Development of a fretting-fatigue mapping concept: The effect of material properties and surface treatments

Fretting-fatigue induced by combined localized cyclic contact motion and external bulk fatigue loadings may result in premature and dramatic failure of the contacting components. Depending on fretting and fatigue loading conditions, crack nucleation and possibly crack propagation can be activated. This paper proposes a procedure for estimating these two damage thresholds. The crack nucleation boundary is formalized by applying the Crossland high cycle fatigue criterion, taking into account the stress gradient and the ensuing #size##effect#. The prediction of the crack propagation condition is formalized using a short crack arrest description. Applied to an AISI 1034 steel, this methodology allows the development of an original material response fretting-fatigue map (FFM). The impact of material properties and surface treatments is investigated

Development of a Wöhler-like approach to quantify the Ti(CxNy) coatings durability under oscillating sliding conditions

The selection of a proper material for the particular engineering application is a complex problem, as different materials offer unique properties and it is not possible to gather all useful characteristics in a single one. Hence, employment of different surface treatment processes is a widely used alternative solution. In many industrial applications, coating failure may be conducive to catastrophic consequences. Thus, to prevent the component damage it is essential to establish the coating endurance and indicate the safe running time of coated system. To this study PVD TiC, TiN and TiCN hard coatings have been selected and tested against polycrystalline alumina smooth ball. The series of fretting tests with reciprocating sliding at the frequency 5Hz have been carried out under 50-150N normal loads and under wide rage of constant as well as variable displacement amplitudes from 50µm to 200µm at a constant value of relative humidity of 50% at 296K temperature. To quantify the loss of material a dissipated energy approach has been applied where the wear depth evolution is referred to the cumulative density of friction work dissipated during the test. Different dominant damage mechanisms have been indicated for the investigated hard coatings, which is debris formation and ejection in case of TiC coating and progressive wear accelerated by cracking phenomena in case of TiN and TiCN coatings. Energy-Wöhler wear chart has been introduced, in which the critical 1 dissipated energy density corresponds to the moment when the substrate is reached after a given number of fretting cycles. Two different methods to determine the critical dissipated energy density are introduced and compared. The Energy-Wöhler approach has been employed not only to compare the global endurance of the investigated systems but also to compare the intrinsic wear properties of the coatings. It has been shown that the fretting wear process is accelerated by the stress-controlled spalling phenomenon below a critical residual thickness and a severe decohesion mechanism is activated. Finally the applicability of the investigated method to other coated systems subjected to wear under sliding conditions is discussed and analyzed. The perspectives of this new approach are elucidated

Behaviour of shot peening combined with WC-Co HVOF coating under complex fretting wear and fretting fatigue loading conditions

This study investigated the fretting and fretting fatigue performance of tungsten carbide–cobalt (WC–Co) HVOF spray coating systems. Fretting wear and fretting fatigue tests of specimens with shot peening and WC–Co coatings on 30NiCrMo substrates were conducted. The WC-Co coating presents very good wear resistance and decreases by more than 9 times the energy wear coefficient (α) under fretting conditions. The tested coating reduces crack nucleation under both fretting and fretting fatigue studied situations. Finally the crack arrest conditions are evaluated by the combined fretting and fretting fatigue investigation. It is shown and explained how and why this combined surface treatment (shot peening and WC–Co) presents a very good compromise against wear and cracking fretting damage

Comparison of shot peening and nitriding surface treatments under complex fretting loadings

Considered as a plague for numerous industrial assemblies, fretting associated with small oscillatory displacements is encountered in all quasi-static contacts submitted to vibrations. According to the sliding conditions, fretting cracks and/or fretting wear can be observed in the contact area. On the other hand an important development has been achieved in the domain of surface engineering during the past three decades and numerous new surface treatments and coatings are now available. Therefore there is a critical challenge to evaluate the usefulness of these new treatments and/or coatings against fretting damage. To achieve this objective, a fast fretting methodology has been developed. It consists in quantifying the palliative friction, cracking and wear responses through a very small number of fretting tests. With use of defined quantitative variables, a normalized polar fretting damage chart approach is introduced. Finally, to evaluate the performance of the assemblies after these protective surface treatments under complex fretting loadings, an original sequence of partial slip and gross slip sliding procedure has been applied. It has been demonstrated that performing of a very short sequence of gross slip fretting cycles can critically decrease the resistance of the treated surfaces against cracking failures activated under subsequent partial slip loadings

Impact of variable loading conditions on fretting wear

Fretting is considered as a specific type of reciprocating sliding. It is defined as a small displacement amplitude oscillatory motion between two solids in contact, usually induced by vibrations. Depending on the loading conditions (displacement amplitudes, normal loading), fretting causes damage by surface fatigue and wear induced by debris formation. To prevent such damage, numerous hard coatings have been developed which improve the wear resistance of contacts. However, one difficulty is to estimate how long it will be before the coating wears through. Studies have been conducted to analyze the effect of displacement amplitude, normal force or ambient atmosphere, but usually under constant loading conditions. Such a situation is far from real operating components, where elements are subjected to variable loadings implying variable displacement amplitudes. To predict the durability of a coating under variable fretting displacements, wear depth is quantified as a function of the maximum accumulated dissipated energy density by derivation from a global energy wear approach. This model is compared to TiC vs. alumina fretting experiments. Very good correlation is observed between the prediction and the wear depth, independently of the applied variable amplitude sequences. An equivalent “Miner-Energy” wear model is introduced which permits the durability of the coating to be estimated

Prediction of Fretting-fatigue Crack Nucleation Using a Surface Shear - Sliding Size Crack Analog Parameter

AbstractFretting fatigue is a critical load that appears on many structures, such as the blade/disk contact of aircraft engines, train wheel assemblies, etc. Predicting crack nucleation risk is essential for safety, but is particularly complex. Fretting contact stress is multiaxial, with severe stress gradients. To palliate this difficulty, a common approach consists in computing multiaxial fatigue at a critical distance, thus correcting the stress gradient effect and achieving stable pertinent predictions. However, this strategy is very costly in FEM computation due to very fine FEM mesh size, which may be <10μm, and application needs to be limited in large 3D industrial contacts. Investigating the partial slip fretting crack nucleation boundaries of 35NCD16 steel (plane) fretted against 52100 steel cylinders, a new semi-empirical contact loading parameter was introduced, defined as the maximum shear stress generated in the interface (qmax) multiplied by the square-root of the sliding size (s) of the partial slip interface (i.e., ϕ = qmax ×√s). Using this very simple parameter inspired by “crack analog strategy”, it was found that all the crack nucleation data obtained for a wide spectrum of contact pressures and cylinder radii were aligned along a single master curve. Scatter was very low, even less than for the costly “fatigue-critical distance method”. The approach was extended to various fretting-fatigue loading conditions, confirming stability of prediction

Interface roughness effect on friction map under fretting contact conditions

In many industrial applications where fretting damage is observed in the contact (e.g. rotor/blade, electrical contacts, assembly joint, axe/wheel, clutch) the external loadings or geometry design cannot be changed. Therefore, the surface preparation and finishing process become essential to control and reduce the damage caused by fretting. In this paper, the authors present the experimental study of the initial surface roughness and machining process influence on fretting conditions in both partial and full sliding regimes. Surfaces prepared by milling and smooth abrasive polishing processes have been analysed. The influence of roughness on sliding behaviour and analysis of friction have been reported. Also, the contact pressure influence and qualitative analysis of fretting wear scar have been presented

Predicting the linear response of self-gravitating stellar spheres and discs with LinearResponse.jl

We present LinearResponse.jl, an efficient, versatile public library written in julia to compute the linear response of self-gravitating (3D spherically symmetric) stellar spheres and (2D axisymmetric razor-thin) discs. LinearResponse.jl can scan the whole complex frequency plane, probing unstable, neutral and (weakly) damped modes. Given a potential model and a distribution function, this numerical toolbox estimates the modal frequencies as well as the shapes of individual modes. The libraries are validated against a combination of previous results for the spherical isochrone model and Mestel discs, and new simulations for the spherical Plummer model. Beyond linear response theory, the realm of applications of LinearResponse.jl also extends to the kinetic theory of self-gravitating systems through a modular interface.Comment: Software available at https://github.com/michael-petersen/LinearResponse.j

The role of temperature and frequency on fretting wear of a like-on-like stainless steel contact

The influences of environmental temperature and fretting frequency on the mechanisms and rates of wear in a like-on-like 304 stainless steel contact were examined, and mainly attributed to changes in the mechanical response of the bulk material and to changes in the behaviour of the oxide debris formed in the fretting process. At low temperatures, wear proceeds by continual oxide formation and egress from the contact, whilst at high temperatures, the rate of wear is much reduced, associated with the development of oxide formed into a protective bed within the contact. The temperature at which the change between these two behaviours took place was dependent upon the fretting frequency, with evidence that, at this transition temperature, changes in behaviour can occur as the fretting test proceeds under a fixed set of conditions. An interaction diagram has been developed which provides a coherent framework by which the complex effects of these two parameters can be rationalised in terms of widely accepted physical principles