FE8 type laboratory testing of white etching crack (WEC) bearing failure mode in 100Cr6

Danielsen, Hilmar Kjartansson; Guzmán, Francisco Gutiérrez; Muskulus, Michael; Rasmussen, Birgitte Buur; Shirani, Mehdi; Cornel, Daniel; Sauvage, Paul; Wu, Jun; Petrov, Roumen; Jacobs, Georg

doi:10.1016/j.wear.2019.202962

Cited by 10 publications

(20 citation statements)

References 40 publications

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“…The test conditions are characterised by an axial load of 60 kN, a shaft speed of 300 rpm and a bearing temperature of 100 °C. These conditions have been previously used in further FE8 related WEC studies such as (Danielsen et al, 2019). As shown in the work of DANIELSEN (Danielsen et al, 2019) these conditions usually lead to failures between 100 h and 300 h.…”

Section: Development Of a Roller Bearing Damagementioning

confidence: 99%

Condition Monitoring of roller bearings using Acoustic Emission

Cornel¹,

Guzmán²,

Jacobs³

et al. 2020

Preprint

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Abstract. Roller bearing failures in wind turbines gearboxes lead to long downtimes and high repairing costs, which could be reduced by the implementation of a predictive maintenance strategy. In this paper and within this context an acoustic emission based condition monitoring system is applied to roller bearing test rigs with the aim of identifying critical operating conditions before bearing failures occurs. Furthermore, a comparison regarding detection times is carried out with a traditional vibration based condition monitoring systems, with focus on premature bearing failures such as white etching cracks. The investigations show a sensitivity of the acoustic emission system towards lubricating conditions. In addition, the system has shown, that a damaged surface can be detected at least ~ 4 % (8 hours, regarding the time to failure) earlier than by using the vibration based system. Furthermore, significant deviations from the average acoustic emission signal were detected up to ~ 50 % (130 hours) before the test stop and are possibly related to sub-surface damage initiation and might result in an earlier damage detection in the future.

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Section: Development Of a Roller Bearing Damagementioning

confidence: 99%

Condition Monitoring of roller bearings using Acoustic Emission

Cornel¹,

Guzmán²,

Jacobs³

et al. 2020

Preprint

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“…Two lubricants are used in the tests on the roller bearing test rig. The first lubricant is a fully-formulated mineral oil from a group I base oil with a viscosity class ISO VG 100 and referred to as "mineral oil" in the following, which has already been used in previously published work [28][29][30][31][32]. Analysis results of the elemental analysis are shown in Table 1.…”

Section: Lubricantsmentioning

confidence: 99%

“…Both the bearing washers and the rollers are made of martensitic through-hardened 100Cr6 steel (AISI 52100). In alignment with previously conducted investigations, a polyamide cage (PA66) with fifteen rollers was used [28][29][30][31][32]. Figure 1(b) shows exemplarily the FE8 test rig for cylindrical roller thrust bearings of the type 81212, comprehensive details of which can be seen in Refs.…”

Section: Test Bearingsmentioning

confidence: 99%

“…The second objective is to examine whether a continuous increase in hydrogen content occurs during the formation and propagation of WEC and to correlate hydrogen content with the lubricant composition. In order to achieve this, tests will be conducted under operating conditions favouring the formation of WEC in alignment with previously conducted investigations [28,29] and manually stopped after pre-defined test durations. Two lubricants are used, a fully formulated mineral oil and a perfluoralkylether (PFAE) which contains neither additives nor any hydrogen.…”

Section: Introductionmentioning

confidence: 99%

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Post-testing measurement of freely movable and diffusible hydrogen in context of WEC formation at cylindrical roller thrust bearings from 100Cr6

et al. 2020

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Sub-surface crack networks in areas of altered microstructure are a common cause for bearing failures. Due to its appearance under light microscopy, the damage pattern is referred to as White Etching Cracks (WEC). The root causes leading to the formation of WEC are still under debate. Nevertheless, it has already been shown that atomic hydrogen can have an accelerating effect on the formation and propagation of WEC. In addition to hydrogen pre-charging, hydrogen can be released and absorbed during rolling/sliding due to the decomposing of the lubricant and water. The current work focuses on the analysis of the hydrogen content of cylindrical roller thrust bearings after testing in a FE8 type test rig using two different lubricants. Within the framework of this work, two different hydrogen analysis methods were used and assessed regarding their applicability. The results show that the so-called Hydrogen Collecting Analysis (HCA) is more suitable to investigate the correlation between lubricant chemistry and hydrogen content in the test bearings than the Local Hydrogen Analysis (LHA). The measurements with the HCA show a continuously increasing freely movable and diffusible hydrogen content under tribological conditions, which leads to the formation of WEC. Comparative tests with an oil without hydrogen showed that the tendency of the system to fail as a result of WEC can be reduced by using a lubricant without hydride compounds.

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“…These hypotheses are mainly based on tests of 81212 bearings on FE-8 rigs with a ''WEC-critical'' oil. [15][16][17][18][19] Based on this, it is suggested that WECs develop due to high frictional energy accumulation, 20,21 promoted by specific additives, [22][23][24][25][26] which lead to hydrogen ingress and subsequent weakening of the material. 4,19,23,[27][28][29][30] Lubricant additives, specifically extreme pressure and anti-wear (EP/AW) additives, are used to prevent from surface deterioration in mixed lubrication, notably to compensate lower and lower base oil viscosities.…”

Section: Introductionmentioning

confidence: 99%

The influence of lubricant formulation on early thrust and radial bearing damage associated with white etching cracks

Ruellan

Stadler

Rydel³

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part J:

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In the past, results have shown the influence of oil-additive systems in the life of rolling bearings, also hypotheses have been formulated on the influence of lubricant formulation on the development of early bearing damage associated with white etching cracks. In some earlier work of the authors with different operating conditions, early damage, and white etching cracks had been generated by mechanical stresses. In this study, tests with custom-made lubricants have been performed on thrust as well as radial bearings to clarify some assumptions. The tested oils differ only by the presence of three additives, but only one oil has led systematically to white etching cracks despite the fact that both oils lead to similar mechanical stresses. The results confirm that under mixed lubrication conditions with certain lubricant formulations, early damage, in particular white etching cracks, can be influenced by the oil-additive system likely affecting the bearing steel. Hypotheses are formulated and the influence of different parameters is discussed. This paper, combined with earlier work of the authors, confirms that the understanding and solution to an early bearing damage associated with white etching cracks can only be validated using the appropriate test method.

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FE8 type laboratory testing of white etching crack (WEC) bearing failure mode in 100Cr6

Cited by 10 publications

References 40 publications

Condition Monitoring of roller bearings using Acoustic Emission

Condition Monitoring of roller bearings using Acoustic Emission

Post-testing measurement of freely movable and diffusible hydrogen in context of WEC formation at cylindrical roller thrust bearings from 100Cr6

The influence of lubricant formulation on early thrust and radial bearing damage associated with white etching cracks

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