Disc Couplings - Failure Analysis

Misalignment Failures

Misalignment Failure
Like many other coupling types, disc couplings often fail in with telling or "signature" ways that
point to a likely culprit. As pictured at right, when a disc coupling is subject to excessive
misalignment it is likely to experience disc pack cracking near the bushings, with the outer layers
fracturing first.

Misalignment Failure
Note: Given disc packs generally crack from the outer layers in, it is certainly possible that a
coupling will continue to transmit torque/function with cracks in the outside layers. This means
that it is still important to inspect the disc pack on a periodic basis even if the coupling appears to
be functioning properly. Fortunately, disc packs can generally be inspected without disassembling
the coupling, and possibly even when the coupling is running (by using a strobe light assuming
the coupling guard is not solid steel).

If misalignment is the likely source of a disc pack failure, it is important to realign the coupling
prior to restarting the system, less the issue repeat itself. (Two options to consider when
realigning a coupling are laser alignment and dial indicators.) An additional step you can take if
you are not using a scalloped disc pack by Lovejoy (which offers increased misalignment
handling over legacy designs), you can source a replacement coupling from us!
 Misalignment Failure

Torque Overload Failures

Disc Pack Torque Overload Failure

Torque overload failures in disc packs look different from misalignment failures in that the fatigue
cracks tend to form in the center of the disc pack rather than up against the bushings (as pictured
at right).

A second thing to look for when suspecting torque overload on this disc pack is any evidence that
the disc pack layers (or laminates) are separating or ballooning away from each other in the
center sections between bushings.

Bent Disc Pack Bolts

In addition to the disc packs themselves, the bolts used to connect the disc pack to the flanges
may be bent or distorted. Such distortions are another excellent indication that the coupling is
seeing torque in excess of what it was designed to handle.
 Disc Coupling Hub Burst
A third and final common way that torque overload reveals itself in a disc coupling is if a coupling
hub actually bursts over the corner of the keyway. This is a failure mode common across many
coupling types, and the reason the coupling fails at this point is because, due to the cut keyway,
this is the weakest point in the hub.

Installation & Fastener Failures

One of the fastest ways to damage a disc coupling during installation is to use impact wrenches.
(Do not do this!) Not only does using an impact wrench raise the potential of twisting the disc
pack (pictured at right) in a destructive manner, but it also raises the possibility of friction welding
the fastener bolts to either the disc pack and or the connected flange. Fasteners should be
lubricated prior to installation and torqued with care.

On the other end of the spectrum, improper torque of the fasteners may cause them to loosen.
This loosening can then lead to damage and wear to the fasteners as well as hole elongation and
cracking of the disc packs. To avoid either over or under torqueing the fasteners, be sure to read
and follow the disc coupling's installation instructions.
Environmental Failures

While disc couplings generally hold up very well to many

environmental conditions, they are certainly not impervious to everything. As such, it is critical
that coupling users understand what corrosive agents may be present for a given application, and
that the disc coupling is designed to operate under those conditions. (Pictured at right is a
circular, non-scalloped, disc pack layer that has been corroded.)

Life Expectancy

Having just covered misalignment, torque overload, installation, fastener, and environmental
failures of disc couplings, a natural question might be "How long is my coupling going to last?"
Unfortunately, like all other coupling type, disc coupling life is not generically predictable as it is
highly dependent upon the application and the misalignment of the given system it is driving.
Shaft alignment does correlate strongly with longer coupling life... so taking the time to align the
system properly with periodic checks should pay lasting dividends and not be overlooked.