Fatigue limit of induction hardened railway axles

A new surface induction hardening technology was designed for the purpose of increasing the resistance of railway wheelsets to fatigue damage. This paper gives a detailed presentation of the technological aspects of induction hardening of axles. The increased fatigue resistance in hardened surfaces compared with standard heat treatment of EA4T steel was verified using tensile test specimens, press‐fitted wheel seat/axle joints at 1:3 scale and press‐fitted wheel/axle joints at actual size. The 70% increase in the fatigue limit of induction hardened EA4T steel specimens compared with material subjected to standard heat treatment clearly demonstrates the effectiveness of this technology.     

Prediction of fatigue limit of induction surface hardened 1.05Cr–0.23Mo steel alloy using extreme value statistics

Fatigue characteristics of the surface hardened steel are different from that of normal steel, so the prediction of the fatigue limit of surface hardened steel is very complicated. In this paper, specimens are tested using rotary bending, and the surface of 1.05Cr–0.23Mo steel alloy is hardened by induction surface hardening. Variation of the distribution of microvickers hardness and residual stress is discussed, and the difference of S-N diagram between surface hardened steel and unhardened steel is examined. The maximum defect size of surface hardened specimen is calculated by the extreme value statistics to predict conservative fatigue limit. Actual shape of defect in the specimen is three dimensional, so a conversion method from 2D to 3D defect size based on examination volume and inclusion size is used to predict statistical maximum defect size. The predicted results can be defined as a lower fatigue limit which may be useful to predict conservative fatigue limit of surface hardened specimen.     

Stabilität der tatsächlichen Schadenssumme gegen eine Variation des Kollektivumfangs,der Kerbschärfe und des Kollektivhöchstwertes am Beispiel der warmausgehärteten Knetlegierung AlMgSi1

Stability of the real damage sum for a variation of spectrum length, stress concentration and load level by the example of the age‐hardened aluminium alloy AlMgSi1 Using the concept of damage accumulation for the fatigue design of components under operational conditions, the correct damage sum is an important quantity. Assuming the theoretical quantitiy D = 1, the calculated life time is often higher than the experimental. Therefore, the real damage sum combined with the corresponding modified Miner rule should be determined. The investigation is based on fatigue tests with different notched specimens under constant amplitude loading and various gaussian spectra. Damage calculation were carried out by four different modifications of the Miner rule: Miner original, Miner‐Haibach, Miner elementar (Corten‐Dolan) and Miner‐Liu/Zenner. The applied methods showed different behaviour concerning a variation of spectrum length, stress concentration and load level. For the investigated material the modification of Miner's rule according to Haibach showed the highest insensitivity with regard to stress concentration and spectrum length.     

Predicting the effects of material properties gradient and residual stresses on the bending fatigue strength of induction hardened aeronautical gears

This paper proposes an experimental methodology to characterize complex parts presenting various gradients using aeronautical induction surface hardened spur gears. A 3D fatigue model taking into account residual stresses, microstructure variations, and surface roughness is then proposed for the prediction of the bending endurance limit. The model is based on the well-known Crossland criterion; calibrated with representative axial and torsion laboratory specimens. The results are compared with testing performed on a custom-made single tooth bending fatigue (STBF) rig. Fracture surface analysis using electronic microscopy is used to investigate the crack initiation sites. It is shown that residual stresses can have a significant impact on bending fatigue and that two induction treatments can present very different fatigue resistance even if the shape and depth of the hardened layer is identical in the root. The proposed methodology could be adapted to other geometries and surface treatments.     

Das Konzept der lokalen Dauerfestigkeit und seine Anwendung auf martensitische Randschichten,insbesondere Laserhärtungsschichten

The local fatigue strength concept and its application to martensitic surface layers, especially laser hardened layers Starting from the known local fatigue strength concept problems of its application to martensitic surface layers, especially laser hardened layers have been discussed. A method for calculation of the fatigue limit of surface hardened specimens or components from quench-hardenable steels has been proposed, including the influence of surface roughness on fatigue strength. There is given a new formula for estimation of the mean and residual stress sensitivity. The limits of the concept have been shown and its practical use has been demonstrated exemplarily.     

Verhalten laserschockverfestigter und festgewalzter Randschichten der Ti‐Legierung Ti‐6Al‐4V bei schwingender Beanspruchung unter erhöhten Temperaturen

Residual stress stability and near‐surface microstructures in high temperature fatigued mechanically surface treated Ti‐6Al‐4V It is well known that mechanical surface treatments, such as deep rolling, shot peening and laser shock peening, can significantly improve the fatigue behavior of highly‐stressed metallic components. Deep rolling is particularly attractive since it is possible to generate, near the surface, deep compressive residual stresses and work hardened layers while retaining a relatively smooth surface finish. In the present investigation, the effect of deep rolling on the low‐cycle and high‐cycle fatigue behavior of a Ti‐6Al‐4V alloy is examined, with particular emphasis on the thermal and mechanical stability of the residual stress states and the near‐surface microstructures. Preliminary results on laser shock peened Ti‐6Al‐4V are also presented for comparison. Particular emphasis is devoted to the question of whether such surface treatments are effective for improving the fatigue properties at elevated temperatures up to ～450 °C, i.e., at an homologous temperature of ～0.4 T/T_m (where T_m is the melting temperature). Based on cyclic deformation and stress/life (S/N) fatigue behavior, together with the X‐ray diffraction and in situ transmission electron microscopy observations of the microstructure, it was found that deep rolling can be quite effective in retarding the initiation and initial propagation of fatigue cracks in Ti‐6Al‐4V at such higher temperatures, despite the almost complete relaxation of the near‐surface residual stresses. In the absence of such stresses, it is shown that the near‐surface microstructures, which in Ti‐6Al‐4V consist of a layer of work hardened nanoscale grains, play a critical role in the enhancement of fatigue life by mechanical surface treatment.     

Fatigue strength and fracture mechanism of steel modified by super-rapid induction heating and quenching

Four kinds of surface hardened-specimens (ordinary structural steel with carbon content of 0.45% C) having hardened thicknesses of 0.7–1.8 mm were prepared using a ‘super-rapid induction heating (SRIH) system’. Rotation bending fatigue tests were performed with special focus on the effect of a hardened thickness on fatigue properties. Measurement of residual stress and observation of the fracture surface were also carried out to investigate the fracture mechanism of the specimen with a shallow hardened layer. It was found that there is not much improvement of fatigue strength at 10⁷ cycles for specimens with shallow hardened layers in spite of having a high compressive residual stress of about 1000 MPa. This is because the fatigue crack originating from inside the hardened layer leads to the final fracture of the specimen (internal fracture mode). Improvement of fatigue strength has been achieved on the specimen with thick hardened layers, such as those about 1.8 mm thick. In this case, fatigue cracks originate from inclusions located in hardened layers, which leads to final fracture (hardened-layer fracture mode).     

Influence of surface condition on the fatigue behaviour of specimens made of a SAE 5115 case-hardened steel

The effect of different surface conditions on the fatigue properties of cyclically loaded bending specimens of the case‐hardened steel SAE 5115 (Material Number 1.7131) was investigated. The aim of the investigations was to achieve further knowledge of the processes that finally lead to the failure of case‐hardened and cyclically loaded bending specimens. Surface roughness, microstructure and residual stress distribution were regarded as parameters that govern the fatigue process. On the basis of a well‐defined adjustment of different surface conditions the effect of internal oxidation, surface roughness and residual stresses on fatigue crack initiation and growth were assessed. The effect of different parameters on the endurance limit has been quantified by the application of a fracture mechanics and a weakest‐link approach. The calculations contributed to a deeper insight into the complex interaction between the parameters governing the fatigue process.     

Untersuchungen zur Wälzermüdung nach induktivem Kurzzeitanlassen

Ball bearing fatigue after inductive short time tempering To improve toughness, machiniability and to avoid distortion under operating conditions inductive hardened components often were additional tempered in an oven. As a general rule tempering is applied when grinding is required. According to tempering conditions the present hardness, toughness and the microstructure will change. In the present studies it is shown, that with optimized inductive short term tempering conditions it was possible to achieve even better mechanical properties in comparison with oven tempered components. Ball bearing fatigue testings showed an improvement of wear resistance. The achieved findings opens the possibility for numerous applications to exchange the previous oven tempering through the more rapid and more low‐cost inductive short‐term inductive surface layer hardening.     

Größeneinfluß und Dauerfestigkeitseigenschaften unter Besonderer Berücksichtigung optimierter Oberflächenbehandlung

Size Effect and Fatigue Properties with Respect to Optimized Surface-Treatment. A hyperbolic function describes the geometrical size effect of notched specimens made from heat treated steel. An estimation of fatigue properties of components under one level fatigue tests is possible, if there are comparable materials and surface properties. The fatigue properties of specimens are well described by standardized stress-N graphs. The slope of the stress-N graphs in the range of load cycle depends on the concentration factor and not on the size effect. The fatigue properties of components are largely increased by thermal and mechanical surface strengthening. For the determination of the improvement of fatigue properties it is important to known the initiation of cracking. The improved fatigue properties of inductive surface hardened smooth specimens can be explained by the initiation of cracking below the surface. Mechanically strengthened notched specimens start cracking on the surface. The increase of fatigue properties for these specimens is explained by compressive residual stresses. The fatigue properties of notched specimens can be improved by the optimisation of mechanical strengthening, to higher values than for smooth surface strengthened specimens. This is due to compressive residual stresses. They decrease the tensile stresses which are responsible for crack propagation. If the tensile stress is below fatigue limit for initiation of cracking the crack arrests immediately.     

The local strain energy density approach applied to pre‐stressed components subjected to cyclic load

Ahead of sharp V‐notches, residual stresses, arising from the solidification of a fusion zone, have the same asymptotic nature of the stress field induced by mechanical loads. This stress field significantly affects the engineering properties of structural components, notably fatigue life and corrosion resistance of welded joints. Tensile residual stresses can reduce the fatigue strength of welded joints particularly in the high‐cycle regime, where no stress redistribution due to local plasticity phenomena is expected to be present. The aim of this work is to analyse, by means of the numerical simulation, the residual stress redistribution near a V‐notch tip induced by cyclic loads and to propose a method, based on the local strain energy approach, for the fatigue resistance estimation of pre‐stressed components. The numerical solutions of the problem were carried out under the hypothesis of generalized plane strain conditions by means of SYSWELD and SYSTUS codes.     

Werkstoffauswahl für schlagartig und zyklisch belastete metallische Bauteile

Material Selection for Impact and Fatigue Loading The structural durability of components is dominated mainly by the geometry, i.e. notches. Compared with the impact resistance of forged components from ductile materials high impact values can be realized by an appropriate shaping also using less ductile cast materials. Creep deformations can be suppressed in presence of notches. The strength level of the base material remains for stress concentrations above K_t = 2.5 and for the welded state without influence on the fatigue behaviour. If sharp notches cannot be avoided by a new design, benefits from high‐strength materials can be taken only in connection with surface treatments which introduce high compressive residual stresses. Principally, advantages from high‐strength materials can be gained for unwelded components only by reduction of the stress‐concentration and in case of welded joints by smoothening or removal of the weld notches and in case of spot welds by transferring of the failure location outside of the nugget.     

Morphology of step-wise S–N curves depending on work-hardened layer and humidity in a high-strength steel

The present paper describes the effects of work‐hardened layer and humidity on the fatigue response of high strength steel, JIS SNCM439 (AISI4340). Tests were conducted in laboratory air and in dry air using cantilever‐type rotating bending fatigue testing machines. The dew point of dry air was ?60 °C. Specimens with two different surface conditions were prepared, i.e., buff‐finished and electro‐polished specimens. In the buff‐finished specimens, a stepwise S–N curve was seen in both environments, but the transition stress below which subsurface crack initiation occurred shifted to a higher stress level in dry air than in laboratory air. In the electro‐polished specimens, stepwise S–N curve was not observed in laboratory air, but seen in dry air. At stress levels where cracks initiated at the surface, the fatigue lives of the electro‐polished specimens were shorter than those of the buff‐finished specimens. At stress levels where subsurface cracks initiated, the fatigue lives of both specimens were the same, irrespective of surface finishing condition and humidity.     

Standing contact fatigue with a cylindrical indenter

A hardened steel cylinder was repeatedly pressed against a flat case‐hardened steel specimen that was equally wide as the cylinder was long. Some contact end effects were noted as a result of limited plastic deformation. A strain gauge on the contact surface, just outside the contact and oriented perpendicular to the cylinder detected a surface strain when the cylinder was loaded. The non‐zero surface strain was the result of boundary effects of the finite specimen. Four different types of contact fatigue cracks developed in and below the specimen contact surface. The cracks were named lateral, median, contact end and edge cracks. Changes in the measured surface strain values could be used to determine when the lateral and edge cracks developed. The order in which all four crack types typically developed was determined from optical crack observation at test termination, strain measurements and stress computations. Numerical computations using finite‐element (FE) analyses were used to verify the surface strain behaviour due to loading and cracking; to verify contact end effects; crack locations and crack orientation by aid of the Findley multi‐axial fatigue criterion.     

Monotonic and Cyclic Deformations of Case‐Hardened Steels Including Residual Stress Effects

Abstract: Monotonic and cyclic deformations of case‐hardened steel specimens under axial loading were investigated experimentally and analytically. A finite element (FE) model for the case‐hardened specimens was constructed to study multiaxial stresses due to different plastic flow behaviour between the case and the core, as well as to evaluate residual stress relaxation and redistribution subsequent to cyclic loading. The multiaxial stress is shown to increase the effective stress on the surface, and, therefore, unfavourable to yielding or fatigue crack nucleation. The residual stresses are shown to relax or redistribute, even in the elastic‐behaving region, when any part of a case‐hardened specimen or component undergoes plastic deformation. Multi‐layer models were used to analyse and predict monotonic and cyclic deformation behaviours of the case‐hardened specimen based on the core and case material properties, and the results are compared with the experimental as well as FE model results. The predicted monotonic stress–strain curves were close to the experimental curves, but the predicted cyclic stress–strain curves were higher than the experimental curves.     

Durability analysis of carburized components using a local approach based on elastic stresses

The carburizing of non‐homogeneously stressed components is often used to improve the fatigue properties. In order to predict fatigue life curves the local behavior has to be analyzed. Therefore, cyclic material properties of the carburized surface layer and the core were investigated. In general it is challenging to obtain the input data necessary for a durability analysis of carburized components with the local strain approach. Therefore, a simple method is proposed to estimate the life curve of carburized components under proportional constant‐ and variable‐amplitude loading. With a S‐N curve for a similar component as input local elastic stresses can be back‐calculated. Experimental results show a strong influence of the highly stressed volume on the fatigue properties of the carburized surface layer. This effect can be taken into account with a size correction factor calculated on the basis of a weakest link model. Based on an appropriate local elastic stress‐life curve and regarding the size effect, durability analysis can be improved in an early stage of design. Fatigue tests on notched specimens and components of vehicle transmission cases were used to compare experimental and numerical results.     

Load distribution in the axial direction in a spline coupling

A finite element model has been made of a spline coupling between a shaft and a sleeve. The stress concentration factor is calculated and compared to analytical calculations. An analytical model for the load distribution in the axial direction and the torque transfer between shaft and sleeve is presented and compared to finite element results. Methods to uniform the load distribution and thereby decrease the stress concentration factor are tested with the analytical model. The induction hardened shafts with splines are fatigue tested and the lives are presented. The residual stress on the shaft surface is measured. The analytical model shows that the best way uniform the load is to vary the thickness of the spline tooth in the axial direction. Different shapes and sizes of the tooth thickness variation are also investigated. It is probably possible to extend the fatigue life at least two times for this spline, by uniforming the load distribution.     

Zum Mechanismus der Wechselfestigkeitssteigerung durch Werkstoffverfestigung und Druckeigenspannungen nach einer Oberflächenbehandlung

The Improvement of Fatigue Limit as a Result of Hardening and Macrostresses Due to a Surface Treatment Surface treatments, that increase the hardness as well as induce surface residual macrostresses, are universaly able to improve the fatigue limit. It is shown, that depending on the shape of specimens both effects together are responsible for the raise of the fatigue strength, which is in contrast to former opinions. The increase of hardness increases the stress required for crack initiation and is thus decident for unnotched specimens, whereas in this case the influence of permanent residual stresses is relatively smaller. Notched specimens of sufficient stress concentration factor k_t are determined by the crack propagation conditions, which can be controlled decisively by mean loads. The increase of hardness improves the resistance against crack initiation proportional to the 1/k_t portion of the unnotched fatigue limit, but cracks remain nonpropagating as long as a certain minimum alternative stress, which can be raised by compressive residual stresses, is not exceeded. Depending upon concentration factor, mean compressive load and hardness the transition from crack initiation to crack propagation as the criterion for fatigue fracture can be estimated by several fatigue-strength-diagrams, which are evaluated for specimens of constant hardness but are valid for surface hardened specimens as well.     

喷丸强化对OCr13Ni8Mo2Al钢疲劳性能的影响

研究了表面喷丸强化后表面残余应力、表面粗糙度和表面层残余压应力场对0Cr13Ni8Mo2Al钢疲劳性能的影响.结果表明:0Cr13Ni8Mo2Al钢经喷丸强化后,在表面层残余压应力场的作用下疲劳裂纹源由表面被"驱赶"到表面强化层下,疲劳寿命得到显著提高.