10 Most Common Bearing Failures and How to Prevent Them in 2025
Summary:
Bearings are the backbone of countless machines, but even the best can fail if not properly maintained. In this guide, we reveal the 10 most common bearing failures seen in 2025, explain their root causes, and provide actionable prevention strategies. Whether you’re an engineer, maintenance manager, or equipment owner, these insights will help you extend bearing life, reduce downtime, and keep your operations running smoothly. Plus, discover recommended products from ebearingstore.com to help you prevent these failures.
Table of Contents
- Lubrication Failure
- Contamination
- Fatigue (Spalling)
- Misalignment
- Overloading
- Improper Handling and Installation
- Corrosion
- Electrical Erosion
- Creep and Fretting
- Improper Bearing Selection
- Conclusion & Next Steps
1. Lubrication Failure
What it is: Insufficient, excessive, or incorrect lubrication is the leading cause of bearing failure.
Symptoms: Overheating, noise, discoloration, and premature wear.
Prevention:
- Use the right lubricant for your application (check manufacturer specs).
- Follow recommended relubrication intervals.
- For hard-to-reach areas, consider sealed or pre-lubricated bearings like the Deep Groove Ball Bearing 6204.
2. Contamination
What it is: Ingress of dirt, dust, water, or other foreign materials into the bearing.
Symptoms: Pitting, scoring, and increased vibration.
Prevention:
- Use sealed or shielded bearings such as the Deep Groove Ball Bearing 6804.
- Maintain clean work environments and proper storage.
- Inspect seals regularly.
3. Fatigue (Spalling)
What it is: Surface or subsurface cracks due to repeated stress cycles.
Symptoms: Flaking or pitting on raceways and rolling elements.
Prevention:
- Choose bearings with appropriate load ratings, like the Cylindrical Roller Bearing NNU4938.
- Avoid overloading and ensure proper installation.
4. Misalignment
What it is: Shaft and housing are not properly aligned, causing uneven load distribution.
Symptoms: Uneven wear, noise, and vibration.
Prevention:
- Use self-aligning bearings where possible.
- Ensure precise installation and alignment.
- For high-precision needs, consider Angular Contact Ball Bearing 70 Series.
5. Overloading
What it is: Loads exceed the bearing’s design limits.
Symptoms: Plastic deformation, excessive heat, and rapid failure.
Prevention:
- Calculate loads accurately during design.
- Select bearings with sufficient load capacity, such as the Cylindrical Roller Bearing NN3940.
6. Improper Handling and Installation
What it is: Physical damage during transport, storage, or installation.
Symptoms: Brinelling, scratches, and premature failure.
Prevention:
- Handle bearings with care; use clean gloves and proper tools.
- Avoid striking bearings directly.
- Store in a clean, dry environment.
7. Corrosion
What it is: Chemical or moisture-induced damage to bearing surfaces.
Symptoms: Rust, pitting, and reduced performance.
Prevention:
- Use corrosion-resistant bearings or coatings.
- Apply proper lubrication and use seals.
- Store bearings in climate-controlled areas.
8. Electrical Erosion
What it is: Electrical currents passing through the bearing, causing pitting and fluting.
Symptoms: Patterned damage on raceways, increased noise.
Prevention:
- Use insulated bearings in electric motor applications.
- Properly ground equipment.
9. Creep and Fretting
What it is: Micro-movement between bearing and housing/shaft, leading to wear and looseness.
Symptoms: Discoloration, wear marks, and looseness.
Prevention:
- Ensure correct fits and tolerances.
- Use anti-fretting lubricants and secure mounting.
10. Improper Bearing Selection
What it is: Using the wrong bearing type or size for the application.
Symptoms: Frequent failures, poor performance, and increased maintenance.
Prevention:
- Consult with experts or use selection guides.
- For robotics and EVs, consider the Ultra High Speed Angular Contact Ball Bearing 95BTR10.
Conclusion & Next Steps
Preventing bearing failures in 2025 is all about proactive maintenance, correct selection, and using quality products. By understanding these common failure modes and following the prevention tips, you can dramatically extend the life of your machinery and reduce costly downtime.
Ready to upgrade your bearings or need expert advice? Browse our full bearing collection or contact our team for personalized recommendations.
This article is for informational purposes only. For specific product recommendations, consult with a qualified engineer or bearing specialist. For more technical resources, visit the American Bearing Manufacturers Association (ABMA).