Couplings are essential mechanical components used to connect two rotating shafts and transmit power efficiently across industrial systems. From manufacturing plants and power stations to pumps and compressors, the reliability of couplings directly affects machine performance and uptime. However, coupling failures remain one of the most common causes of unexpected breakdowns in rotating equipment. Understanding the causes of coupling failures, along with effective prevention and maintenance strategies, can significantly extend equipment life. This blog provides a comprehensive guide to coupling failures, supported by industry best practices and the engineering excellence of Rathi Couplings. Common Causes of Coupling Failures One of the primary causes of coupling failure is shaft misalignment. Angular, parallel, or axial misalignment creates excessive stress on couplings, leading to premature wear, overheating, and vibration. Another major factor is improper installation, includin