Gearbox Failure Analysis

A significant benefit that DCL Engineering Group can offer you is Failure Analysis. Tools which we utilise to correct inaccuracies, wear and failures will also tell us the likely cause of the failure which in turn allows us to suggest ways to minimise the chances of that failure in future. Several of these tools are described here.

  • Gearbox consulting
  • Engineering consulting
  • Finite element analysis
  • Metallurgical analysis
  • Reverse process machinery and equipment drawings
  • Site repair work
  • CMM inspection facilities / CMM mobile crew

Co-ordinate Measuring Machine (CMM)

The CMM used by DCL Engineering Group is the Platinum version of the Faro Arm, the world’s most accurate and advanced portable measurement arm in manufacturing history. This is an advantage over any other company’s methods of checking gearbox and component dimensional accuracy.

The Platinum Faro Arm’s ±0.05mm accuracy renders traditional CMMs, hand tools and other portable inspection equipment slow and inefficient.

Inspect, reverse engineer gear cases and components, or perform CAD-to-Part-analysis on parts, fixtures and assemblies with previously unheard of precision.

Carry out dimensional checks and on the spot quality control inspections of equipment.

Dye Penetrate Inspection

Dye Penetrate Inspection (DPI), also known as liquid penetrant inspection, is a common and low-cost method to detect surface cracks on non-porus materials (not having vessels that appear as pores). DPI can also be used on non-ferrous materials and is used to detect cracks, leaks, casting and forging defects. Liquid penetrant is applied to the surface and absorbed into defects by capillary action. After a period of time the penetrant is drawn out and a visual inspection is performed on defects.

DPI is used when Fluorescent Magnetic Particle Testing is impractical due to the size or shape of a component is by using a dye to see if it soaks into a surface crack. This is most often used on larger fabrications or castings, such as gearbox housings and large flanged couplings.

Fluorescent Magnetic Particle Testing

Magnetic particle testing is effective in finding surface deterioration on ferromagnetic (materials that can be magnetised) materials. Once the item is temporarily magnetised, fine iron particles are applied to the surface and will form along the lines of the magnetic force from the magnet. Flaws on the surface will cause the lines to be distorted and this method is best suited for detecting surface flaws.

Non-Destructive Testing

Non-Destructive Testing (NDT) is a cost effective process for checking deterioration of items (scoring, unseen cracks) and is used to determining whether an item is fit for use and assists DCL in the following areas:

  • Quality Assurance
  • Ensuring Safety
  • Failure Prevention
  • Client Satisfaction

 The advantage of NDT is that the item being tested remains in its original state unchanged and not destroyed. If no faults are found after testing, the item can continue to be used for its original intended purpose. DCL Engineering Group use several different forms of non-destructive testing to ensure soundness in the materials and components used in our gearbox refurbishment. The following detail out three methods used by DCL.


If a component is suspected of internal faults which don’t show on the surface, such as some forgings, then the component can be x-rayed to determine the internal structural soundness prior to proceeding with the component.

Vibration Analysis

Vibration Analysis

Flir – Thermal Imagery

Equotip – Hardness Testing

Platinum Faro Arm

Platinum Faro Arm

Non-Destructive Testing

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