White etching crack (WEC) failure is distinct to classical fatigue and driven by the composition of lubricants under special loading conditions; for example, slippage and electricity. The white etching area (WEA) within WEC contains carbon supersaturated ferrite (bcc-iron) and carbides, with a size of a few nanometers. This article presents investigations supporting the hypothesis that WEC processes start within a failure-free period by successive accumulation of a structural distortion. This can be measured by acoustic emission. Failure statistics show a steep ascent in the Weibull diagram (ß values beyond 1) leading to the assumption that WEC processes start unsuspicious, as one would see as a failure-free period, but imply a hidden subsurface accumulation of material defects. It is suggested and supported by the evidence presented within this article that WEC is neither related to the presence of nonmetallic inclusions nor related to other impurities in the steel. Instead, the failure is a sequence and accumulation of plastic deformations in the microstructure. Within the SAE 52100 material as discussed in this article, this accumulation is located in the microstructure around cementite, seen in a turn of hard magnetization toward soft magnetization proven by Barkhausen noise measurements. This decay is caused by the plastic deformation of such domains. Distortions in the vicinity of a cementite first would lead to carbon supersaturation by diffusion processes and later to a plastic deformation of the carbides. In the end, the complete distorted region will release the accumulated energy by downsizing the microstructure toward WEC.
White etching cracking (WEC) is a subsurface bearing failure mechanism influenced by a number of factors, including lubricant composition. Certain metal-containing lubricants have been reported to promote WEC-induced failure; however, the exact mechanisms linking lubricant effects on WEC propensity are still not fully understood. An interesting field that has not been elucidated is the influence of additive concentration and tribofilm growth on WEC initiation, propagation, and failure. The investigations conducted in this work involved two series of oil formulations: one with additives that give rise to WEC (WEC oils) in different combinations and concentrations and another with additives that do not cause WEC (non-WEC oils). A mini traction machine (MTM) in combination with a spacer layer imaging machine (SLIM) was employed to study the growth of tribofilms and their influence on friction response. Insights from the MTM-SLIM study allowed for better interpretation of FE8 bearing tests. When using oils that contribute to WEC formation, the tribofilm-induced WEC mechanism was confirmed, with cracks initiating as early as after 20 h of FE8 testing. Metal-containing additives were found to favor the formation of WECs by generating a high-friction tribofilm and increasing the water content in the lubricant. Furthermore, the source of subsurface H associated with WEC failure is investigated using heavy water (D2O)-saturated oil. A mechanism of water dissociation induced in tribofilm growth (incubation period) is proposed in this article.
Insufficient understanding of tribological behaviour in total joint arthroplasty is considered as one of the reasons for prosthesis failure. Contrary to the continuous motion input profiles of hip simulators, human locomotion contains motion interruptions. These occurring resting periods can cause stick phenomena in metal-on-metal hip joints. The aim of the present study was to investigate the tribological sensitivity of all-metal bearings to motion interruptions on in vitro test specimens and retrieved implants. Friction and wear with and without resting periods were quantified. Unlike the metal-on-polyethylene joints, the static friction of metal-on-metal joints increased up to micros = 0.3 with rest, while wear appeared to be unaffected. This effect is caused by the interlocking of firmly adhered carbon layers, which were generated from the protein-containing lubricant through tribochemical reactions. Since more than 80 per cent of the retrieved implants exhibited macroscopically visible carbon layers, the increase in friction presumably also occurs under physiological conditions, which is then transferred to the bone-implant interface. These recurrent tangential stress peaks should be considered for the design features of the cup-bone interface, in particular when larger-sized implant heads are used.
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