Defects as a root cause of fatigue failure of metallic components. II: Non-metallic inclusions

Zerbst, Uwe; Madia, Mauro; Klinger, Christian; Bettge, Dirk; Murakami, Yukitaka

doi:10.1016/j.engfailanal.2019.01.054

Cited by 115 publications

(55 citation statements)

References 96 publications

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“…This process forms striations on the fracture surface, where each striation corresponds to the crack front arrest line. Striations can be found in Zr‐, 16 Al‐, 17 Ti‐alloys, 18 steel, 19 metallic glasses 20 and even polymers 21 . Measurement of striation's width is the most simple and direct method of calculation of a CGR.…”

Section: Introductionmentioning

confidence: 99%

On the formation of ridges and burnished debris along internal fatigue crack propagation in 42CrMo4 steel

Seleznev

Weidner

Biermann

2020

Fatigue Fract Eng Mat Struct

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A detailed microscopic analysis of fracture surfaces of 42CrMo4-hardened steel after ultrasonic fatigue testing revealed globular and cylindrical particles located in ridges along the crack propagation direction. Observed particles could be easily taken for non-metallic inclusions; however, chemical analysis showed that they are of the same composition as the steel matrix. The formation of such round-shaped debris was found to be a result of cutting out the matrix fragments by 'en passant' cracks interaction and their subsequent fretting burnishing. Possible correlation of the parameters of ridges and debris with cyclic plastic zone width and martensite structure is discussed.42CrMo4 steel, en passant cracks, fretting, high cycle fatigue, ultrasonic fatigue testing (USFT)

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Section: Introductionmentioning

confidence: 99%

On the formation of ridges and burnished debris along internal fatigue crack propagation in 42CrMo4 steel

Seleznev

Weidner

Biermann

2020

Fatigue Fract Eng Mat Struct

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“…After turning and grinding (average particle size ≈10 μm), fatigue specimens were austenitized and quenched in He. This hardening procedure was performed to raise the sensitivity of the steel matrix to the NMIs . As NMIs located at or in direct vicinity to the surface exhibit a higher stress concentration than those in the specimen's interior, crack initiation preferentially occurs at the surface .…”

Section: Methodsmentioning

confidence: 99%

“…Nonmetallic inclusions (NMI) detrimentally affect the mechanical behavior of steel . Among other grades, high‐strength steels are more sensitive to the presence of NMIs in terms of crack initiation . The stress‐raising effect acts under cyclic as well as quasi‐static and dynamic loading conditions …”

Section: Introductionmentioning

confidence: 99%

Effect of Filter Functional Coating on Detrimental Nonmetallic Inclusions in 42CrMo4 Steel and Its Resulting Mechanical Properties

et al. 2019

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Carbon‐bonded ceramic foam filters with different functional coatings are immersed in a 42CrMo4 steel melt within a steel casting simulator. The solidified steel is analyzed with respect to the size distribution and the chemical composition of the remaining nonmetallic inclusions (NMI). Cyclic loading and quasi‐static tests are performed to determine the fatigue limit, the strength, deformability, and toughness of the steel after filter immersion. The immersion of filter with calcium hexaluminate (CA6) coating significantly reduces the population of small (4–20 μm) NMIs. This leads to an increased deformability and, thus, ability for energy dissipation during deformation. However, the maximum size of NMIs is increased from 100 to 150 μm, which results in fatigue limit reduction, despite the decrease in NMIs total density. The majority of inclusions are found to be pure alumina. Large (up to 150 μm) plate‐like alumina inclusions introduce most of the detrimental effects on cyclic strength, whereas significant effect on quasi‐static strength is not found.

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“…Frost 11 focused on the relationship between fatigue strength and crack length, and it indicated that the fatigue strength decreased with increasing of crack length. Specially, it has been found that the nonmetallic inclusions in gears are one of the major reasons for the failure of gears, bearings or springs under fatigue loading conditions 12,13 . For gear steels, the nonmetallic inclusions can be oxides, sulfides or nitrides in composition, formed by reactions of the liquid steel with deoxidizers such as silicon, manganese or aluminium.…”

Section: Introductionmentioning

confidence: 99%

Fatigue life analysis of wind turbine gear with oxide inclusion

Liu

Sun

Hou

et al. 2020

Fatigue Fract Eng Mat Struct

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Considering a great deal of wind turbine gear failure cases, it is shown that the oxide inclusion has been one of the main reasons for the failure of the gear shaft under fatigue loading condition. In this paper, the fatigue behaviour of gears involving oxide inclusion under real operating condition is investigated. A three-dimensional finite element model for helical gear pair applied in the middle stage of wind power increasing gearbox is established, and the fatigue life of nonmetallic inclusion zone of middle gear shaft is predicted using Miner's theory and real load spectrum of wind power growth gearbox. Then, the effects of several factors (such as the size and position of oxide inclusion and residual stress induced by manufacturing) on the fatigue life of gears with inclusion are studied. The results show that both inclusion size and position have great influence on the fatigue life of gears, and the compress residual stress will prolong the fatigue life of gears. Furthermore, the critical safety line and safety region of gears with oxide inclusion have been obtained for three representative inclusion positions. The present work is expected to provide a guidance for the engineering design and life safety evaluation of wind turbine gears.

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Defects as a root cause of fatigue failure of metallic components. II: Non-metallic inclusions

Cited by 115 publications

References 96 publications

On the formation of ridges and burnished debris along internal fatigue crack propagation in 42CrMo4 steel

On the formation of ridges and burnished debris along internal fatigue crack propagation in 42CrMo4 steel

Effect of Filter Functional Coating on Detrimental Nonmetallic Inclusions in 42CrMo4 Steel and Its Resulting Mechanical Properties

Fatigue life analysis of wind turbine gear with oxide inclusion

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