The use of bearings can be found in virtually all aspects of mechanical systems today. Reliability of these critical components is an important issue. Fatigue performance of bearings is a function of many factors, including service conditions, loading, material properties, environmental factors, and manufacturing processes. Crack nucleation, first spall generation and spall growth in rolling contact fatigue are known to be highly sensitive to the heterogeneity of the microstructure. Yet the current state-of-the-art in the design of high performance bearing materials and microstructures is highly empirical requiring substantial lengthy experimental testing to validate the reliability and performance of these new materials and processes. The approach presented here is designed to determine relative rolling contact fatigue performance as a function of microstructural attributes. A fully three-dimensional finite element modeling allows for end effects to be captured that were not previously possible with two-dimensional plane-strain models, providing for a more realistic assessment of inclusion morphology and arbitrary orientations. The scaling of the finite element models has been optimized to capture the cyclic microplasticity around a modeled inclusion accurately and efficiently. To achieve this, two scales of geometric models were developed to incorporate different sized microstructural phenomena, with both models using traction boundary conditions derived from Hertzian contact stresses. A microstructure-sensitive material model adds additional capability. A hybrid model that includes both martensite and austenite phases with additional internal state variable to track the volume fraction of retained austenite due to stress-assisted transformation were developed. This represents an advance over previous models where transform plasticity and crystal plasticity were not simultaneously accounted for in a homogenized element containing both phases. Important links between microstructural features and fatigue indicator parameters (and relative fatigue performance) were determined. Demonstration cases show the relationship between inclusion orientation and relative fatigue performance, allowing for the identification of critical angles which maximize fatigue and reduce performance. An additional case study showed that increasing initial volume fraction of retained austenite reduces relative fatigue life. The tools developed allow for investigations of the influence of many microstructural aspects on relative fatigue performance with a numerical model that were not previously possible.

The formation of microstructural alterations in bearing steels under rolling contact fatigue (RCF) is systematically studied. A literature review summarizes current understanding in this field, leading to the key to the formation of these microstructural features being carbon redistribution as a consequence of cyclic rolling contact. In this context, a novel theory is postulated to describe the migration of carbon caused by gliding dislocations. The theory combines the Cottrell atmosphere theory with the Orowan equation and is capable of quantifying the dislocation-assisted carbon flux. Based on the proposed theory, models are suggested for different types of microstructural alterations formed in rolling contact fatigued bearings – dark etching regions (DERs), white etching bands (WEBs) and white etching areas (WEAs). Very good agreement is obtained between the predications made by the models and the experimental data from both this research and the literature. Moreover, the models consider the effects of contact pressure, temperature, rotational speed and number of cycles, and thus can be applied for universal RCF testing conditions. The reproduced microstructural features are also characterized using advanced characterization techniques such as scanning electron microscopy (SEM), transmission electron microscopy (TEM) and atom probe tomography (APT), with the observation validating the postulated formation mechanisms. It is demonstrated that DERs, WEBs and WEAs follow the same principle during formation – strain induced carbon redistribution. This is the first time that these microstructural alterations are quantitatively described using a unified theory. The achievements obtained from this research can be far reaching. It not only leads to great progress in understanding the phenomenology of RCF in bearing steels, but also can be further extended to other scenarios with similar phenomena such as severe plastic deformation and hydrogen embrittlement.

In this thesis, the behavior of pearlitic steel was characterized under controlled wear conditions in the laboratory and service conditions in two ore mining stages, comminution and transportation. The thesis consists in three experimental chapters, divided according to the tribosystems analyzed. On all the chapters Electro Microscopy techniques for the microstructural analysis were employed. Scanning Electron Microscopy (SEM), Focused Ion Beam (FIB-SEM), Electron Backscatter Diffraction (EBSD) and Transmission Electron Microscopy (TEM) were used. The first experimental chapter shows the analysis of the pearlite under abrasive wear with loose abrasive particles in multi-events conditions. The sample was taken from Semi-Autogenous Grinding mills (SAG) and experimental simulation was carried out in laboratory using the Dry Sand Rubber Wheel Abrasion Test (DSRW). The results show a polycrystalline layer formation in both cases, characterized by ultra-fine grains of ferrite in the layer closer to the surface. It was also concluded that the DSRW can simulate the wear produced on field (superficial and microstructural features) in conditions of higher normal load than recommended by the ASTM Standard G65. The second experimental chapter explores the characterization of the microstructure after the indenter pass in scratch test using two conditions of normal load applied and five sequences of scratch. The microstructural analysis shows the formation of two subsuperficial layers identified by the level of the microstructural alterations. In the subsuperficial layer (close to the surface), the formation of new ultra-fine grains of ferrite was observed. A second layer was observed deeper in the sample and denominated as layer of the microstructure transition, characterized by the combination of deformed (reduction of the interlamellar spacing) and pearlite colonies not affected plastically by the mechanical loading. On this layer, the crystallographic texture in RD // in samples tested at 4 N (normal load) and one-pass scratch was determined. Later, on this chapter, the microstructure in a ground rail (industrial procedure characterized as a multi-event scratch test) was analyzed. Two grinding conditions were used for the analysis with variation of the grinding linear speed and load on the grinding stones (discs). The combination of low grinding speed and high load promotes a higher deformed layer formation beneath the patch zone and low randomized orientation of the pearlite colonies. Finally, in the third experimental chapter, the pearlitic characterization was concluded with the study of samples of railway wheel and rail under wear in service and Rolling Contact Fatigue (RCF) in laboratory. The laboratorial simulation was carried out using the twin-disc rolling contact tribometer with a variation of number of cycles. The characterization of railway wheel shows that the WEL is characterized by levels of breaking and aligned cementite and zones with dissolution of the carbon atom in the ferrite to form the supersaturated carbon ferrite. The polycrystalline ferrite formation (ultra-fine grains) in the sub-superficial layer and it was identified a preferential orientation of RD // in the layer of microstructural transition. The results of the laboratory test show surface crack nucleation and propagation at low angle in the more severe deformed layer. The microstructure of the layer consists in polycrystalline ferrite and the cementite dissolution. / Nesta tese foi caracterizado o comportamento do aço perlítico em condições controladas de desgaste em laboratório e em serviço em dois estágios do processo de mineração de minério, cominução e transporte ferroviário. A tese consiste em três capítulos experimentais divididos segundo o tribosistema analisado. Em todos os capítulos do trabalho foi utilizada a técnica de microscopia eletrônica para análise microestrutural. Foi utilizado Microscopia eletrônica de varredura (MEV), Focused Ion Beam (FIB-SEM), Electron Backscatter Diffraction (EBSD) e Microscopia eletrônica de transmissão (MET). O primeiro capítulo experimental mostra a análise da perlita in condições de desgaste abrasivo com partículas soltas em eventos múltiplos. As amostras foram tiradas de um moinho semi-autógeno (SAG) e realizada uma simulação experimental do desgaste em condições controladas usando o tribômetro de roda de borracha (RWAT). Os resultados mostraram a formação de camada branca em ambas as condições de análise, consistindo em uma camada poli cristalina caracterizada pela formação de grãos ultrafinos na camada mais próxima da superfície de desgaste. Também foi concluído que a roda de borracha pode simular o desgaste produzido nos moinhos SAG tanto nas características superficiais quanto microestruturais em condições de maior severidade as comumente utilizadas na norma ASTM G65 (procedimento B). O Segundo capítulo experimental explora a caracterização da microestrutura depois da passagem do endentador no ensaio de riscamento (scratch test) utilizando duas condições de carga normal aplicada e 5 sequências de riscamento. A análise microestrutural mostrou a formação de duas camadas subsuperficiais identificadas pelo nível de alteração microestrutural. Na camada mais próxima da superfície de desgaste foi observada a formação de grãos ultrafinos de ferrita. A segunda camada identificada mais profundamente na amostra, denominada como camada de transição, é caracterizada pela combinação de colônias deformadas (redução do espaçamento interlamelar) e camadas não afetadas pelos esforços produzidos no contato. Nesta camada foi determinada a texturização em direção RD // nas amostras testadas a 4 N (carga normal aplicada) e uma passada. Posteriormente à análise de riscamento foi caracterizada a microestrutura de uma amostra tirada de um trilho esmerilhado (processo industrial que pode ser considerado como aplicação do ensaio de riscamento). Foram consideradas duas condições de esmerilhamento com variação de velocidade de esmerilhamento (deslocamento linear do veículo esmerilhador) e potência dos motores dos rebolos usada no procedimento. A combinação de baixa velocidade de esmerilhamento e alta potência nos motores controladores dos rebolos promoveu uma grande deformação nas camadas subsuperficiais na região de contato e uma baixa aleatoriedade das orientações cristalográficas das colônias de perlita. Finalmente, no capítulo três, a caracterização da microestrutura perlitica foi finalizada com o estudo de amostras de roda e trilho em condições de desgaste em campo e de Rolling Contact Fatigue (RCF) em ensaios de laboratório. A simulação experimental foi realizada utilizando o tribômetro twin-disc rolling (configuração disco-disco) com variação do número de ciclos. A caracterização da roda ferroviária mostrou a formação da camada branca caracterizada por níveis de cementita fraturada e alinhada em direção do movimento de rolamento/deslizamento com áreas de dissolução do átomo de carbono na ferrita formando uma ferrita supersaturada. Foi identificado a formação de policristais de ferrita (grãos ultrafinos) na camada mais superficial e uma orientação preferencial RD // na camada de transição. Os resultados dos ensaios de laboratório mostraram a nucleação de trincas superficiais se propagando a baixo ângulo na camada branca. A transformação microestrutural dessa camada após ensaios de laboratório consiste em policristais de ferrita e dissolução da cementita.

Hydrogen embrittlement is a problem that offers challenges both to technology and to the theory of metallurgy. In the presence of a hydrogen rich environment, applications such as rolling bearings display a significant decrease in alloy strength and accelerated failure due to rolling contact fatigue. In spite of these problems being well recognised, there is little understanding as to which mechanisms are present in hydrogen induced bearing failure. The objective of this thesis are twofold. First, a novel alloy combining the excellent hardness of bearing steels, and resistance to hydrogen embrittlement, is proposed. Second, a new technique to identify the nature of hydrogen embrittlement in bearing steels is suggested. The new alloy was a successful result of computer aided alloy design; thermodynamic and kinetic modelling were employed to design a composition and heat treatment combining (1) fine cementite providing a strong and ductile microstructure, and (2) nano-sized vanadium carbide precipitates acting as hydrogen traps. A novel technique is proposed to visualise the migration of hydrogen to indentation-induced cracks. The observations employing this technique strongly suggest that hydrogen enhanced localised plasticity prevails in bearing steels. While proposing a hydrogen tolerant bearing steel grade, and a new technique to visualize hydrogen damage, this thesis is expected to aid in increasing the reliability of bearings operating in hydrogen rich environments.

Diploma thesis describes influence of directed modificated topography of frictional surfaces on fatigue wear non-conformal incurvate solids. It was created 3D parametric model of experimental test rig in modelling environment Autodesk Inventor. With the help of model was designed and carried reconstruction of experimental test rig so to possible obtain repeatable results under the sliding conditions of frictional surfaces. It enabled show influence of surface iregularities (dents) frictional surfaces on contact fatigue service life in conditions mixed lubrication regime and different values of slide to roll ratio.

<p>QC 20110523</p>

Rolling contact fatigue is a problem encountered with many machine elements.In the current report a numerical study has been performed in order to predictthe crack path and crack propagation cycles of a surface initiated rolling contactfatigue crack. The implementation of the contact problem is based on theasperity point load mechanism for rolling contact fatigue. The practical studiedproblem is gear contact. Different loading types and models are studied andcompared to an experimental spall profile. Good agreement has been observedconsidering short crack lengths with a distributed loading model using normalloads on the asperity and for the cylindrical contact and a tangential load on theasperity. Several different crack propagation criteria have been implemented inorder to verify the validity of the dominant mode I crack propagation assumption.Some general characteristics of rolling contact fatigue cracks have beenhighlighted. A quantitative parameter study of the implemented model hasbeen performed. / Utmattning med rullande kontakter är ett ofta förekommande problem för många maskinelement. I den aktuella rapporten utfördes en numerisk studieför att förutsäga sprickvägen hos utmattningssprickor som initierats i ytan vidrullande kontakter. Implementeringen av kontaktproblemet bygger på asperitpunktlastmekanismen för rullande kontakter. Studien av kontaktproblemetär tillämpad till kugghjul. Olika belastningstyper och modeller studeradesoch jämfördes med profilen hos en experimentell spall. Bra överensstämmelseobserverades för korta spricklängder när en modell med fördelad belastninganvänds för en belastningstyp där en normalbelastning agerar på asperiten ochvid cylindriska kontakten och en tangentialbelastning införs på asperiten. Olikakriterier för spricktillväxt implementerades för att verifiera giltigheten av antagandetatt mode I spricktillväxt är dominant. Några generella kännetecken avutmattningssprickor med rullande kontakter framhävdes. En kvantitativ parameterstudie för den implementerade modellen utfördes.

This PhD thesis deals with the experimental study of more precise rolling contact fatigue damage detection using acoustic emission method. A series of experiments was carried out on two representatives bearing steels and the analysis of sensitivity for the presence of contact damage was performed on selected parameters of acoustic emission. The extent of damage was classified into four classes and signal parameters the most characterizing the development of damage were correlated with the extent of damage. It was also verified the influence of lubricants on acoustic emission signals. The results have an impact on the implementation of more precise rolling contact fatigue tests and evaluation of parameters of acoustic emission signal. On the basis of experiments was established methodology for more precise RCF testing method using acoustic emission on test-rig AXMAT II.

Le 32CrMoV13 nitruré est un matériau à gradient de propriétés utilisé pour la réalisation de bagues de roulements aéronautiques. Il présente l’avantage d’être dur en surface et ductile à cœur, facilitant ainsi la lutte contre les effets de la pollution des contacts par les lubrifiants. De plus, afin d’améliorer les performances des roulements, la tendance est à l’utilisation de céramique (nitrure de silicium Si3N4) pour les éléments roulants à la place de l’acier (M50). Ainsi, le travail de thèse proposé ici est l’étude du comportement en fatigue de contact en présence d’indentations pour deux couples de matériaux (32CrMoV13 nitruré / M50 et 32CrMoV13 nitruré / Si3N4). Ce comportement est principalement orienté en terme de durée de vie du contact indenté par l’intermédiaire d’un critère d’amorçage de fissures. Une étude des propriétés mécaniques du 32CrMoV13 nitruré, nécessaires à l’application du critère, a été réalisée. La loi d’écrouissage et l’ouverture micro-plastique cyclique de la couche nitrurée du 32CrMoV13 nitruré ont été identifiées. Puis, par l’intermédiaire de défauts géométrique de type trous cylindriques, les propriétés d’amorçage de fissures ont été étudiées lors d’essais de compression uniaxiale. Le comportement en fatigue de contact en présence d’indentations a été étudié sur machine bi-disques. Ces essais ont permis de caractériser la différence de comportement du 32CrMoV13 nitruré, et indenté, dans un contact acier / acier et acier / céramique. L’effet du glissement a notamment été mis en évidence. Ces études expérimentales ont été couplées avec des simulations numériques afin d’étalonner le modèle physique d’amorçage de fissures et d’en valider sa bonne représentativité. En conclusion un modèle de prédiction de durée de vie en fatigue de roulement a été proposé. Il est particulièrement adapté aux cas où des contraintes résiduelles sont présentes, par exemple suite à l’indentation des surfaces. Le modèle s’appuie sur la caractérisation mécanique des couches traitées thermo-chimiquement de l’acier 32CrMoV13 nitruré. / The nitrided 32CrMoV13 steel is a gradient properties material used for the production of aeronautical bearing rings. The principal advantages are its surface hardness and core ductility, useful against debris denting. Moreover, to improve rolling bearing performances, ceramic balls (silicon nitride Si3N4) instead of steel (M50). The present study aims to investigate the contact fatigue performance in presence of indentation for two pairs of materials (nitrided 32CrMoV13 steel / M50 and nitrided 32CrMoV13 steel / Si3N4). This performance is mainly oriented in terms of lifetime of the indented contact by a crack initiation criterion. A study of the mechanicals properties of the nitrided 32CrMoV13 steel, required for the application of the criterion, is then performed. It allows to characterize the hardening law and the cyclic micro-plastic behavior of the nitrided layer of the nitrided 32CrMoV13 steel. Crack initiation properties of the nitrided surface layer have been evaluated by compression tests on thin hollow cylindrical specimens with small cylindrical holes. The contact fatigue behavior in presence of indentations was studied on a high-speed twin-disks machine. These tests allowed to characterize the difference in behavior of nitrided 32CrMoV13 steel (indented) in a steel-to-steel contact or steel-to-ceramic contact. The major effect of sliding has been highlighted. All these experimental studies were coupled with numerical simulations to calibrate the physical model of crack initiation and to show its capabilities. In conclusion a new model of rolling contact fatigue life has been proposed. It is specifically adapted to operation in presence of residual stresses such as resulting from debris denting. The model uses mechanical properties that have been identified for thermo-chemically treated layers of nitrided 32CrMoV13 steel.

High rolling contact fatigue parts are vital for the long service life of fuel pumps. Cummins Fuel Systems are currently using an M2 tool steel for one of the most important roller bearing application in their pumps, namely the cam follower. The future design of the cam follower is a pin-less tappet roller. The wear and fatigue properties of the roller is vital to ensure reliability of the fuel system. M2 tool steel is an expensive material and becomes even more so if diamond like coating (DLC) is needed to decrease the friction coefficients. To cut costs of the fuel pump it might be possible to replace the M2 tool steel with 52100 steel (100Cr6). Competitive methods have proven that carbonitrided 52100 can reach excellent wear and fatigue properties making it a candidate to replace M2 tool steel. How the properties of hardness, toughness and compressive residual stresses are developed in 52100 and how they affect the fatigue and wear resistance has been researched from the literature. A big part of this project was to do an extensive analysis of a roller bearing that was believed to have gone through one of these competitive methods that produce excellent wear and fatigue resistance. The analysis was done with background to the knowledge gathered from the literature. Finally process trials were set up to carbonitride 52100 steel samples. The trials were done to develop a better understanding of how adding carbon together with nitrogen to the surface of 52100 steel will influence the metallurgical parameters that results in good wear and fatigue resistance. From this analysis Cummins hope to create a process recipe that can be used for carbonitriding the cam follower and maybe other components in their fuel systems.