Rolling and Rolling-Sliding Contact Fatigue Failure Mechanisms in 32 CrMoV 13 Nitrided Steel—An Experimental Study

The aim of this work is to characterize the rolling and rolling-sliding contact fatigue failure mechanisms on the 32CrMoV13 nitrided steel. During rolling contact fatigue tests (RCF), two general features were observed: specimens presenting short lives and rough and sharpened spalling damage and specimens presenting long lives and only microspalling marks. It was possible to determine a contact fatigue limit of 3 GPa. During rolling-sliding contact fatigue tests (RSCF), a clearly different behaviour between the two specimens in contact has been observed: the driver shows circumferential and inclined cracks and only inclined cracks appear in the follower. This behaviour can be understood if the effect of the residual stress state in near-surface layers is considered. Before RCF tests, the residual stresses are compressive in all near-surface layers. After RCF tests, strong residual stress relaxation and even reversing behaviour was observed in the axial direction, which facilitates the surface crack initiation in the circumferential direction at rolling track borders.

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FATIGUE TESTS OF METAL MATERIALS (review) Part 1. Main definitions, loading parameters, representation of results of tests

«Aviation Materials and Technologies» ◽

10.18577/2071-9140-2020-0-4-59-70 ◽

2020 ◽

pp. 59-70

Author(s):

V.S. Erasov ◽

◽

E.I. Oreshko ◽

Keyword(s):

Hysteresis Loop ◽

Distinctive Feature ◽

Main Crack ◽

Elastoplastic Deformation ◽

Cyclic Fatigue ◽

Fatigue Tests ◽

Surface Layers ◽

Near Surface ◽

Mechanical Hysteresis ◽

Metal Materials

The article gives the review of techniques of fatigue tests of metal materials and presents the results of such tests . It has been shown that the low-cyclic fatigue occurs in conditions of elastoplastic deformation in material microvolume from the first cycles of loading. Its distinctive feature is influence on durability of the size and form of a mechanical hysteresis loop . Nucleation of fatigue microcracks and formation of the main crack occurs on the surface and in near-surface layers of a sample.

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Effect of thermal relaxation on residual stress and microstructure in the near-surface layers of dual shot peened Inconel 625

Advances in Mechanical Engineering ◽

10.1177/1687814018800530 ◽

2018 ◽

Vol 10 (10) ◽

pp. 168781401880053

Author(s):

Lihong Wu ◽

Chuanhai Jiang

Keyword(s):

Residual Stress ◽

Compressive Residual Stress ◽

Elevated Temperatures ◽

Thermal Relaxation ◽

Diffraction Method ◽

Relaxation Behavior ◽

Inconel 625 ◽

Surface Layers ◽

Near Surface ◽

Subsurface Layers

Thermal relaxation behavior of residual stress and microstructure in the near-surface layers of dual shot peened Inconel alloy 625 was investigated by X-ray diffraction method. Residual stress on the top surface layer was significantly relaxed in the first 15 min at the elevated temperatures of 500°C, 600°C, and 700°C. However, there was still high maximum compressive residual stress in subsurface layers. The relaxation behavior of residual stress has contributed to the thermally activated process. The activation enthalpy Δ H and m were calculated according to the Zener–Wert–Avrami method, the values of which were 1.59 eV and 0.4934, respectively. Microstructural evaluation revealed that it was slightly changed in the near-surface layers after various isothermal treatments. Accordingly, high level of compressive residual stress and dislocation density resulted in the retained mechanical properties of dual shot peened Inconel 625, which was discussed based on the relaxation of microstructure and microhardness.

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Wear and Surface Residual Stress Evolution on Twin-Disc Tests of Rail/Wheel Steels

Materials Science Forum ◽

10.4028/www.scientific.net/msf.768-769.707 ◽

2013 ◽

Vol 768-769 ◽

pp. 707-713

Author(s):

António Castanhola Batista ◽

Daniel F.C. Peixoto ◽

Joao P. Nobre ◽

Luís Coelho ◽

Diogo Mesquita Ramos ◽

...

Keyword(s):

Residual Stress ◽

Fatigue Behavior ◽

Contact Fatigue ◽

Major Influence ◽

Stress Evolution ◽

X Ray Diffraction ◽

Surface Layers ◽

Surface Residual Stress ◽

X Ray ◽

Initiation And Propagation

Twin disc tribological tests were performed in wheel and rail materials, with specimens taken from a Spanish AVE train wheel and a UIC60 rail, in a program intended to characterize their contact fatigue behavior. The X-ray diffraction technique was used to characterize the residual stress distribution at the initial and damaged stages, as well as in intermediate stages, since existing residual stresses in the surface layers of the railways steels and its evolution during contact loading can have a major influence on crack initiation and propagation.

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Experimental and Fracture Mechanics Study of the Pit Formation Mechanism Under Repeated Lubricated Rolling-Sliding Contact: Effects of Reversal of Rotation and Change of the Driving Roller

Journal of Tribology ◽

10.1115/1.2833886 ◽

1997 ◽

Vol 119 (4) ◽

pp. 788-796 ◽

Cited By ~ 26

Author(s):

Y. Murakami ◽

C. Sakae ◽

K. Ichimaru ◽

T. Morita

Keyword(s):

Fatigue Crack ◽

Rolling Contact Fatigue ◽

Contact Fatigue ◽

Surface Damage ◽

Fatigue Tests ◽

Rolling Contact ◽

Sliding Contact ◽

Hydraulic Pressure ◽

Pit Formation ◽

Original Crack

Five rolling contact fatigue tests, Tests {1}–{5} have been conducted. In Tests {1}–{3}, when a fatigue crack was initiated on the surface of a follower, the test was halted. Then, in Test {1} the rotating direction was reversed. In Test {2} the follower and driver were interchanged, and in Test {3} the test was continued unchanged. In Test {3} the original crack grew to a pit. In Tests {1} and {2} the original crack immediately stopped propagating. In Tests {4} and {5}, mating with a harder roller, a softer roller was used as the follower in Test {4} and as the driver in Test {5}. A typical pit occurred in Test {4}. In Test {5}, surface damage substantially different from a typical pit was generated. Based on these experimental results, a 3-D crack analysis including the effect of frictional force on the contact surface and oil hydraulic pressure on crack surfaces, was conducted to elucidate the mechanisms of pit formation and surface damage in contact fatigue.

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Rolling contact fatigue failure mechanisms in plasma and HVOF sprayed WC-Co coatings

Wear ◽

10.1016/s0043-1648(97)00138-5 ◽

1997 ◽

Vol 212 (1) ◽

pp. 66-77 ◽

Cited By ~ 68

Author(s):

R. Nieminen ◽

P. Vuoristo ◽

K. Niemi ◽

T. Mäntylä ◽

G. Barbezat

Keyword(s):

Fatigue Failure ◽

Rolling Contact Fatigue ◽

Failure Mechanisms ◽

Contact Fatigue ◽

Rolling Contact

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Fatigue Failure, Residual Stress and Misorientation - A Possible Correlation

Materials Science Forum ◽

10.4028/www.scientific.net/msf.702-703.307 ◽

2011 ◽

Vol 702-703 ◽

pp. 307-310 ◽

Cited By ~ 1

Author(s):

Partha Biswas ◽

P.S. Kannaki ◽

Satish Kumar Shekhawat ◽

Indradev Samajdar ◽

V. Deshmukh ◽

...

Keyword(s):

Residual Stress ◽

Fatigue Failure ◽

Fatigue Tests ◽

Clear Correlation ◽

Martensitic Structure ◽

X Ray Diffraction ◽

Cross Sectional ◽

X Ray ◽

Electron Back Scattered Diffraction ◽

Compressive Residual Stresses

Two grades of Steel, with tempered martensitic structure, were used for fatigue tests. From such tests, samples were obtained with significant differences in the probability of fatigue failure. The latter was related to surface/sub-surface misorientation developments and developments in compressive residual stresses. A combination of glancing incidence X-ray diffraction (GIXRD) and high resolution cross-sectional EBSD (electron back scattered diffraction) were used. The study brings out a clear correlation between misorientation, residual stress and fatigue life.

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Corrosion and Fatigue of AL-Alloys AA359.0 and AA6060 in Different Surface Treatment States

Materials Science Forum ◽

10.4028/www.scientific.net/msf.768-769.572 ◽

2013 ◽

Vol 768-769 ◽

pp. 572-579 ◽

Cited By ~ 1

Author(s):

Klaus Timmermann ◽

Wolfgang Zinn ◽

Berthold Scholtes

Keyword(s):

Residual Stress ◽

Corrosion Fatigue ◽

Fatigue Behavior ◽

Salt Spray ◽

Fatigue Tests ◽

Surface Treatments ◽

Near Surface ◽

Materials Properties ◽

Surface Materials ◽

Mechanical Surface

The consequences of near surface materials properties and residual stress states produced by specific manufacturing operations on damage evolution during corrosion fatigue of the Al-base alloys AA359.0 (German grade G-AlSi9Cu3) and AA6060 (German grade AlMgSi0.5) were systematically investigated. Specimens were processed applying mechanical surface treatments like shot peening or deep rolling and investigated in comparison with turned states. Surface topographies as well as near surface work hardening states and residual stress depth distributions were analyzed. Tension-compression fatigue tests were carried out under laboratory air as well as under salt spray test conditions or in salt solution. Crack formation and crack propagation was studied and characteristic examples are presented. The influence of the mechanical surface treatments on the electrochemical behavior was also investigated. To assess the consequences of near surface materials properties on the corrosion fatigue behavior, their stability during fatigue, in particular the relaxation of residual stress distributions introduced by mechanical surface treatments, was taken into account.

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Discussion: “Effect of Three-Dimensional Near Surface Defects on Rolling and Sliding Contact Fatigue” (Liu, M., and Farris, T. N., 1994, ASME J. Tribol., 116, pp. 841–848)

Journal of Tribology ◽

10.1115/1.2927344 ◽

1994 ◽

Vol 116 (4) ◽

pp. 849-849

Author(s):

L. M. Keer

Keyword(s):

Surface Defects ◽

Three Dimensional ◽

Contact Fatigue ◽

Sliding Contact ◽

Near Surface

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Study on contact fatigue of a wind turbine gear pair considering surface roughness

Friction ◽

10.1007/s40544-019-0277-3 ◽

2019 ◽

Vol 8 (3) ◽

pp. 553-567 ◽

Cited By ~ 5

Author(s):

Heli Liu ◽

Huaiju Liu ◽

Caichao Zhu ◽

Zhangdong Sun ◽

Houyi Bai

Keyword(s):

Mechanical Properties ◽

Residual Stress ◽

Surface Roughness ◽

Wind Turbine ◽

Fatigue Failure ◽

Fatigue Behavior ◽

Contact Fatigue ◽

Tooth Surface ◽

Failure Risk ◽

Material Points

AbstractContact fatigue issues become more and more crucial in gear industry as they significantly affect the reliability and service life of associated mechanical systems such as wind turbine gearboxes. The contact fatigue behavior is mostly determined by the mechanical properties of materials and stress fields near the contact area, which is further influenced by the lubrication and surface roughness due to pressure fluctuations. In this study, a numerical model incorporating the lubrication state, tooth surface roughness, residual stress, and mechanical properties of the material is developed to determine the contact fatigue behavior of a megawatt level wind turbine carburized gear. The variations of the hardness and residual stress along the depth were characterized by the Vickers hardness measurement and X-ray diffraction test, respectively. The elastohydrodynamic lubrication theory was applied to predict the contact pressure distribution, highlighting the influence of the surface roughness that stemed from the original measurement through an optical profiler. The stress histories of the studied material points during a complete contact loading cycle were fast calculated using the discreteconcrete fast Fourier transformation (DC-FFT) method. Modified Dang Van diagrams under different working conditions were determined to estimate the contact fatigue failure risk. The effect of the root mean square (RMS) value of the surface roughness on the failure risk at critical material points were discussed in detail. Results revealed that the surface roughness significantly increases the contact fatigue failure risk within a shallow area, and the maximum risk appears near the surface.

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