Describe bearing construction, load paths and lubrication regimes relevant to common failure modes.
Engineering & Maintenance
Bearing Failure Analysis and Root Cause Classification for Rotating Equipment
Learn to examine failed bearings, classify damage under ISO 15243, correlate vibration and lubricant evidence, and identify the true root cause behind repeat bearing failures.
🗓️Duration5 training days
📚Content4 modules · 8 sessions
🎓On completionAccredited attendance certificate
About the programme
Course Overview
A bearing is rarely the true cause of its own failure: fatigue, corrosion, electrical erosion and lubrication breakdown each leave a distinct physical signature, but the underlying trigger is usually contamination, misalignment, poor handling or an unsuitable lubricant introduced somewhere else in the system. Replacing the bearing without reading that signature guarantees the replacement will fail again on a similar schedule. This course teaches systematic bearing failure examination, from construction and load path fundamentals through to the damage classification scheme in ISO 15243, so participants can name a failure mode with confidence rather than guessing from a worn appearance. It covers fractography and surface examination technique, the vibration defect frequencies associated with outer race, inner race, ball and cage faults, and lubricant sampling as evidence of contamination or degradation. Sessions use real failed bearings and photographs worked through a structured classification framework, ending with root cause conclusions rather than a failure mode label alone. The course closes with the precision mounting, handling and installation controls that prevent the same failure recurring, and the verification steps that confirm a corrective action actually worked.
Expected Learning Outcomes
Classify bearing damage patterns using the ISO 15243 failure mode taxonomy.
Distinguish fatigue, wear, corrosion and electrical erosion damage through fractography and surface examination.
Calculate bearing defect frequencies, including BPFO, BPFI, BSF and FTF, and relate them to vibration spectra.
Use lubricant sampling and contamination analysis as evidence within a bearing root cause investigation.
Apply a structured root cause classification framework to separate bearing symptoms from underlying triggers.
Specify precision mounting and handling controls that prevent a diagnosed bearing failure from recurring.
Who Should Attend
Reliability engineers investigating repeat bearing failures on rotating equipment.
Vibration analysts wanting to strengthen physical failure examination alongside spectral analysis.
Maintenance technicians responsible for bearing installation, handling and mounting practice.
Lubrication engineers correlating oil and grease analysis with bearing condition.
Root cause analysis facilitators covering rotating equipment failure investigations.
Equipment reliability specialists in sectors with high bearing replacement frequency.
Course Modules
Select any module to see its sessions and points.
01Bearing Construction and Failure Mode Fundamentals
2 sessions · 8 points
Session 1Bearing Types, Load Paths and Lubrication Regimes
- Compare ball, roller and plain bearing designs and the load paths each is intended to carry.
- Explain boundary, mixed and full-film lubrication regimes and their effect on bearing wear rate.
- Relate bearing internal clearance and fit tolerances to expected operating temperature and life.
- Identify which bearing type and arrangement is appropriate for radial, axial and combined loading.
Session 2Classifying Failure Modes Under ISO 15243
- Apply the ISO 15243 taxonomy to classify observed bearing damage into standard failure mode categories.
- Distinguish primary damage from secondary damage that develops after the initial failure mode began.
- Use standard terminology so failure classifications are understood consistently across sites and teams.
- Record classification evidence, including photographs, alongside each entry in a bearing failure database.
02Physical and Visual Failure Examination
2 sessions · 8 points
Session 1Fractography and Surface Damage Examination Techniques
- Examine fracture surfaces to identify fatigue beach marks, origin points and propagation direction.
- Use magnification and lighting technique to reveal surface damage not visible to the naked eye.
- Preserve failed bearing evidence correctly so examination is not compromised before analysis.
- Document examination findings with consistent photography angles and reference scales.
Session 2Distinguishing Fatigue, Wear, Corrosion and Electrical Erosion
- Differentiate classical subsurface fatigue spalling from surface-initiated fatigue damage.
- Recognise abrasive and adhesive wear patterns caused by contamination or inadequate lubrication.
- Identify corrosion damage patterns, including those caused by water ingress or storage conditions.
- Detect electrical erosion and fluting patterns caused by current passing through the bearing.
03Vibration and Lubricant Evidence in Bearing Failures
2 sessions · 8 points
Session 1Bearing Defect Frequencies: BPFO, BPFI, BSF and FTF
- Calculate ball pass frequency outer race, inner race, ball spin and cage frequencies for a given bearing.
- Identify defect frequency harmonics and sidebands in a vibration spectrum from a damaged bearing.
- Distinguish early-stage bearing defects, visible mainly in high-frequency detection, from advanced damage.
- Correlate vibration trend severity with the physical damage found on inspection.
Session 2Lubricant Sampling and Contamination Analysis for Root Cause
- Take representative lubricant samples from a bearing housing without introducing new contamination.
- Interpret particle count, water content and wear metal results as evidence of a bearing's operating history.
- Identify lubricant degradation or incorrect grease selection as a contributing root cause.
- Cross-reference lubricant analysis results with the physical damage classification from inspection.
04Root Cause Classification and Corrective Action
2 sessions · 8 points
Session 1Structured Root Cause Classification Frameworks for Bearings
- Separate the observed failure mode from the underlying root cause using a structured classification framework.
- Distinguish installation, contamination, lubrication and design-related root causes from one another.
- Build a bearing failure database that captures failure mode, root cause and corrective action together.
- Identify recurring root causes across an equipment population rather than treating each failure in isolation.
Session 2Precision Mounting, Handling Controls and Corrective Action Verification
- Specify precision mounting practices, including heating method and fit checks, for bearing installation.
- Introduce handling and storage controls that prevent contamination and impact damage before installation.
- Select corrective actions that address the identified root cause rather than the failure mode alone.
- Verify corrective action effectiveness through a follow-up inspection or extended vibration trend.
What the participant receives
4 course modules
A structured syllabus
8 training sessions
across 5 days
32 detailed points
Applied, detailed content
Accredited attendance certificate
On completing the programme
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