Dual Analytical Ferrograph

Dual Analytical Ferrograph – QualiFG™ 1000

The Dual Analytical Ferrograph QualiFG™ 1000 is a precision laboratory ferrograph developed to prepare ferrograms from used lubricants for advanced wear particle analysis and equipment condition monitoring. Through a controlled magnetic separation process, wear particles are isolated and deposited onto a ferrogram substrate for microscopic evaluation, helping laboratories assess wear severity, identify particle characteristics, and determine likely machine operating conditions.

Built with two independent preparation channels, QualiFG™ 1000 enables simultaneous production of two ferrograms, increasing laboratory efficiency and supporting higher daily sample capacity. The system offers automatic, semi-automatic, and manual preparation modes, providing flexibility for routine oil analysis, verification procedures, and lower-volume testing requirements.

Designed for oil analysis laboratories, reliability engineering teams, and predictive maintenance programs, this ferrograph provides a practical solution for detecting abnormal wear patterns in lubricated equipment. It is well suited for applications across transportation, steel production, heavy industry, power generation, marine systems, and defense drivetrain monitoring, supporting more informed maintenance decisions and improved asset performance.

Dual Analytical Ferrograph – QualiFG™ 1000 Applications

Transportation and Rail Equipment
QualiFG™ 1000 supports wear debris monitoring in locomotive, engine, and drivetrain lubrication systems. By identifying unusual wear patterns at an earlier stage, maintenance teams can make more informed service decisions and reduce the risk of unexpected downtime and costly repairs.

Steel and Heavy Industry
The system is well suited for circulating oil systems operating in fans, gearboxes, bearings, and other rotating machinery across steel and heavy industrial environments. Analytical ferrography enables effective separation and classification of wear particles, allowing laboratories to detect abrasive, fatigue, and sliding wear conditions with greater confidence.

Power Generation
QualiFG™ 1000 assists with oil debris analysis in generator sets, turbines, auxiliary drives, and related equipment where lubricant condition provides valuable insight into machine health. Its dual-channel configuration supports efficient comparative testing and repeat sample analysis for laboratory workflows.

Marine and Defense Drive Systems
This ferrograph is also suitable for transmission gearboxes and other mission-critical drive systems that require dependable condition monitoring. Early identification of wear particles supports improved equipment availability, operational reliability, and proactive maintenance planning.

Standards

• ASTM D7690 – Standard test method for the microscopic characterization of particles extracted from in-service lubricants using analytical ferrography, supporting detailed wear particle evaluation and machine condition assessment.

• ASTM D7684 – Standard guide for the microscopic characterization, classification, and reporting of particles found in in-service lubricants to support consistent wear analysis practices.

• SH/T 0573 – Test method for evaluating wear particles in used lubricating oils through the analytical ferrography method, supporting lubricant condition analysis and machinery monitoring.

Dual Analytical Ferrograph – QualiFG™ 1000 Key Features

Dual Independent Preparation Channels
QualiFG™ 1000 generates two ferrograms simultaneously through separate circuits. This dual-path configuration improves laboratory throughput and supports efficient handling of paired or repeat samples for side-by-side comparison during routine oil analysis.

Flexible Operating Modes
The system provides automatic, semi-automatic, and manual preparation options, allowing operators to align the workflow with sample volume, diagnostic requirements, and laboratory procedures for greater operational flexibility.

High Magnetic Field Performance
With a maximum magnetic flux density of approximately 1.8 T and a magnetic field gradient exceeding 0.5 T/mm, the instrument ensures effective particle separation and consistent deposition patterns on the ferrogram substrate, supporting reliable wear analysis.

Adjustable Sample Transport Flow
Oil transport flow can be adjusted within a range of 10 to 30 mL/h, helping improve deposition stability and repeatability across test runs. This controlled flow contributes to more consistent analytical results.

Fast Preparation Cycle
Under specified operating conditions, two ferrograms can be prepared in less than 20 minutes. This rapid cycle supports high-throughput laboratory environments without disrupting routine oil analysis workflows.

Transparent Ferrogram for Improved Diagnosis
The transparent ferrogram format enhances visual distinction between metallic, organic, and non-metallic debris, improving clarity during microscopic examination and supporting faster interpretation.

Particle Arrangement for Better Interpretation
Wear particles are deposited according to magnetic response and size, allowing clearer identification of wear severity and probable wear sources during microscopic evaluation.

Microscope Compatibility
The system is compatible with an integrated optical setup featuring an infinite optical system, wide-field eyepiece, multiple objectives, and both reflected and transmitted illumination options, enabling detailed post-preparation analysis.

Pneumatic Sample Transport
QualiFG™ 1000 uses a pneumatic transport mechanism to guide oil samples through the preparation path, ensuring controlled and stable delivery throughout the ferrogram formation process.

Theory and Method

A ferrograph operates by passing a used lubricating oil sample over a ferrogram substrate while it is exposed to a strong magnetic field. During this process, ferrous and magnetically responsive wear particles are attracted and deposited in patterns influenced by both particle size and magnetic properties. In addition, non-ferrous debris and other contaminants may also be retained on the substrate, allowing broader analysis of lubricant condition. The prepared ferrogram is then examined under a microscope to evaluate particle morphology, size distribution, concentration, and spatial arrangement for wear assessment.

QualiFG™ 1000 utilizes dual independent sample pathways, enabling simultaneous processing of two oil samples in parallel. This configuration improves laboratory efficiency and supports comparative analysis of related or repeat samples. A controlled sample transport system helps maintain stable deposition conditions, improving repeatability and supporting consistent time-based comparison of ferrograms.

Particles are organized on the ferrogram according to their magnetic response and size, which facilitates faster interpretation during microscopic examination. The transparent ferrogram design further enhances visual distinction between metallic, organic, and non-metallic debris, improving clarity during diagnostic evaluation and supporting more accurate wear characterization.

Dual Analytical Ferrograph – QualiFG™ 1000 Technical Specification

Parameter	QualiFG™ 1000
Product Type	Dual Analytical Ferrograph
Preparation Channels	Dual independent circuits
Preparation Modes	Automatic / Semi-automatic / Manual
Maximum Magnetic Flux Density	≈ 1.8 T
Maximum Magnetic Field Gradient	> 0.5 T/mm
Oil Transport Flow Range	10–30 mL/h
Oil Line Size	OD 2.3 mm, ID 1.7 mm
Transport Method	Pneumatic
Ferrogram Inclination Angle	1°–5°
Ferrogram Substrate Size	60 × 24 × 0.12 mm
Instrument Dimensions	395 × 355 × 330 mm
Weight	13.5 kg
Optical System	Infinite optical system
Eyepiece	EW10×/22
Objectives	Multiple BF/DF options as listed by supplier
Referenced Standards	ASTM D7690, ASTM D7684