Bearing Spalling: A Comprehensive Guide to Prevention and Repair

Bearing spalling is a common problem that can lead to premature bearing failure. It is estimated that bearing spalling accounts for up to 50% of all bearing failures. [1]

Bearing spalling occurs when small pieces of metal are chipped or flaked off the surface of a bearing race or rolling element. This can be caused by a number of factors, including:

Excessive load

Impact loading

Improper lubrication

Contamination

Bearing spalling can lead to a number of problems, including:

Increased vibration

Increased noise

Reduced bearing life

Premature bearing failure

Cause of Bearing Spalling	Preventive Measures
Excessive load	Use bearings with a load rating that is appropriate for the application.
Impact loading	Use bearings with a high impact load rating.
Improper lubrication	Use the correct lubricant for the application and relubricate bearings regularly.
Contamination	Keep bearings clean and free of contaminants.

Benefits of Preventing Bearing Spalling

There are a number of benefits to preventing bearing spalling, including:

Reduced maintenance costs

Increased bearing life

Improved machine reliability

Reduced downtime

Benefit of Preventing Bearing Spalling	How to Prevent Bearing Spalling
Reduced maintenance costs	Use high-quality bearings and follow proper maintenance procedures.
Increased bearing life	Use bearings with a high load rating and impact load rating.
Improved machine reliability	Keep bearings clean and free of contaminants.
Reduced downtime	Use bearings with a long life expectancy and relubricate bearings regularly.

How to Prevent Bearing Spalling

There are a number of things you can do to prevent bearing spalling, including:

Use high-quality bearings

Follow proper maintenance procedures

Use the correct lubricant for the application

Relubricate bearings regularly

Keep bearings clean and free of contaminants

Challenges and Limitations

There are some challenges and limitations associated with preventing bearing spalling. These include:

Cost

Time

Expertise

Challenge or Limitation	Mitigating Risk
Cost	Use cost-effective bearings and maintenance procedures.
Time	Use bearings with a long life expectancy and relubricate bearings regularly.
Expertise	Consult with a qualified bearing engineer or technician.

Conclusion

Bearing spalling is a common problem that can lead to premature bearing failure. However, it can be prevented by following proper maintenance procedures and using high-quality bearings. By taking these steps, you can help to reduce maintenance costs, increase bearing life, improve machine reliability, and reduce downtime.

References

[1] Bearing Failure Analysis and Prevention, SKF, 2019

Bearing Spalling: A Comprehensive Guide to Prevention and Repair