Engine Bearing Failure Analysis Guide

Fatigue of Aluminum Fatigue of Babbitt Fatigue of Bronze Edge Wear Due to

Lining Overlay Intermediate Layer Surface Wear Distorted Connecting Rod

Appearance: Appearance: Appearance: Appearance: Appearance:

Cracks, cratered & distressed bearing surface due to Irregular spider web-like cracks and craters in the overlay. Babbitt surface missing and intermediate layer cracked Accelerated wear - shiny surface Localized excessive wear of the bearing surface along the
loss of aluminum lining material. Fatigue may lead to partial flaking of the overlay, followed and cratered. Fragments are detached from the steel Heavy wear - signs of overheating (blackening), partial bearing edge. Possibility of fatigue cracks in the affected area.
by fatigue of the copper-lead intermediate layer. back causing imminent bearing failure. melting/removal of overlay (top shell)
Severe wear - torn surface, heavy overheating, Possible causes:
Possible causes: melted/missing overlay and lining material (bottom shell) Rod distortion caused by:
Possible causes: Possible causes:
Overloading
Wrong selection of engine bearing material
Wrong selection of engine bearing material Wrong selection of engine bearing material Possible causes:
Detonation
Engine power increased beyond original design Insufficient oil supply (starvation)
Engine power increased beyond original design Engine power increased beyond original design Excessive torque
Excessive clearance Non-uniform/unstable oil film (due to bearing fatigue)
Excessive clearance Excessive clearance Distorted rod produces non-parallel orientation of the
Fuel detonation/advanced ignition Geometrical irregularities or poor journal surface finish
Fuel detonation/advanced ignition Fuel detonation/preignition bearing and journal surfaces
Geometry defects causing localized bearing overloading Grinding chatter marks and lobing Metal-to-metal contact occurs along the bearing edge
Geometry defects causing localized bearing overloading Geometry defects causing localized bearing overloading
Contaminated oil
Corrective actions: Corrective actions:
Corrective actions: Corrective actions: Corrective actions:
Check oil supply system, prevent oil dilution/contamination Replace the distorted parts
Select a bearing material with higher load capacity Select a bearing material with higher load capacity Select a bearing material with higher load capacity Change bearing material Prevent engine detonation and pre-ignition (check
Check: clearances and component geometry Check: clearances and component geometry Check: clearances and component geometry Verify proper grinding/polishing procedures cooling system, air-fuel ratio, ignition timing, knock
Retard ignition or use fuel with higher octane number Retard ignition or use fuel with higher octane number Retard ignition or use fuel with higher octane number Improve cleaning procedures, replace oil and filter more sensor, octane number of fuel)
Repair/replace distorted parts Repair/replace distorted parts Repair/replace distorted parts frequently Choose higher strength connecting rods

Imperfect Journal Cavitation Erosion Spinning of the Bearing Fatigue in the Crush Damage Caused
Geometry in the Housing Relief Area by Foreign Particles

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Localized wear in parts of the bearing surface. Erosion damaged areas on the overlay due to sharp Highly polished area on the bearing back caused by Fatigue cracks in the area of crush relief. Circumferential scores or scratches on the bearing
Fatigue cracks may occur in these areas. changes of pressure in the oil film. bearing spinning in the housing. surface.
Possible causes: Possible causes:
Possible causes:
Possible causes: Possible causes: Excessive crush height - upon torqueing the housing,
Vapor cavities (bubbles) in the oil – when the load applied Particles of grinding abrasive entrapped in crankshaft
the parting line region of the bearings deflects inward.
Inconsistent journal diameter. Areas of greater diameter to a bearing fluctuates at high frequency (high RPM). Insufficient crush height oil passages and/or other engine block components
This reduces the gap between the journal and bearing
produce metal-to-metal contact with the bearing The oil pressure can instantly fall, causing vapor cavities Oil starvation/lugging the engine causing seizure Ambient dirt, sand or dust
surfaces. Such change of bearing profile at the parting
surface, causing local wear Housing diameter greater than specified value Metal particles (e.g. fragments of fatigued material
(bubbles) due to fast evaporation (boiling). When the line region produces localized peak oil film pressure,
Use of worn or improperly dressed grinding wheel from failed components)
pressure rises, vapor cavities (cavitation bubbles) contract which can cause fatigue of the bearing material.
when resizing the crankshaft. Journals may result as at high velocity. Such collapse results in impact pressure, Excessive RPM producing rod bore stretch Corrective actions:
tapered, hourglass shape or barrel shape that can erode the bearing material. Corrective actions: Find the origin of the abrasive particles and other
Choose bearings with sufficient crush height Corrective actions: contaminants
Corrective actions:
for the application Prevent excessive crush height Replace air filter, oil and oil filter
Corrective actions:
Select stronger (harder) bearing material Eliminate the cause of seizure Check the housing diameter Check crankshaft oil passages and all engine
Replace/redress grinding wheel Decrease oil clearance Check housing diameter for size and roundness Avoid over-torqueing the rods components. Thoroughly clean them with hot soapy
Re-grind the crankshaft Avoid running the engine at extremely high rotation speeds Tighten bolts to the specified torque value Choose more rigid connecting rods water prior to assembly.

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