DC Motors
Excessive sparking at brushes may be caused due to

Misaligment of machine
Loose coupling
Dirt on the commutator
Worn bearings

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DC Motors
If a D.C. shunt motor is working at full load and if shunt field circuit suddenly opens

This will result in excessive speed, possibly destroying armature due to excessive centrifugal stresses
This will make armature to take heavy current, possibly burning it
Nothing will happen to motor
Motor will come to stop

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