带有微动磨损缺口钢丝的疲劳特性

在自制的微动磨损试验机上进行钢丝的微动磨损试验,将微动磨损后的钢丝试样在液压伺服疲劳试验机上进行不同应力比和不同应力幅下的疲劳试验。结果表明,钢丝的微动磨损深度随微动时间和接触载荷的增加而增加,磨损缺口处的应力集中使其成为了裂纹萌生源,也使钢丝试样的疲劳寿命大大降低,微动磨损后钢丝试样的疲劳寿命和磨损深度呈反比关系。通过钢丝疲劳断口的SEM形貌分析了其疲劳断裂机制,断口对应不同的疲劳阶段,可分为裂纹萌生区、裂纹扩展区和裂纹瞬断区。     

Finite Element Analysis of Localized Plasticity in Al 2024-T3 Subjected to Fretting Fatigue

Fretting fatigue is a combination of two complex mechanical phenomena, namely, fretting and fatigue. Fretting appears between components that are subjected to small relative oscillatory motion. Once these components undergo cyclic fatigue load at the same time, fretting fatigue occurs. Fretting fatigue is an important issue in aerospace structural design. Many studies have investigated fretting fatigue behavior; however, the majority have assumed elastic deformation and very few have considered the effect of plasticity. The main goal of this study is to monitor the effect of different fretting fatigue primary variables on localized plasticity in an aluminum alloy (Al 2024-T3) test specimen. In order to extract the stress distribution at the contact interface under elasto-plastic conditions, a modified finite element contact model was used. The contact model was verified through comparison with an elastic analytical solution. Then, a bilinear elasto-plastic isotropic hardening model with a von Mises yield surface was implemented to simulate the material behavior of the aluminum alloy. The effect of different fretting fatigue primary variables, such as axial stress, contact geometry, and coefficient of friction, on localized plasticity was investigated. Finally, the relationship between the location of maximum localized plasticity and Ruiz fretting damage parameter with the crack initiation site is discussed.     

Progress in standardization of fretting fatigue terminology and testing

This paper reviews the current ASTM, ISO, and other standards that pertain in part to fretting fatigue and fretting wear testing. A historical perspective gives some background on why there still are relatively few standards for fretting fatigue and fretting wear testing. Current standards on the books tend to be application specific. In the past few years, there have been some new activities in standardization. These developments along with future needs in standardization are discussed.     

Effect of contact load on fretting fatigue behaviour of steel wires

Abstract

The tension–tension fretting fatigue tests of steel wires were performed on a self-made fretting fatigue test equipment under contact loads ranging from 40 to 70 N and a strain ratio of 0·8. The results showed that when the contact load increased, the fretting regime of steel wires transformed from gross slip regime to mixed fretting regime. The fretting fatigue life in the mixed fretting regime was significantly lower than that in the gross slip regime. The main fretting wear mechanisms in the gross slip regime, where there were serious fretting damage and a lot of wear debris, were abrasive wear and fatigue wear. Microcracks were observed in the fretting scar of the mixed fretting regime, and the main fretting wear mechanisms were adhesive and fatigue wears. The fretting wear scar was the fatigue source region, and the fatigue fracture surface could be divided into three regions.     

Experimental investigation on sliding and fretting wear of steam generator tube materials

In nuclear power steam generators, high flow rates can induce vibration of the tubes resulting in fretting wear damage due to contacts between the tubes and their supports. In this paper, the sliding and fretting wear tests were performed using Inconel 600HTMA and 690TT against STS 304, which are the steam generator tube materials. The sliding wear tests with a pin-on-disk type tribometer were carried out under various applied loads and sliding speeds at air environment. The fretting wear tests were carried out under various vibrating amplitudes and applied normal loads.

The result of sliding and fretting wear tests show that the heat-treated Inconel 690TT has better wear resistance than Inconel 600HTMA in air. The fretting wear regimes were plotted using the test results and the wear coefficient was calculated also. From the results, it was observed that the wear and tear by stick-slip has very strong effect on the fretting wear behavior.     

Characterization of fretting wear behavior of Cu–Al coating on Ti–6Al–4V substrate

Fretting wear and fretting fatigue are two commonly observed material damages when two contacting bodies with a clamping load are under the oscillatory motion. In this study, fretting wear damage of Cu–Al coating on titanium alloy, Ti–6Al–4V substrate was investigated using the dissipated energy approach. Fretting tests were conducted with either no fatigue load or the maximum fatigue load of 300 MPa and stress ratio of 0.1 on the substrate (specimen). In order to investigate the effect of contact load and contact size, different pad sizes and contact loads were used in the tests. Accumulated dissipated energy versus wear volume data showed a linear relationship regardless of fatigue loading condition on specimen with the smaller pad size. However, two separate linear relationships were observed based on the fatigue loading condition with the larger pad size, such that a relatively more dissipated energy was required for a certain amount of wear with fatigue load on the specimen. The linear relationship between the accumulated dissipated energy and wear volume for both pad sizes extended from partial to gross slip regimes and was not affected by the applied contact load. Further, fretting tests with and without fatigue load resulted in different shapes of fretting loops when the larger pad size was used.     

Progress in fretting maps

In recent years, fretting maps on fretting wear and fretting fatigue conditions proposed by various researchers have been frequently cited in literature. In this paper, four kinds of main fretting maps have been reviewed in detail. Some ambiguity, contradiction, deficiency and common ground have been noted on these maps. The application and further research of the fretting maps has also been noted.     

Fretting wear behaviors of steel wires under friction-increasing grease conditions

Fretting wear tests were performed on the self-made fretting wear rig to investigate fretting wear behaviors of steel wires under friction-increasing grease conditions. The results demonstrated that the fretting regimes were dependent on displacement amplitudes and normal loads. The friction coefficient exhibited different variation trends in different fretting regimes. Friction-increasing grease changed the fretting running behavior and had a very good wear resistance for steel wires. Wear was slight in partial slip regime. Mixed regime was characterized by plastic deformation, fatigue cracks and abrasive wear. Slip regime presented main damage mechanisms of abrasive wear, fatigue wear and oxidation.     

微动疲劳寿命的估算方法研究

着重分析了零构件由于微动磨损而造成的疲劳失效机制 ,说明了在这种微动疲劳模式下疲劳寿命的组成情况 ,用门槛值应力公式估算了当磨蚀坑根部萌生扩展性裂纹时蚀坑的临界深度尺寸 ,并分析了微动裂纹尖端的应力强度因子 ,得出了计算微动裂纹萌生尺寸的表达式 ,最后用上述方法计算了螺纹联接件的微动磨损寿命与裂纹萌生尺寸 ,用局部应力应变法计算了微动裂纹的萌生寿命 ,所得到的估测寿命与试验值相符 ,由此可见 ,该微动疲劳寿命的估测方法是合理的、有效的     

On the fretting wear mechanism of Zr-alloys

Zirconium alloys are highly desirable in nuclear applications due to their transparency to thermal energy neutrons and for their high corrosion resistance. The main objective of this study is to investigate the fretting wear mechanism of Zr–2.5%Nb alloy. The experimental work was carried out in air at 265 °C, using a specially designed fretting wear tribometer. The transfer of material, the change in the wear volume and the maximum wear depth with the number of cycles were measured through 3D mapping of the topography of the fretted surface. SEM and Fourier Transform Infrared Interferometry methods were used to examine the microspall pits and to measure the distribution of the thickness of oxide layer in the fretting region. For relatively small slip amplitude, the results showed that the fretting wear mechanism is initially dominated by adhesion and abrasion actions and then by delamination and surface fatigue. The time variation of the wear losses was shown to be cyclic until a steady state value is reached. At high slip amplitudes, however, abrasion and delamination are the only dominant wear mechanisms. The volumetric wear losses were found to decrease monotonically with the number of cycles. A novel approach was introduced, whereby the thermal and electrical contact resistances of the fretting interface are simultaneously measured. The results demonstrated the potential use of this non-intrusive approach for real-time monitoring of the fretting wear mechanism.     

Fretting fatigue of zinc coated low carbon steel EN H320 M

The object of the present study was to investigate the influence of zinc coatings on steel sheets during fretting fatigue and fatigue tests. The influence of the fatigue stress range, normal pressure and amplitude of slip, on the fracture life was studied for both coated and uncoated EN H320 M steel. The wear produced by fretting was measured and compared with the fracture life evolution for different values of slip amplitude. The wear scars and the fracture surfaces were examined by scanning electron microscopy to identify the degradation mechanism. Although zinc films do not influence the fatigue life of the tested steel, when fretting is superposed on to a fatigue stress the coating markedly improves the fracture life.     

Application of influence function method on the fretting wear of tube-to-plate contact

The structural integrity of steam generators in nuclear power plants is much dependent on the fretting wear characteristics of Inconel 690 U-tubes. The influence function method for the tube-to-plate contact model is demonstrated in this study to investigate the fretting wear problems on the secondary side of the steam generator, which are caused by flow induced vibrations between the U-tubes and supports. Two-dimensional numerical contact model is developed and formulated in terms of the Cauchy singular integral equation. The distributions of normal pressures, shear stresses and displacement fields are derived between two contact bodies which have similar elastic properties. Based on the algorithms for normal pressures and relative slip, a numerical approach is developed to simulate the fretting wear of tube-to-plate contacts. The work rate model is adopted in this study to find the wear amounts between two materials. The results are compared with the solutions by finite element analyses to validate the application of the present method to fretting wear problems.     

Effect of contact pressure on fretting fatigue of austenitic stainless steel

The effect of contact pressure on fretting fatigue in solution-treated austenitic stainless steel was studied. With an increase in contact pressure, fretting fatigue life was almost unchanged at low contact pressures, however it decreased drastically at high contact pressures. At low contact pressures, stress concentration due to fretting damage occurred at the middle portion of the fretted area and the main crack responsible for failure was initiated there. At high contact pressures, concavity was formed at the fretted area without accompanying heavy wear. The main crack was initiated at the outer edge corner of the concavity which probably acted as a notch. Plain fatigue prior to the fretting fatigue test increased the fretting fatigue life at high contact pressures since the concavity formation was suppressed by the cyclic strain hardening.     

Friction and Wear Characteristics Due to Stick-Slip under Fretting Conditions

Friction and wear characteristics between two steel surfaces under fretting conditions are investigated experimentally. The fretting damage caused by low-amplitude oscillatory sliding can be classified into three regimes of gross-slip, mixed-slip, and partial-slip due to the stick-slip phenomenon. One of the most important characteristics of fretting wear is the transition from gross-slip to mixed-slip. Several criteria have been introduced for a quantitative determination of the transition between mixed-slip and gross-slip. However, the transition criteria have some problems in determining the regimes because parameters are difficult to calculate or depend on the system. To introduce new transition criteria in this study, the phase difference between friction force and relative displacement is used to determine the transition and predict the fretting wear. It is found that the phase difference with a range of 0° to 90° can predict the onset of fretting conditions.     

A fatigue endurance criterion in two stages with application to fretting contact

In this paper we propose a fatigue endurance criterion suitable for mechanical components under high stress gradients. It is composed of two stages in order to predict both short and long crack arrest. In the first stage, a non-local multiaxial fatigue criterion measures the potential for crack initiation/short crack arrest. In the second stage, linear elastic fracture mechanics is used to evaluate the possibility of long crack arrest. The predictions of the fatigue criterion are compared with available experimental data obtained with cylinder-flat contacts under partial slip, fretting wear conditions. The results show that the proposed criterion can describe the endurance mechanisms observed in the experimental data.     

Elevated Temperature Evaluation of Fretting and Metal Transfer between Coated Titanium Components

During fretting, small amplitude displacements and high normal surface loads combined with abrasive oxide particles cause surface damage that acts as initiation sites for fatigue cracks. Since these conditions are prevalent within the titanium dovetail joints of jet engines a wear mode analysis was performed on extended service jet engine disks and compressor blades. The results of the wear mode analysis indicated that titanium from the uncoated disk was transferred to the softer copper-nickel-indium coated dovetail surface of the blades. This transfer created titanium on titanium contact and eventually fretting wear. In order to simulate these conditions, a moderate displacement (125 μm), low cycle phase followed by a small displacement (25 μm), high cycle fretting phase utilizing a cylinder on flat configuration was developed. The analysis and test procedure developed during this study will ultimately aid in the selection and evaluation of a new coating capable of preventing fretting.     

Finite element analysis of shot-peening effect on fretting fatigue parameters

Shot peening is widely used to improve the fretting fatigue strength of critical surfaces. Fretting fatigue occurs in contacting parts that are subjected to fluctuating loads and sliding movements at the same time. This paper presents a sequential finite element simulation to investigate the shot peening effects on normal stress, shear stress, bulk stress and slip amplitude, which are considered to be the controlling parameters of fretting damage. The results demonstrated that among the modifications related to shot peening, compressive residual stress has a dominant effect on the fretting parameters.     

Friction behavior of quenched and tempered steel in partial and gross slip conditions in fretting point contact

Tangential traction caused by friction in contacting surfaces is a major factor in fretting fatigue that increases stress levels and leads to a reduction in fatigue life. Friction in fretting contact was studied in partial, mixed and gross slip conditions on quenched and tempered steel. Measurements were made with sphere-on-plane contact geometry for polished and ground surfaces. Friction was evaluated from on-line energy ratio and, after the tests, from wear marks. A maximum friction coefficient of over 1.0 was measured at mixed slip zone with polished surfaces, whereas ground surfaces promote lower values in similar operating conditions. The friction coefficient dependence on load cycles and loading frequency is also presented and briefly discussed. The friction data and understanding thus gained is to be used for evaluation of crack initiation with the numerical fretting fatigue model.     

Effect of shot peening on the fretting wear of Ti–6Al–4V

In this paper, we report on the fretting wear behaviour of polished and shot peened Ti–6Al–4V specimens. For fretting experiments, due to micro-displacements at the interface between two contacting surfaces, two types of damage can be observed: crack initiation and debris formation. Shot peening, which is already well known for improving fatigue resistance of titanium alloys, is shown to have a beneficial effect on the crack initiation and propagation under fretting wear loading, as cracks observed on specimens after cylinder-on-flat fretting tests are shorter in shot peened specimens than in polished ones. It is also demonstrated that shot peening decreases the friction coefficient only at the beginning of the test, as long as the asperities induced by shot peening are not worn-off. The effects of displacement amplitude, normal force and test duration on the wear volume have been investigated: in all cases, shot peening has no significant impact on the wear process. The same amount of debris are formed and ejected for both polished and shot peened specimens. Moreover, it is found that, for both types of specimens, the linear relation, developed for steels and hard coatings, between wear volume and cumulated dissipated energy is not valid in the present case as different wear volumes are measured for the same cumulated dissipated energy, depending on the experimental conditions (normal force, displacement amplitude). Using the test duration as the variable parameter, energy wear coefficients are calculated for different experimental conditions.     

Effect of surface treatments on fretting fatigue damage of biomedical titanium alloys

Fretting fatigue is an adhesive wear damage caused by tangential micromotion under normal force at contact areas. It is observed along the contact points of hip implants and bone plates. Surface-modified biomedical titanium alloys offer better resistance against fretting damage. PVD TiN coatings and plasma nitriding have proved effective in minimizing friction and delaying the failure of materials. In the present study, attempt has been made to explain the fretting fatigue failure mechanism sequence of PVD TiN-coated and plasma-nitrided Ti–6Al–4V and Ti–6Al–4V couple through friction measurement and microscopic examination.