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System Program
Cody Anderson Roozbeh Kiamanesh Lars Ponten
Engineer II Engineer III Aerospace Project
Bell Helicopter Textron Bell Helicopter Textron Engineering Manager
Fort Worth, TX, USA Fort Worth, TX, USA CEROBEAR GmbH
Herzogenrath, Germany
ABSTRACT
Today’s rotorcraft transmissions predominately utilize fully metallic bearings where both the raceways and rolling
elements are metal. Ceramic bearing materials offer the potential for meeting the demand for weight reduction and
increased power-to-weight ratios. Hybrid ceramic bearings incorporate both ceramic and metallic components
forming an assembly that lends itself to improvements in weight, corrosion resistance, reduced friction, and
improved surface characteristics. Typically, hybrid ceramic bearings consist of ceramic rolling elements and
metallic raceways. Hybrid ceramic bearings have demonstrated feasibility for both remotely and non-remotely
monitored applications in rotorcraft drive systems. Characterization of potential material combinations of hybrid
ceramic bearings is needed to guide the design of hybrid ceramic bearings for use in future and modified rotorcraft
transmissions. This research, conducted under the Future Advanced Rotorcraft Drive System (FARDS) program,
examined multiple bearing material combinations and characterized them in fatigue testing. Hybrid ceramic bearing
material combinations showed increased performance when compared to fully metallic bearing material
combinations. Favorable results indicate that hybrid ceramic bearings can have immediate impact on rotorcraft
transmission designs.
TEST APPROACH
As stated earlier, nine different bearing material Figure 2: Test bearings with M50 balls shown at top and
combinations were tested to investigate fatigue life Si3N4 balls shown at bottom.
characteristics of these bearings. Modified hybrid and steel The test plates were manufactured from Si3N4, ZrO2, M50,
thrust ball bearings were utilized as test specimens. The Cronidur 30, X53, and C64. All of the test plates were
cross-section of a modified thrust ball bearing is shown in machined by hard turning, except for Si3N4 and ZrO2 which
Figure 1. The bearing contains two races (counter plate and were ground. The exception was the X53 test plates, which
test plate), a set of rolling elements, and a cage that supports were machined by both hard turning and grinding. The test
the rolling elements. The test plate is a flat housing race with balls were manufactured from M50 and Si3N4. The counter
a small contact area while the counter plate is a shaft race plates were manufactured from Cronidur 30 and the cages
that includes curvature (broad contact area) to ensure that were manufactured from Polyetheretherketone (PEEK),
failure would occur on the test plate rather than the counter which is a high-performance thermoplastic with great
plate. mechanical, thermal, and chemical resistance properties. All
components were processed in accordance with industry
standards.
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Test Setup
To conduct the bearing evaluations, ten test fixtures (shown
in Figure 3) were built and used by CEROBEAR at their
research facility in Herzogenrath, Germany. A test fixture
consists of a test spindle, a drive, sensors, a data acquisition
system, and associated software. The test spindle, drive, and
sensors are located within the translucent enclosure seen to
the left of the computer monitors in Figure 3. Measurement
hardware, a frequency converter, and a switch unit were
contained below the working area of the spindle. Tests were
monitored with a LabView-based software program.
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Table 1: Defined test parameters. generate a meaningful life characteristic for each material
combination. However, due to longer than anticipated run
Description Definition times for some of the specimens, suspension limits and
reduced sample sizes were required to complete the testing
Speed 2575 rpm within the project’s available time.
Acceleration
500 rpm/s
Ramp The baseline configuration consisted of M50 test plates with
λ-ratio >2.5 M50 test balls, a common material combination used in
rotorcraft transmissions. In addition to the hybrid ceramic
Contact Stress 600 ksi
and fully metallic material combinations, fully ceramic
Sampling Rate 6400 Hz material combinations were also tested for further
Failure or Suspension understanding and comparison.
Test Duration
Point
For all of the test plates that spalled, the spall was located in
the middle of the rolling path unless mentioned otherwise.
Test Analysis The form of the spalls on the metallic test plates was typical
for metallic components. Indentations were also observed in
At the completion of testing for each bearing material a majority of the rolling paths. The occurrence of
combination, life data analysis was performed using a 2- indentations appeared to depend on the material fragments
parameter Weibull distribution. This type of analysis is used that broke away from the test plate (after the initiation of
for predicting part life characteristics such as reliability, spalling) and the time required for shutting the test fixture
mean life, and the failure rate. The two different types of life down. Only one test plate that failed (due to spalling) is
data generated during testing were “complete data” and discussed for each of the material combinations tested.
“suspended data”. Complete data consists of tests where the
exact time-to-failure for a particular bearing component was M50 Test Plate and M50 Test Balls
determined in the test. Suspended data consists of tests
where bearing components operated without failure for a Twenty specimens of this material combination were tested,
known time. Each type of data influences the analysis with 20 failures occurring. The time till failure ranged from
differently. 37 hours to 2,164 hours. In Figure 5, an image of the rolling
path of test plate AB057483 before testing is shown. At 56.3
With a 2-parameter Weibull distribution, the scale parameter hours, the same test plate (AB057483) failed due to spalling
(η), also known as the characteristic life, defines the time and the rolling path (after failure) is shown in Figure 6. The
where 63.2% of the samples will have failed. The shape spall is the large, dark indication and to either side of the
parameter (β), also known as the slope, defines the shape of spall are indentations due to fragments of material from the
the distribution. The rate of failure for parts can be spall that were over rolled by the rolling elements.
characterized by use of the shape parameter. Failure rates
that decrease with time will be less than one, while constant
failure rates will be at or near one and failure rates that
increase with time will be greater than one. In addition to the
scale parameter and shape parameter, the basic rating life at
10% was calculated. The “basic rating life at 10%” refers to
the calculated time where 90% of an identical group of parts,
operating under consistent conditions, should reach or
surpass before fatigue damage occurs. The basic rating life
at 10% is typically used for the design of rolling element
bearings.
RESULTS
Since statistical significance increases with sample size, 20
failures for each of the nine material combinations were
originally desired. This would provide enough samples to
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Spall
Discoloration
Indentations
Figure 6: Spalling on M50 test plate AB057483 after Figure 8: Spalling on Cronidur 30 test plate AB056094
testing with M50 test balls (100x magnification). after testing with Si3N4 test balls (100x magnification).
All of the life data points were within the confidence All of the life data points were within the confidence
bounds. The primary failure mode was assumed to be fatigue bounds. In comparing to the baseline configuration basic
wear, based on its shape parameter of 1.13. With the rating life at 10%, an improvement of at least a factor of two
exception of the C64 test plate and Si3N4 test balls material was observed. The primary failure mode was assumed to be
combination, the lowest basic life rating at 10% was with the fatigue wear as the shape parameter was greater than 1.
M50 test plate and M50 test balls material combination at
90.5 hours. M50 Test Plate and Si3N4 Test Balls
Twenty specimens for this material combination were tested,
Cronidur 30 Test Plate and Si3N4 Test Balls with 20 failures occurring. The time till failure ranged from
Twenty specimens for this material combination were tested, 155.7 hours to 3,391.8 hours. In Figure 9, an image of the
with 19 failures and one suspension (occurring at 5,276 rolling path of test plate AB057505 before testing is shown.
hours). Due to the high test time and limited test capacity, At 592.4 hours, the test plate failed due to spalling and the
one test was suspended. The time till failure ranged from rolling path (after failure) is shown in Figure 10.
168.6 hours to 3,343.6 hours. In Figure 7, an image of the
rolling path of test plate AB056094 before testing is shown.
At 1,908.7 hours, the test plate failed due to spalling and the
rolling path (after failure) is shown in Figure 8.
Discoloration in the rolling path can be seen, which is
attributed to the interaction between the contacting materials
and the lubricant.
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Initial Spall
Figure 10: Spalling on M50 test plate AB057505 after Figure 12: Spalling on ZrO2 test plate AB002273 after
testing with Si3N4 test balls (100x magnification). testing with Si3N4 test balls (100x magnification).
All of the life data points were within the confidence All of the life data points were within the confidence bounds
bounds, except for two on the upper bound. In comparing to except for one that was outside of the upper bound. With a
the baseline configuration basic rating life at 10%, an high shape parameter (2.75), it is probable that the ZrO2
improvement of about a factor of two was observed due only material is near its wear out life at the given test conditions.
to changing the material of the test balls from M50 to Si3N4.
With a shape parameter greater than one, the primary failure Si3N4 Test Plate and Si3N4 Test Balls
mode was assumed to be fatigue wear.
Thirteen specimens for this material combination were
ZrO2 Test Plate and Si3N4 Test Balls tested, with three failures and ten suspensions occurring.
Due to high test times and limited test capacity, a 3,000-hour
Twenty specimens for this material combination were tested, suspension point was implemented. When the suspension
with 20 failures occurring. The time till failure ranged from point was implemented, two tests had exceeded 6,000 hours
149 hours to 1,008.7 hours. In Figure 11, an image of the without failure. The time till failure ranged from 1,116.5
rolling path of test plate AB002273 before testing is shown. hours to 2,500.7 hours. In Figure 13, an image of the rolling
At 434.4 hours, the test plate failed due to spalling and the path of test plate AB0042782 before testing is shown. At
rolling path (after failure) is shown in Figure 12. The 1,116.5 hours, the test plate failed due to spalling and the
extension of damage from the initial spall in the rolling path rolling path (after failure) is shown in Figure 14. The spall
extended significantly in the circumferential direction. The was similar in shape to that observed on the metallic test
extension was dependent upon the time between plates. Unlike the metallic test plates, no indentations in the
identification of the spall and shut down of the test fixture. roller path were observed which is likely due to the higher
The pattern of wear in the roller path was highly visible. hardness of Si3N4
Figure 11: ZrO2 test plate AB002273 before testing with Figure 13: Si3N4 test plate AB0042782 before testing with
Si3N4 test balls (100x magnification). Si3N4 test balls (100x magnification).
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Figure 14: Spalling on Si3N4 test plate AB0042782 after Figure 16: Spalling on X53 test plate AE003731 after
testing with Si3N4 test balls (100x magnification). testing with Si3N4 test balls (100x magnification).
With only three failures, direct comparison with the other The shape parameter (1.08) indicates that the rate of failure
material combinations was difficult, but the suspended data was nearly constant as it was very close to one. All of the
supports significant performance improvement over the complete life data points were within the confidence bounds.
other material combinations tested.
X53 Ground Test Plate and Si3N4 Test Balls
X53 Test Plate and Si3N4 Test Balls
Eleven specimens of this material combination were tested,
Thirteen specimens of this material combination were tested, with five failures and six suspensions occurring. For the six
with eleven failures and two suspensions at 6,524.2 hours suspended tests, excessive test run times (without failure),
and 4,564.9 hours occurring. Due to limited test time, the resulted in ending the tests with maximum test run time at
final two tests were required to be suspended prior to failure. 9,483.3 hours. For the five failures, the time till failure
The time till failure ranged from 322.2 hours to 7,538.2 ranged from 72.1 hours to 7,367.4 hours. Figure 17 shows
hours. Figure 15 shows, the rolling path of test plate the rolling path of test plate AE021739 before testing. At
AE003731 before testing. At 914.3 hours, the test plate 7,367.4 hours, the test plate failed due to spalling and the
failed due to spalling. The rolling path (after failure) is rolling path (after failure) is shown in Figure 18.
shown in Figure 16. Plate indentations (from spall debris Discoloration in the rolling path can be seen.
being over rolled by the rolling elements) were barely
identifiable.
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Figure 18: Spalling on X53 ground test plate AE021739 Figure 20: Spalling on X53 test plate AE003713 after
after testing with Si3N4 test balls (100x magnification). testing with M50 test balls (100x magnification).
The shape parameter (0.83) was largely influenced by one With only two failures, direct comparison with the other
very early failure. All of the complete life data points were material combinations was not possible.
within the confidence bounds. In comparison to test plates of
similar material combination that were hard turned, the C64 Test Plate and Si3N4 Test Balls
ground test plates were found to be more reliable over time.
Twelve specimens of this material combination were tested,
This observation is contrary to other research findings and
with 12 failures occurring. The time till failure ranged from
field experience (Reference 4). Further testing is required to
28.9 hours to 891.8 hours. Figure 21 shows the rolling path
understand why this was so.
of test plate AE051987 before testing. At 475.6 hours, the
test plate failed due to spalling and the rolling path (after
X53 Test Plate and M50 Test Balls
failure) is shown in Figure 22. Overall, the C64 test plates
Eight specimens of this material combination were tested, with Si3N4 test balls performed below expectations. In trying
with two failures at 512.2 hours and 596.8 hours and six to identify any indicators of the low test plate performance,
suspensions. Due to the limited test time available, the final evaluations of the microstructure, hardness profile, and
six tests were suspended prior to failure with the maximum residual stress profile were performed by CEROBEAR. No
time at suspension being 4,511.7 hours. In Figure 19, an clear conclusions were able to be drawn from the
image of the rolling path of test plate AE003713 before evaluations. Further, no anomalies with the test fixtures or
testing is shown. At 512.2 hours, the test plate failed due to test procedure were identified. Therefore, additional
spalling and the rolling path (after failure) is shown in evaluations and testing are required to better understand the
Figure 20. Based on the appearance of the spall, the rate of performance of C64 test plates with Si3N4 test balls.
spall growth was greater than the other metallic test plates.
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In comparison to the other material combinations, C64 test
plates with Si3N4 test balls were at the low end for scale
parameter and basic life rating at 10%. All of the life data
points were within the confidence bounds.
Table 2: Summary of life data analysis for all tested bearing material combinations.
Basic Rating
Material Combination Scale Parameter, η
Failures Suspensions Shape Parameter, β Life at 10%
(Test Plate / Test Balls) (hours)
(hours)
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Author contact:
Cody Anderson canderson01@bh.com
Roozbeh Kiamanesh rkiamanesh@bh.com
Lars Ponten Lars.Ponten@cerobear.de
Jason Fetty ADD_TA_Drives@amrdec.army.mil
Treven Baker ADD_TA_Drives@amrdec.army.mil
ACKNOWLEDGMENTS
The work discussed in this paper was performed under the
Future Advanced Rotorcraft Drive System (FARDS)
program. The FARDS program is a cooperative agreement
between the Aviation Development Directorate (ADD) and
Bell Helicopter Textron. Project support for the hybrid
ceramic bearing task was provided by CEROBEAR GmbH.
The views and conclusions contained in this document are
those of the authors and should not be interpreted as
representing the official policies, either expressed or implied
of the Aviation Development Directorate or the U.S.
Government.
REFERENCES
1
Jackson, M.K., “Evaluation Testing of Ceramic Hybrid
Bearings For Helicopter Hanger Bearing Applications,”
Proceedings of the American Helicopter Society 62 nd Annual
Forum, Pheonix, AZ, May 2006
2
Chavez, A., Fetty, J., and Gerardi, J., “Non-Metallic
Debris Monitor For a Helicopter Transmission,”
Proceedings of the American Helicopter Society 70 th Annual
Forum, Montréal, Québec, Canada, May 2014.
3
Kozachyn, M., Bednar, J., Naffin, R., and Robuck, M.,
“Seeded Fault Testing of Hybrid Bearings in a Rotorcraft
Transmission,” Proceedings of the American Helicopter
Society 71st Annual Forum, West Palm Beach, FL, May
2016.
4
Jacobson, M., Gunnberg, F., “Effects of hard turning on
the fatigue life of ball bearings,” Proceedings of the
Institution of Mechanical Engineers, Part B: Journal of
Engineering Manufacture, Vol. 218, (12), December 2004.
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