Service Loading of Rolling Bearings in Wind Turbine Gearboxes: X-ray Diffraction Material Response Analysis of White Etching Crack Premature Failures

Rolling bearings in wind turbine gearboxes occasionally fail prematurely due to white etching cracks. The appearance of preparatively opened fracture faces indicates damage initiation from the surface in most cases due to brittle spontaneous tensile stress–induced cracking. Under the influence of decomposition products of the penetrating lubricant, branching crack growth is subsequently driven by corrosion fatigue. The material response analysis of rolling bearings from all gearbox locations, based on X-ray diffraction residual stress measurements, reveals vibrations in service as the root cause of surface crack initiation. The occurrence of high local friction coefficients in the rolling contact is described by a tribological model. Depth profiles of the equivalent shear and normal stresses are respectively compared with the measured residual stress patterns and a relevant fracture strength. White etching crack failures are experimentally reproduced on a rolling contact fatigue test rig under increased mixed friction. Causative vibration loading is evident from material response analysis. The generation of compressive residual stresses by cold-working the surface is proven to be an effective countermeasure.