Industrial wear expertise: identifying the origin of defects in the laboratory

Industrial wear can result in performance losses, production stoppages, non-conformities, or premature failures. When a part shows surface defects, localized corrosion, cracking, scoring, coating adhesion loss, or breakage, it is essential to determine the exact origin of the wear. The challenge is not only to observe the damage, but to reconstruct the mechanism behind it: friction, fatigue, corrosive environment, material defect, unsuitable surface treatment, or external contamination. Wear expertise carried out in the laboratory makes it possible to substantiate the causes and guide corrective actions.

Analysis can reveal surface irregularities, microcracks, scoring, abnormal roughness, friction marks, adhesion loss, localized wear, or coating thickness loss. Studying the surface topography helps characterize the severity of the degradation and verify the compliance of the treatment applied to the part.

Investigations rely in particular on SEM-EDX to observe morphology and obtain semi-quantitative elemental identification, optical microscopy for metallographic examinations, the hardness tester for Vickers, Brinell, or Rockwell hardness measurements, as well as ICP and elemental analyzers to verify the composition of the metal part. Surface chemistry analysis by XPS can complement the study when the interface or coating is involved.

Using a specialized laboratory makes it possible to go beyond a simple visual assessment. A structured wear expertise provides a well-supported diagnosis of the failure mechanism, the initiation area, aggravating factors, and the compliance of the material or coating. This approach reduces assumptions, facilitates decision-making, and helps define targeted corrective actions on the process, material, or operating conditions.

The laboratory uses a multi-technique approach to connect visual, topographical, metallographic, and chemical observations. This approach makes it possible to study the fracture surface, microstructure, hardness, elemental composition, surface condition, and corrosion resistance. Depending on the need, investigations may include observation in a Laboratoire Analyse Meb, examinations in Laboratoire analysis Met, inclusion searches via Analyse Inclusion Laboratoire, or specific compliance checks. The goal is to characterize the phenomenon, locate the point where degradation began, and provide actionable results for production, quality, and R&D.

When a part is broken or corroded, the expertise aims to determine whether the fracture is brittle, ductile, or fatigue-related, to locate the initiation point, and to track propagation. Comparing the sound area with the failed area can reveal differences in hardness, microstructure, or composition. Oxidizing or corrosive agents, as well as external contamination, may also be sought in order to assess the mismatch between the part and its operating environment.

For corrosion or material performance issues, electrochemical tests can be carried out: open-circuit potential OCV, corrosion rate LSV, electrochemical impedance EIS, and galvanic coupling studies. Accelerated aging and salt spray tests make it possible to assess resistance under stressed conditions. In some cases, complementary analysis such as XRD or checks against technical standards, for example Laboratoire Analyse Iso 21392, may be relevant.

The analysis results are useful for addressing a non-conformity, settling a technical dispute, securing a part before returning it to production, or validating a material choice during the R&D phase. They also make it possible to anticipate corrosion and wear phenomena before industrialization. For companies involved in innovation projects, the support of a Laboratoire Agree Cir can also be part of a development and technical justification approach.

To begin, you should provide the part’s operating context, the loading conditions, the symptoms observed, compliance requirements, and, if possible, a sound reference part. The laboratory then defines a suitable testing strategy: inspection, metallographic sectioning, hardness measurement, chemical analysis, surface characterization, or corrosion testing. This step-by-step approach makes it possible to answer the initial questions quickly and then go deeper if needed.