – both IB, OB – chipping, flaking or porous. Porosity in the
Edges of fit – both IB, OB – chipping, flaking or
porous.
Porosity in the fit.
Overspray – threads, radiuses, edges of fit, ect.
Rough matte finish in hydraulic assist groove, and
edges of fit.
Pins or dowels in fit, face of journal, or hydraulic assist
groove.
Sleeve seam lines at IB,OB edge of fit, and or face of
journal.
No radius IB bearing fit.
Seam line at step or radius.
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Grinding chatter marks on fit. Horizontal weld seam - shiny spots / lines (heat). Weld
Grinding chatter marks on fit.
Horizontal weld seam - shiny spots / lines (heat).
Weld pitting at seams and other places on fit.
Weld irregularities (voids from slag) on face of journal,
edges of fit, keyway, and/or adjoining fits.
Threading pattern under surface of bearing fit.
Remember an experienced machinist, and your NDT
technician are your greatest allies.
NEVER PUT A REPAIR ON TOP OF ANOTHER
REPAIR !
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Thermal spra ye d fits – metal spra y Fit may show discoloration. Edges of fit
Thermal spra ye d fits – metal spra y
Fit may show discoloration.
Edges of fit – both IB, OB – chipping, or porosity.
Porosity in spray material itself (thermal spray porosity).
Overspray – threads, radiuses, edges of fit, ect.
Seams were spray starts IB, and OB.
Threading pattern visible under surface of fit.
Hydraulic assist groove edges – chipping, or porosity.
Hydraulic assist hole edges – chipping.
Hydraulic assist hole –enlarged, off centered, chamfered, or
angled.
Hydraulic assist has been widened or deepened, or location looks
off (typically the groove is 1/3 distance from leading edge). There
is a specification on this.
NDT may pick up seams.
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Clues a fit was previously thermal sprayed – metal spray Hydraulic assist groove edges –
Clues a fit was previously thermal sprayed – metal spray
Hydraulic assist groove edges – chipping, or porous.
Edge of fit flaking, and porous.
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Clues a fit was previously thermal sprayed – metal spray Groove deeper than normal, and
Clues a fit was previously thermal sprayed – metal spray
Groove deeper than normal, and hole is off centered.
Edges of fit flaking.
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Clues a fit was previously thermal sprayed – metal spray Inboard seam Outboard seam 10
Clues a fit was previously thermal sprayed – metal spray
Inboard seam
Outboard seam
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Clues a fit was previously thermal sprayed – metal spray Overspray in radius. 2 Spray
Clues a fit was previously thermal sprayed – metal spray
Overspray in radius.
2 Spray jobs on top of each other with porosity, and flaking.
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Thermal spra ye d fits – brass spra y All of the same characteristics of “
Thermal spra ye d fits – brass spra y
All of the same characteristics of “ metal thermal spray “.
Dull brass colored fit.
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Electropl ated fits - nickel Bearing fit has a golden colored hue. Look for “break thru”
Electropl ated fits - nickel
Bearing fit has a golden colored hue.
Look for “break thru” or discoloration by hydraulic assist groove,
and keyways on thin plaiting jobs.
Dull matte finish in hydraulic assist groove, and edges of fit.
Swirled polish marks are common.
Hydraulic assist hole edges may have chipping.
Hydraulic assist hole may appear oversized, or undersized.
OB edge of fit may have chipping.
NDT may pick up roughness by edges of fit.
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Clues a fit was previously electroplated – nickel Bearing fit has a golden colored hue.
Clues a fit was previously electroplated – nickel
Bearing fit has a golden colored
hue.
“Break thru” or discoloration by
hydraulic assist groove, and
keywa ys.
Swirled polish marks.
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Clues a fit was previously electroplated – nickel Hea vy plating deposit Dull matte rough
Clues a fit was previously electroplated – nickel
Hea vy plating deposit
Dull matte rough finish in
hydraulic assist groove,
and edges of fit.
Hydraulic assist groove
appears narrowed, and
hole is undersized.
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Clues a fit was previously electroplated – nickel Bearing fit has a golden colored hue.
Clues a fit was previously electroplated – nickel
Bearing fit has a golden
colored hue.
Flaked plating from
disassembly tearing.
Swirled polish marks.
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Clues a fit was previously electroplated – nickel Bearing fit has a golden colored hue.
Clues a fit was previously electroplated – nickel
Bearing fit has a golden
colored hue.
Dull matte finish in
hydraulic assist groove.
Swirled polish marks.
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Electropl ated fits - copper All of the same characteristics of “ nickel plating “. Semi
Electropl ated fits - copper
All of the same characteristics of “ nickel plating “.
Semi - bright copper color.
Copper fits are often flashed up with nickel on top.
These fits may show copper at the edges of the fit, and
or the hydraulic assist groove. Typically this is a sign
there is a lot of plating present.
Copper plating is softer than nickel plating, scratching fit
with scribe will leave very noticeable shiny scratch.
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Clues a fit was previously electroplated – copper Copper plated internal bearing bore. Semi -
Clues a fit was previously electroplated – copper
Copper plated internal
bearing bore.
Semi - bright copper
color.
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Clues a fit was previously electroplated – copper Scratch test with scribe left very noticeable
Clues a fit was previously electroplated – copper
Scratch test with scribe left very
noticeable shiny scratch.
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Sleeved fits Dutch dowels in face of journal. Pins in fit itself. Pins in hydraulic assist
Sleeved fits
Dutch dowels in face of journal.
Pins in fit itself.
Pins in hydraulic assist hole.
Seam lines at beginning, and end of sleeve.
Seam lines on face of journal will be visible.
No radius present on IB side of bearing fit.
NDT will show seam lines.
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Clues a fit was previously sleeved 5/8” Pin in bearing fit itself. Dutch do wels
Clues a fit was previously sleeved
5/8” Pin in bearing fit itself.
Dutch do wels in face of journal on seam line.
Seam line on face of journal.
Seam line at end of sleeve.
No radius.
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Clues a fit was previously sleeved Seam line at end of sleeve. 23 | Conf
Clues a fit was previously sleeved
Seam line at end
of sleeve.
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Clues a fit was previously sleeved Seam line at end of sleeve, and no radius.
Clues a fit was previously sleeved
Seam line at end of sleeve,
and no radius.
Seam line on face
of journal.
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Clues a fit was previously sleeved - On a large press roll journal Sleeved area.
Clues a fit was previously sleeved
- On a large press roll journal
Sleeved area.
Seam line at end of sleeve,
and no radius.
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Clues a fit was previously sleeved - On same large press roll journal Pin in
Clues a fit was previously sleeved
- On same large
press roll journal
Pin in hydraulic assist hole.
Seam line on journal face wit h small void.
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Welded split sleeve fits Weld seam (horizontal) shiny spots (heat). Weld pitting at seams. Weld irregularities
Welded split sleeve fits
Weld seam (horizontal) shiny spots (heat).
Weld pitting at seams.
Weld irregularities (voids from slag) on face of journal,
edges of fit, keyway, and/or adjoining fits.
Pins in hydraulic assist hole.
Possible seams lines will be visible.
Radius may not be present on IB side of bearing fit.
NDT should show seam lines, and stress cracking from
welding.
Stowewoodward recommends replacement of any
welded journals, and will not warranty any previously
welded journals.
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Clues a fit has a w elded split sleeve on the fit. Widened thread relief.
Clues a fit has a w elded split sleeve on the fit.
Widened thread relief.
Horizontal weld seam.
Modified radius on IB edge.
Pin in hydraulic assist hole.
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Welded fits Weld pitting. Weld irregularities (voids from slag) on end face of journal, edges of
Welded fits
Weld pitting.
Weld irregularities (voids from slag) on end face of
journal, edges of fit, keyway, snap ring grooves, and/or
adjoining fits.
NDT should show stress cracking from welding.
Stowewoodward recommends replacement of any
welded journals, and will not warranty any previously
welded journals.
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Clues a fit has been repaired by w elding the fit. Weld irregularities on IB
Clues a fit has been repaired by w elding the fit.
Weld irregularities on IB
edge of fit.
Weld irregularities on OB
edge of fit.
Weld irregularities in
radius of keyway.
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Clues a fit has been repaired by w elding the fit. - Nickel electroplating on
Clues a fit has been repaired by w elding the fit.
- Nickel electroplating on top of a welded fit.
Weld irregularities on IB
edge of fit.
Golden colored hue.
Dull matte finish in
hydraulic assist groove.
Edges of hydraulic assist
hole has chipping.
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Ground fits Possible grind chatter marks in fit. Sizes possibly undersize. Bearing centerline possibly shortened. Check
Ground fits
Possible grind chatter marks in fit.
Sizes possibly undersize.
Bearing centerline possibly shortened.
Check for smooth transition point at IB edge of fit.
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Clues a fit has been repaired by grinding the fit. Grind chatter is evident across
Clues a fit has been repaired by grinding the fit.
Grind chatter is evident
across the fit.
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Uniquel y repaired fits Look for seam lines at steps or radiuses. Look for “no radiuses”
Uniquel y repaired fits
Look for seam lines at steps or radiuses.
Look for “no radiuses” were there should be ones.
Look for repairs on top of old repairs.
NDT may detect seams.
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Clues a fit has a unique repair. Threads welded, and re machined. Thermal sprayed fit,
Clues a fit has a unique repair.
Threads welded, and
re machined.
Thermal sprayed fit,
which is lifting.
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Clues a fit has a unique repair. Journal that was partially replaced from the OB
Clues a fit has a unique repair.
Journal that was partially replaced
from the OB edge of the bearing fit
out. It was machined off, and bored
out. A new section was threaded and
installed, then finish machined.
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NDT pict ures Relevant indications. 37 | Conf idential
NDT pict ures
Relevant indications.
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Catas trophic failures 38 | Conf idential
Catas trophic failures
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Why to analyze journals for repairs To determine if fits have been pr eviously repaired. Why
Why to analyze journals for repairs
To determine if fits have been pr eviously repaired.
Why was the fit was previously repaired.
To determine proper way to repair journal if needed.
To aid in the quoting process if repair is required.
To help educate customer if there are any issues.
To help determine structural integrity of journal.
To prevent catastrophic failures from occurring.
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Please feel free to send any pictures of journal repair work, with a detailed description to:
Please feel free to send any pictures of journal repair
work, with a detailed description to:
Wayne S. Millard
Mechanical Quality Assurance Manager
Stow ewoodw ard Neenah, WI
Wayne.Millard@Stowewoodward.com
(920)729-7013
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