White etching crack (WEC) networks were characterized in heavy loaded bearings for wind turbines. Both conventional techniques as reflected light microscopy and (scanning and transmission) electron microscopy as well as electron backscatter diffraction and ion channelling contrast imaging were applied. The complementary use of the techniques in unravelling the complicated failure mechanisms is explored in the present work.

Despite the ongoing debates on influence of hydrogen uptake and penetration in the steel, pulsed and extraordinary fatigue on white etching cracks (WEC) formation in bearing steel SAE52100, the present paper proposes an alternative hypothesis on electrothermal initiation of the WEC. The hypothesis points to differences between electrical and thermal properties of elements of steel microstructure that lead sequentially to redistribution of current, resistivity heating, thermal expansion and deformations of the carbide particle. Appearance of a nano-void is also predicted by the model in the cases of the martensite and the bainite structures. The model also predicts higher probability of the WEC formation for the bainitic steel.

The present paper describes a novel way to detect early stages in the gradual transformation of SAE 52100 bearing steel material to white etching cracks (WEC). The underlying transformation is recorded and investigated by a complementary use of Barkhausen noise measurements, ultrasonic measurements and scanning electron microscopy. While ultrasonic measurements can only be used to detect cracks in a failed component, the recently improved Barkhausen noise measurement technique can be used to detect possible early stages of microstructural transformation. A cross section from a region without ultrasonic signal but with a Barkhausen signal has been investigated by the use of scanning electron microscopes in order to reveal possible pre-stages of WEC formation. These findings support that WEC are locally initiated in subsurface regions. Within those modified regions, carbides start to dissolve in consequence of deformation accumulation, which has been identified as an early state of WEA microstructure formation. This paper is part of a Themed Issue on Recent developments in bearing steels.

In the present work, crack networks with white etching areas (WEAs) in cross-sections of bearings were investigated by a complementary use of SEM and TEM with the focus on the use of orientation contrast imaging and electron backscatter diffraction (EBSD). Orientation contrast imaging was used for the first time to give detailed insight into the microstructure of WEA. A significant difference between Nital-etched and polished WEA samples was observed. It was revealed that WEAs are composed of different areas with varying grain sizes. As a result of secondary transformation, needle-shaped grains were observed within WEAs. Using EBSD analysis, evidence was obtained that WEA formation and accompanying crack growth are without relation microstructural features. In addition, an inhomogeneous chemical structure of WEA as a result of carbide dissolution is revealed by analytical investigations.

No abstract