SK HWT 08 Fretting Ss08

Hhere Werkstofftechnik: Tribologie
Fretting and Fretting Fatigue
Werkstofftechnik Materials Science & Engineering
Fretting Wear and Fretting Fatigue
We would expect all four major wear mechanisms! SF-TCR-AB-AD
Fretting and Fretting Fatigue 1 www.uni-due.de/wt
Universitt Duisburg-Essen Lotharstr 1, 47057 Duisburg, Germany
Werkstofftechnik Materials Science & Engineering Apperance of Fretting on a 12% Cr-Steel; predominantly by surface fatigue
Apperance of Fretting on IN718 at 500C and 100 Hz. Predominantly severe tribochemical reactions
Fretting Wear
from Sulzer Innotec, Switzerland Fretting and Fretting Fatigue 2 www.uni-due.de/wt
from MPA Stuttgart, Germany Universitt Duisburg-Essen Lotharstr 1, 47057 Duisburg, Germany
The dovetails of turbine blades are subjected to fretting; predominantly by surface fatigue
shaft/hub coupling after fretting test
shaft coupling fretting failure washers/disc and bolts/discs
Area of Slip
from Hartmann, PhD Thesis TU Berlin 2005 Fretting and Fretting Fatigue 3 www.uni-due.de/wt
from Falk Corp.. Wilwaukee, WI, USA 2004 Universitt Duisburg-Essen Lotharstr 1, 47057 Duisburg, Germany
Fretting cyclic tangential force (surface)
Fretting Fatigue cyclic normal force (bulk) + cyclic tangential force (surface)
from Venkatesh et al. 2001
from Alfredson et al. 2004
Fretting Wear: The Elastic Hertz-Mindlin* Approach size of contact area: a
a=
3(1 )FNR 2E
distribution of normal pressure: p(r)
p(r ) =
3FN r 1 2a a
distribution of shear traction under small cyclic tangential force FT leading to microslip corona: (r)
(r) =
FT 2a a r
*R.D.Mindlin et al. Trans. ASME Ser. E, J.Appl.Mech. 20 (1953) 327-344 compiled in M.Kalin; Fretting Wear Mechanisms in Contact of Steel and Silicon Nitride Ceramics. Ph.D.Thesis, University of Ljubljana, Slovenia, 1999 Fretting and Fretting Fatigue Universitt Duisburg-Essen 5 www.uni-due.de/wt Lotharstr 1, 47057 Duisburg, Germany
Fretting Wear: The Elastic Hertz-Mindlin* Approach Now for but Thus for
(r ) r=a (r ) p(r) r = a a
for static friction slip occurs
a= a 3 1
FT FN
Fretting Wear: The Elastic Hertz-Mindlin* Approach Surface traction within the slip corona or annulus for a r a
(r ) =
3FN r 1 2a a
Surface traction within the stick zone for r a
(r ) =
r r a 3FN 1 1 a a a 2a
Transition: Stick Partial Slip Influence of the applied tangential force FT
a= a 3 1
FT FN
Stick: a= a if FT very small or FN very big
Partial slip: 0 < a< a if 0 < FT < FN

FN=const, FT increasing
R.D.Mindlin et al. Trans. ASME Ser. E, J.Appl.Mech. 20 (1953) 327-344 K.C.Johnson, Contact Mechanics (1992) Fretting and Fretting Fatigue Universitt Duisburg-Essen 8 www.uni-due.de/wt Lotharstr 1, 47057 Duisburg, Germany
Transition: Stick Partial Slip Gross Slip Influence of the applied tangential force FT
a= a 3 1
FT FN
Stick: a= a if FT very small or FN very big
Partial slip: 0 < a< a if 0 < FT < FN
Gross slip: a= 0 if FT=FN
Fretting Wear Displacement: The Elastic Hertz-Mindlin* Approach The elastic deformation of ball and flat results in tangential displacement
with
2 2 FT 3k 3 FN 3 1 1 = 2 ER FN
k=
(1 + )(2 ) 3
2
2 3(1 )
Displacement: Stick -
Partial Slip -
Gross Slip
PS
2 2 FT 3k 3 FN 3 = 1 1 2 ER FN mit FT=FN
PS GS =
3 F ER N
kFT
*M.dfalk et al. Wear 157 (1992) 435-444 Fretting and Fretting Fatigue 11 www.uni-due.de/wt Universitt Duisburg-Essen Lotharstr 1, 47057 Duisburg, Germany
Displacement: Stick e
Partial Slip e
Gross Slip
Now = e + S
e = reversible part S = irreversible part, slip
While
e =
with
FT
ke
3 F ER N
FT = , FT , FT max = 1
( )
*M.dfalk et al. Wear 157 (1992) 435-444 K.L.Johnson, Contact Mechanics, Cambridge University Press (1985) Fretting and Fretting Fatigue Universitt Duisburg-Essen 12 www.uni-due.de/wt Lotharstr 1, 47057 Duisburg, Germany
ke =
Partial Slip: reversibel and irreversible displacements vs. time , e, and S are not in-phase
Energy lost E =
2 36FN
ke
*M.dfalk et al. Wear 157 (1992) 435-444 K.L.Johnson, Contact Mechanics, Cambridge University Press (1985) Fretting and Fretting Fatigue Universitt Duisburg-Essen 13 www.uni-due.de/wt Lotharstr 1, 47057 Duisburg, Germany
FT 1 1 max FN
3 5FT max 6FN
FT 1 1 max FN
2 3
Fretting Wear: Elastic-Plastic Hertz-Mindlin-Vingsbo Approach If the plastic deformation of asperities is regarded, the contact zone has an yielding annulus within which the asperities are deformed but not fractured. The stick as well as the slip zone still follow the elastic Mindlin approach.
*O.Vingsbo et al. Wear, 126 (1988) 131-147 Fretting and Fretting Fatigue 14 www.uni-due.de/wt Universitt Duisburg-Essen Lotharstr 1, 47057 Duisburg, Germany
Fretting Wear: Elastic-Plastic Hertz-Mindlin-Vingsbo Approach Elastic stick Elastic partial slip plastic displacement
Full FT- cycle
* M.dfalk et al. Wear 157 (1992) 435-444 Fretting and Fretting Fatigue 15 www.uni-due.de/wt Universitt Duisburg-Essen Lotharstr 1, 47057 Duisburg, Germany
Fretting Wear: Regimes and Problems Dissipated Energy Ed is transformed into crack initiation and propagation (partial slip) and wear (gross slip); can be described by the accumulated dissipated energy
Wear follows the accumulated dissipated energy, while crack initiation does not
*Fouvry et al. Wear 255 (2003) 287-298 Fretting and Fretting Fatigue 16 www.uni-due.de/wt Universitt Duisburg-Essen Lotharstr 1, 47057 Duisburg, Germany
Fretting Wear: Wear Rate vs. Displacement
crack initiation wear loss
<a
>a
Vingsbo et al. Wear 126 (1988) 131-147 Fouvry et al. Wear 203-204 (1997) 393-403 Fretting and Fretting Fatigue Universitt Duisburg-Essen 17 www.uni-due.de/wt Lotharstr 1, 47057 Duisburg, Germany
Fretting Wear: Partial Slip Gross Slip Fretting Map FT- curves are significantly different for both regimes
FT
FT
Fouvry et al. Wear 200 (1996) 186-205 Fretting and Fretting Fatigue 18 www.uni-due.de/wt Universitt Duisburg-Essen Lotharstr 1, 47057 Duisburg, Germany
Fretting Wear: Partial Slip Gross Slip FT- curves are significantly different for both regimes but during cycles one may change from one regime (gross slip) to another (partial slip) e.g. because of crack initiation under the contact zone
Fretting Wear Regimes Thus, between partial slip and gross slip a mixed slip regime has to be introduced. These regimes can be distinguished as to certain system dependant and system independant variables
10
Fretting Wear Regimes: Definitions Ed = energy during one cycle Et = total energy during one cycle Energy Ratio Criterion A A = Ed/Et if A < 0,2; then partial slip
FT- curve Et
Ed
Fretting Wear Regimes: Definitions = max. displacement amplitude 0 = displacement amplitude at FT = 0 (aperture) Aperture Ratio Criterion B B = 0/ if B < 0,26; then partial slip
FT- curve 20
11
Fretting Wear Regimes: Definitions Ed = energy during one cycle E0 = energy during one cycle corresponding to the area of a parallelogram in which the loop is located System Free Ratio C C = Ed/E0 if C < 0,77; then partial slip E0
FT- curve
Ed
Fretting Wear Regimes: Definitions Alternatively the normal force FNt or the displacement t at transition PSGRS could be calculated according to
3R FN = t 4Ek1
2 2 1 1 1 1 2 = + E E1 E2
*Fouvry et al. Wear 200 (1996) 186-205 Fretting and Fretting Fatigue 24 www.uni-due.de/wt
3 2
1 2
t = FN 3k1 3R
k1 =
1 4E 3
3 2 1 2 2 + G 16 1 G2
= static friction, Ei = Youngs Moduli, Gi = shear moduli, i = Poissons ratios

12
Fretting Wear: Route to solve Problems
Fretting Wear: Gross Slip Regime Wear Mechanisms
accumulated dissipated energy Ed
E = E
d 1
(i )
energy friction coefficient e

e =
Ed 4 FN g
e =
1 N
4F
1
Ed (i ) N (i ) g (i )
*Fouvry et al. Wear 200 (1996) 186-205, Liskiewicz et al. Tribology Int 38 (2005) 69-79 Fretting and Fretting Fatigue 26 www.uni-due.de/wt Universitt Duisburg-Essen Lotharstr 1, 47057 Duisburg, Germany
13
Fretting Wear: Gross Slip Regime Wear volume follows the accumulated dissipated energy
WGRS Ed
+ contact area
dissipated energy density Edh
*Fouvry et al. Wear 200 (1996) 186-205, Varenberg et al. Wear 252 (2002) 902-910, Liskiewicz et al. Tribology Int 38 (2005) 69-79 Fretting and Fretting Fatigue Universitt Duisburg-Essen 27 www.uni-due.de/wt Lotharstr 1, 47057 Duisburg, Germany
Fretting Wear: Gross Slip Regime dissipated energy density governs the life time
*Fouvry et al. Wear 200 (1996) 186-205, Liskiewicz et al. Tribology Int 38 (2005) 69-79 Fretting and Fretting Fatigue 28 www.uni-due.de/wt Universitt Duisburg-Essen Lotharstr 1, 47057 Duisburg, Germany
14
Fretting Wear: Gross Slip Regime

N Wear volume follows the accumulated dissipated energy E = E (i) d d i =1 for large amplitudes
sliding tangential force
E FT = s FN = d 4D
with D = 0
E d = (4FTi Di )
i =1
Fretting Wear: Gross Slip Regime Wear volume follows the accumulated dissipated energy
WGRS Ed
+ contact area
dissipated energy density Edh is constant and known!

*Fouvry et al. Wear 200 (1996) 186-205, Varenberg et al. Wear 252 (2002) 902-910, Liskiewicz et al. Tribology Int 38 (2005) 69-79 Fretting and Fretting Fatigue Universitt Duisburg-Essen 30 www.uni-due.de/wt Lotharstr 1, 47057 Duisburg, Germany
15
Fretting Wear: Gross Slip Regime Pressure and shear stress field for a full sliding sphere thus, any local dissipated energy analysis has to regard 1. local FT~(p(x,y) and FN~(q(x,y)) 2. transition to reciprocating sliding wear
E d (X, Y) = q 0a 1 Y X dX
X e
X+e
e=
D 0 = a a
Wear: Gross Slip Surface distribution Ed(X,Y) for e=0.5
Reciprocating Sliding Surface distribution Ed (X,Y), e=1.5
16
Fretting Wear: Gross Slip Regime Distribution in axial X, Y=0 and lateral X=0, Y direction differs X+e
E d (X, Y) = q 0a 1 Y X dX
X e
E dA = E d (X, Y = 0)dX
E dA = 2a q 0e = 2aq 0 D
independent of e
E dL = E d (X = 0, Y )dX 2a q 0 for e < 1 E GRS = (3e e) dL 3

RS 4a q 0 for e 1 E dL = 3
Fretting Wear: Gross Slip Regime
E d (X, Y) = q 0a 1 Y X dX
X e
X+e
Evolution of the principal energy variable for one alternated cycle
17
Fretting Wear: Gross Slip Regime Shape of wear scar Contour for q0 and p0
acumulation of third bodies
Fretting Wear: Partial Slip Regime Application of Dang Vans theory of multaxial fatigue to contact problems Estimation of a local cyclic failure criterion dc from local hydrostatic pressure p (x,y,z,t) [=m or h] and macroscopic rotating bending stress D and shear stress D endurance limits:
d(t) =
( y , x , z, t) p( x , y , z, t)
= D =
D 3
D 2
if d > 1 initiation of fatigue crack likely

18
Fretting Wear: Partial Slip Regime The maximum of d(x,y,z,t) has to be estimated according to Fouvry et al.
d is biggest at the edge of the contact zone within the surface x=a, z=y=0
*Fouvry et al. Wear 200 (1996) 186-205, Wear 195 (1996) 21-34, Tribotest J 3-1 (1996) 23-44 Fretting and Fretting Fatigue 37 www.uni-due.de/wt Universitt Duisburg-Essen Lotharstr 1, 47057 Duisburg, Germany
Fretting Wear: Partial Slip Regime Procedure1: - normal pressure from Hertzian theory - partial slip tangential stress loading by Cattaneo and Midlin - is independant of x, y and t - combined isotropic and kinematic hardening4 - computing according to Hamilton5
1Fouvry et al. Wear 195 (1996) 12-34, Cattaneo Rendiconto dellccademia dei lincei 6, 27 (1938) 343-348; 434-436; 474-478, Midlin et al. Trans ASME, J Appl Mech 20 (1953) 327-344, 4Dang Van ASTM Stp. 1191, ASTM Philadelphia, PA (1993) 120-130, 5Hamilton Proc Inst Mech Eng, 197C (1983) 53-59 Fretting and Fretting Fatigue Universitt Duisburg-Essen 38 www.uni-due.de/wt Lotharstr 1, 47057 Duisburg, Germany
19
Schematic Fretting Wear Map with Dang Van Criterion:

Flat: mild steel Ball: 52100 R=50 mm =0.8 (106 cycles) D=660 MPa D=410 MPa Rp=1050 MPa
EXT = external stress from fretting fatigue p0fl = limit fatigue Hertzian pressure
Fouvry et al. 195 (1996) 21-34 Fretting and Fretting Fatigue 39 www.uni-due.de/wt Universitt Duisburg-Essen Lotharstr 1, 47057 Duisburg, Germany
Measured Fretting Wear Map with Dang Van Criterion:
20
Proposed Pressure Crack Nucelation Map for Partial Slip Fretting Wear Regimes
Y = Rp e,max calculated from measured values during fretting tests
Proposed Pressure Crack Nucelation Map for Partial Slip Fretting Wear Regimes
Flat: mild steel Ball: 52100 R=50 mm =0.8 (106 cycles) D=660 MPa D=410 MPa Rp=1050 MPa
21
Notice: - Tribosystems must be definded precisely as to Partial Slip Gross Slip by ABC or other suitable criteria - Gross Slip: Accumulated Dissipated Energy governs wear and, therefore, endurance - Partial Slip: Stress distribution over coordinates and time together with gross bending and torsion fatigue properties govern crack nucleation and propagation and, therefore, endurance. - In a first rough approximation Haigh diagrams and principal stress investigation according to Chivers et al.1 might work as well.
1Chivers
et al. Proc Inst Mech Eng 199 (1985) 283-301 Universitt Duisburg-Essen Lotharstr 1, 47057 Duisburg, Germany
Fretting Fatigue
We would expect all four major wear mechanisms! SF-TCR-AB-AD
22
Fretting Fatigue:
from Venkatesh et al. 2001 from Vallellano et al. 2004
from Alfredson et al. 2004 from Vallellano et al. 2004 Fretting and Fretting Fatigue 45 www.uni-due.de/wt Universitt Duisburg-Essen Lotharstr 1, 47057 Duisburg, Germany

from Kimura et al. 2003
Fretting Fatigue Fretting fatigue brings about very small strokes. This leads to a fretting contact within the partial slip or even stick regime
distribution of internal loads fatigue
Thus, the highest tensile stresses appear at the rim of the stick zone leading to crack initiation and propagation
distribution of external loads fretting
Fretting and Fretting Fatigue 46 www.uni-due.de/wt Universitt Duisburg-Essen Lotharstr 1, 47057 Duisburg, Germany
23
Fretting Fatigue The superposition of internal and external loads brings about a distinct loss of endurance
from Neuner, PhD Thesis, TU ErlangenNuremberg, Germany 2005
-96% -20% Notice: The endurance is not limited by wear but by fatigue properties! Earlier crack initation!
~AISI 1055 (EN Ck53) + pressure 12.5 MPa + pressure 25 MPa
Fretting Fatigue Fretting fatigue is treated according to the crack analogy methodology, because of the similarities of the stress fields with from Naboulsi 2005 fracture mechanics Notice: The loading situation depends on adhesion!
weak adhesion
strong adhesion
crack
24
Fretting Fatigue: under a given load Fmax the maximum contact radius between e.g. a cylinder and flat is given by
3D(1 2 ) amax = 3 FN ,max 4E
for weak adhesion
Ginnakopoulos et al. Acta Mater 46 1998
3D (1 2 ) 3Dwad 3Dwad F + + 3Dwad FN ,max + amax = 3 N ,max 4E 2 2

for strong adhesion
Barquins et al. J Mech Theor Appl 1 (1982)
D = diameter of the cylinder wad = work of adhesion ~ 1 N/m

Semenchenko, Addison-Wesley (1962) Fretting and Fretting Fatigue 49 www.uni-due.de/wt Universitt Duisburg-Essen Lotharstr 1, 47057 Duisburg, Germany
Fretting Fatigue: Due to this similarity of stress fields a fretting contact can be described by means of LEFM The normal load FN, wich is not constant but oscillatory and > 0, brings about a stress field described by KI The tangential load FT, wich is not constant but oscillatory and > 0, brings about a stress field described by KII
KI =
FN ,max
amax
K II =
FT ,max
amax
25
Fretting Fatigue: For e.g. strong adhesion and weak adhesion one can calculate amax and amin from measured FNmax and FNmin as well as the R-values:
RN =
FN ,min FN ,max
RT =
FT ,min FT ,max
FN ,max ( amin amax R N ) K I = amax amin K II = FT ,max ( amin amax RT )
amax amin
Fretting Fatigue: For the bulk material, which is loaded with the oscillatory fatigue stress amplitude a in the tangential direction of the contact one gets:
K bulk =
II
a Ec 2r Ebd (c + d )
with E = Youngs-Modulus r = polar coordinat along contact area 2b = thickness of substrate c = width of contact body d = width of substrate
then
2 2 2 K total = K I + K II + K II
Bulk
26
Fretting Fatigue: (from Naboulsi, Eng.Frac.Mech. 72 (2005)) Ktotal characterizes crack initiation of fretting fatigue. It depends on loading and geometry. If one does not consider the bulk fatigue stress one can express Ktotal by a CAF-factor Notice: CAF is (crack-analogy-fretting) which is a normalized to measure for the damage 6) CAF(Nf=10 tolerance of the system. With increasing CAF the number of cycles to failure Nf decrease. Knowing CAF vs. Nf for one configuration one can recalculate for other configurations for the strong adhesion case (= stick regime).
Fretting and Fretting Fatigue 53 www.uni-due.de/wt Universitt Duisburg-Essen Lotharstr 1, 47057 Duisburg, Germany
27

SK HWT 08 Fretting Ss08

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Hhere Werkstofftechnik: Tribologie

Fretting and Fretting Fatigue

Werkstofftechnik Materials Science & Engineering

Fretting Wear and Fretting Fatigue

We would expect all four major wear mechanisms! SF-TCR-AB-AD

Fretting and Fretting Fatigue 1 www.uni-due.de/wt

Universitt Duisburg-Essen Lotharstr 1, 47057 Duisburg, Germany

from Sulzer Innotec, Switzerland Fretting and Fretting Fatigue 2 www.uni-due.de/wt

Hhere Werkstofftechnik: Tribologie

Fretting and Fretting Fatigue

Werkstofftechnik Materials Science & Engineering

shaft/hub coupling after fretting test

shaft coupling fretting failure washers/disc and bolts/discs

Werkstofftechnik Materials Science & Engineering

Fretting cyclic tangential force (surface)

from Alfredson et al. 2004

Fretting and Fretting Fatigue 4 www.uni-due.de/wt

Universitt Duisburg-Essen Lotharstr 1, 47057 Duisburg, Germany

Hhere Werkstofftechnik: Tribologie

Fretting and Fretting Fatigue

Werkstofftechnik Materials Science & Engineering

Fretting Wear: The Elastic Hertz-Mindlin* Approach size of contact area: a

distribution of normal pressure: p(r)

Werkstofftechnik Materials Science & Engineering

Hhere Werkstofftechnik: Tribologie

Fretting and Fretting Fatigue

Werkstofftechnik Materials Science & Engineering

Surface traction within the stick zone for r a

Werkstofftechnik Materials Science & Engineering

Transition: Stick Partial Slip Influence of the applied tangential force FT

Stick: a= a if FT very small or FN very big

Partial slip: 0 < a< a if 0 < FT < FN

Hhere Werkstofftechnik: Tribologie

Fretting and Fretting Fatigue

Werkstofftechnik Materials Science & Engineering

Stick: a= a if FT very small or FN very big

Partial slip: 0 < a< a if 0 < FT < FN

Gross slip: a= 0 if FT=FN

Werkstofftechnik Materials Science & Engineering

Hhere Werkstofftechnik: Tribologie

Fretting and Fretting Fatigue

Werkstofftechnik Materials Science & Engineering

Werkstofftechnik Materials Science & Engineering

Hhere Werkstofftechnik: Tribologie

Fretting and Fretting Fatigue

Werkstofftechnik Materials Science & Engineering

3 5FT max 6FN

Werkstofftechnik Materials Science & Engineering

Hhere Werkstofftechnik: Tribologie

Fretting and Fretting Fatigue

Werkstofftechnik Materials Science & Engineering

Full FT- cycle

Werkstofftechnik Materials Science & Engineering

Hhere Werkstofftechnik: Tribologie

Fretting and Fretting Fatigue

Werkstofftechnik Materials Science & Engineering

Fretting Wear: Wear Rate vs. Displacement

crack initiation wear loss

Werkstofftechnik Materials Science & Engineering

Hhere Werkstofftechnik: Tribologie

Fretting and Fretting Fatigue

Werkstofftechnik Materials Science & Engineering