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, A.B. Vannes
IFoS lab, STMS Dept, Ecole Centrale de Lyon, 69134 Ecully Cedex, France
Received 22 October 2002; accepted 30 March 2003
An impact test with energy control has been developed to study the degradation phenomena generally encountered on materials
submitted to complex conditions including impacts, for example during erosion. The test permits the material response to single or
multiple impacts at a microscopic and a macroscopic scale to be characterized. The energy of each impact is precisely controlled
and may reach a value of 100 mJ per impact. Experiments have shown that the dynamic loading duration is very short, typically
between 100 and 200 js, and deformation speeds on the impacted metals are in the order of magnitude of 10
3
s
1
. Indenters of
various tip radii have been used and a large range of impacting conditions tested. The high reproducibility of the tests conrms that
it permits the simulation of damage phenomena already identied in metallic substrates submitted to erosion wear induced by hard
particle impacts.
KEY WORDS: impact, dynamic indentation, erosion, tribologically transformed surface
1. Introduction
In service, mechanical parts are generally subjected to
complex conditions generally including several compo-
nents such as sliding, rolling or impact that may lead to
surface damage. While sliding and rolling conditions are
quite commonly reproduced on standard friction rigs,
only a few impact simulators exist [1]. Moreover, these
testers usually tend to reproduce erosion or grinding,
which means that they are designed to perform a large
number of impacts at high frequency. In the case of
erosion, for example, sand-blasting apparatus is gen-
erally used and allows the material weight loss to be
determined as a function of the mass of the projected
sand, the geometry of this sand, the impinging velocity
and the angle of incidence between the sand ow and the
target surface [2,3]. If these data are used in the
aeronautical eld to estimate the endurance life of
components subjected to sand erosion, they do not give
any information about the damage origin and evolution.
These impact testers are generally hardly able to isolate
a single impact [46] or to generate only few tens of
impacts of given energy at the same place [710]. This is,
however, necessary, if one wants to better understand
the material response to an impact event and to identify
the elementary mechanisms responsible for the surface
degradation. Understanding the damage initiation and
evolution is the only viable way to design a long term
anti-erosion solution. A test designed to perform a single
or xed number of impacts of controlled energy was
therefore needed. The objective of our work was to
develop and validate an apparatus able to perform such
a test. This paper reports on this machine and the
adopted testing procedures.
2. Concept
For a realistic evaluation of the erosion resistance of
materials, the impact test conditions should simulate the
same damage mechanisms as those observed on eroded
or abraded pieces. To bring about a real improvement
compared to classical erosion or abrasion rigs, it should
offer new insights into the failure initiation. The issue is
then to control the exact number of impacts performed
on a surface as well as the energy and location of each
shock. The objectives that should be achieved using the
new impact tester we have developed are
. possibility of performing single impact tests,
. feasibility of multi-impact tests at the same place
. possibility of controlling double impact tests to study
the interaction between two impacts as a function of
the separating distance.
In terms of targeted characteristics, the new tester
should ensure:
. a control of the kinetic energy of each impact, Ec
. a control of the number of impacts, N
. a control of the impact location to produce a given
distance d between two impacts or to ensure two
impacts to superimposed.
R
2
a
2
r
q
11
where R is the indenter radius.
This leads to a cumulated energy per impact of
E
i
3o
y
R
3
2
3
a
i
R
2
1
a
i
R
2
r
2
3
1
a
i
R
2
" #
. 12
4. First results and discussion
The macro/micro impact test presented in this paper
enables single or multi impact tests to be performed at a
controlled energy. It has been used to reproduce the
damaging mechanisms encountered in many real tribo-
logical conditions that lead to plastic deformation (shot-
peening), surface fatigue (pitting) or erosion. Two main
kinds of degradation mode have been observed when
performing mono impact tests under fully plastic
conditions on various metallic substrates.
. Crack formation: Observations using optical micros-
copy of impact scars reveal the presence of radial or/
and circular cracks around the impact indent (gure
10). Plastic deformation may also be observed. This
intense plastic deformation occurring in the surround-
Figure 9. Evolution of the dynamic loading force as a function of the square radius indent in the case of impacts on titanium alloy TiAl6V.
Dynamic Meyer hardness (DH
M
) is given in GPa.
Figure 10. Optical observation of radial or/and circular cracks around
the impact indent.
A.C. Sekkal et al./A micro/macro impact test at controlled energy for erosion and phase-transformation simulation 272
ing area creates a stress eld that may lead to cracking
phenomena. By reducing the distance separating two
impacts, the associated stress elds are superimposed,
which enhances crack initiation and propagation
(gure 11). This may also induce particle detachment
in the event that a whole network of cracks is created.
. Plastic deformation and phase transformation:
During multi-impact tests, numerous slip lines
appear all around the indent scar (gure 12). Their
presence is due to the mechanical stress applied to
the substrate during the impacts. The tested sub-
strate, made of ARMCO steel (low-carbon steel) in
the case of gure 12, may be very easily plastically
deformed and the plastic deformation mechanism
involves the formation and displacement of slip-lines.
The density of these lines depends on the grain
orientation.
. Cross-section observations just below the indent
centre reveal the occurrence of a phase transformation
similar to the Tribologically Transformed Surface
commonly found in fretting or ball-bearing applica-
tions [16]. Figure 13 shows the presence of a new
microstructure, which can easily be distinguished
from the original matrix. Further investigations
using scanning electron microscopy as well as nano-
hardness tests [17] have evidenced the presence of
three different domains:
. A transformed volume (zone I), which exhibits a dark
colour compared to the matrix when using HNO
3
-
HF4% chemical reactant and having a nano-hardness
of 7.5 GPa, i.e. twice the value of the initial matrix
material.
. A severely cold-hardened zone (II), without colour
contrast compared to the matrix and having a nano-
hardness of 4.7 GPa. This increase in hardness under
the indenter is similar to that observed on real eroded
components.
. A slightly cold-hardened zone (III) having a nano-
hardness of 4 GPa.
The elastic modulus of the two last zones (II and III)
is almost constant and equal to 125 GPasimilar to the
value obtained on the initial matrix material. In
contrast, a signicant increase of the elastic modulus
in the transformed zone (I) has been evidenced. This
Figure 11. Crack propagation between two closely located impacts.
Figure 12. Slip lines in the surrounding impact area.
Figure 13. Micrographs of the deformation and transformation area in titanium alloy (TiAl6V4) induced by dynamic indentation at 1.86 mJ
kinetic energy and after 1750 impact cycles.
A.C. Sekkal et al./A micro/macro impact test at controlled energy for erosion and phase-transformation simulation 273
increase of about 10% reveals the more elastoplastic
behaviour of the transformed zone.
Different models have been recently developed that
predict the occurrence of such transformations under
mechanical situations similar to those used in this study
[18]. These models enable the possible mechanisms
leading to the formation of a new microstructure to be
described. Most of them suggest synergistic effects of
several complementary phenomena. The mechanical
and thermal effects which may be induced by the plastic
deformation are especially difcult to separate. Among
the different models, we particularly examine the
adiabatic shear-band model [19,20], which favours the
dynamic recrystallization process and the mechanical
alloying model and has been established using test
conditions very similar to ours as demonstrated in table
3. Further work has to be carried out in order to better
understand the conditions of the phase transformation
occurring during multi-impacts tests.
5. Conclusion
A new impact test has been developed to simulate
single or multi-impacts of controlled energy. The device
consists of a modication to and instrumentation of a
standard engraving machine. Impacts of controlled
energy ranging from 0.1 to 100 mJ per impact and
impacting speed of 0.1 to 2.4 ms
1
may be performed at
a very precise location on a sample surface. The very
good repeatability of the impacts enables multi-impact
tests to be performed. Using this test, it is now possible
to study the effect of a given number of impacts of a
given energy, and to evidence the synergistic effect
between two impacts as a function of the separating
distance. The initial stages of the erosion damage can be
examined. Furthermore, two kinds of degradation
mechanisms have been observed: crack formation and
phase transformation. These two phenomena, especially
the Tribologically Transformed Surface are now to be
further investigated. New insights into the transforma-
tion parameters (e.g. cumulated impact energy, volume
of transformed material) are expected.
Acknowledgments
The authors wish to thank Prof. L Maiffredy from
the GMC lab at INSA Lyon for his help in the ultra
rapid video recording manipulations and fruitful dis-
cussions and Mrs C. Vialle from the GEMPPM lab at
INSA Lyon for the nanoindentation experiments.
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Table 3
Impact characteristics compared to typical mechanical alloying test parameters.
Impact test
Grinding systems
Pulvo.0 SPEX
Nature of the impact Impact Impact Impact
Impact speed (m/s) 0.1 $2.4 0.14 $0.24 [20] -3.9 [21]
Kinetic energy (mJ/impact) 0.1 $100 3 $30 -120
Impact frequency (Hz) 11 $125 15 $50 [20] 200 [23]
Impact power per impact (W/g/impact) 0.0006 $0.17 0.005 $0.14 -0.24
A.C. Sekkal et al./A micro/macro impact test at controlled energy for erosion and phase-transformation simulation 274