Effects of temperature,slip amplitude,contact pressure on fretting fatigue behavior of Ti811 alloys at elevated temperatures

Effects of the temperature, slip amplitude, and contact pressure on fretting fatigue （FF） behavior of the Ti811 titanium alloy were investigated using a high frequency fatigue machine and a home-made high temperature apparatus. The fretting fatigue failure mechanism was studied by observing the fretting surface morphology features. The results show that the sensitivity to fretting fatigue is high at both 350 and 500 ℃. The higher the temperature, the more sensitive to the fretting fatigue failure is. Creep is an important factor that influences the fretting fatigue failure process at elevated temperatures. The fretting fatigue life of the Ti811 alloy does not change in a monotonic way as the slip amplitude and contact pressure increase. This is owing to the fact that the slip amplitude affects the action of fatigue and wear in the fretting process, and the nominal contact pressure affects the distribution and concentration of the stress and the amplitude of fretting slip at the contact surface, and thus further influences the crack initiation probability and the driving force for propagation.

Effect of TiN/Ti multilayer on fretting fatigue resistance of Ti-811 alloy at elevated temperature

The TiN/Ti multilayer was deposited on Ti-811 alloy surface by magnetron sputtering(MS) technique for improving fretting fatigue(FF) resistance of the titanium alloy at elevated temperature. The element distribution, bonding strength, micro-hardness and ductility of the TiN/Ti multilayer were measured. The effects of the TiN/Ti multilayer on the tribological property and fretting fatigue resistance of the titanium alloy substrate at elevated temperature were compared. The results indicate that by MS technique a TiN/Ti multilayer with high hardness, good ductility and high bearing load capability can be prepared. The MS TiN/Ti multilayer, for its good toughness and tribological behavior, can significantly improve the wear resistance and FF resistance of the Ti-811 alloy at 350 ℃.

Numerical Simulation of Fretting Fatigue Damage Evolution of Cable Wires Considering Corrosion and Wear Effects

In this paper,a numerical model of fretting fatigue analysis of cablewire and the fretting fatigue damage constitutive model considering the multi-axis effect were established,and the user material subroutine UMAT was written.Then,the constitutive model of wear morphology evolution of cable wire and the constitutive model of pitting evolution considering the mechanical-electrochemical effect were established,respectively.The corresponding subroutines UMESHMOTION_Wear and UMESHMOTION_Wear_Corrosion were written,and the fretting fatigue lifewas further predicted.The results showthat the numerical simulation life obtained by the programin this paper has the same trend as the tested one;the error is only about 0.7%in the medium life area;When the normal contact force increases from 120 to 240 N,the fretting life of cable wire decreases by 25%;When the evolution of wear morphology and corrosion effect are considered simultaneously,the depth of the wear zone exceeds 0.08mm after 600,000 loads,which ismuch larger than 0.04 mmwhen only the evolution of wear morphology is considered.When the evolution of wear morphology and corrosion morphology is considered simultaneously,the damage covers the whole contact surface after 300,000 loads,and the penetrating damage zone forms after 450,000 loads,which is obviously faster than that when only the wearmorphology evolution is considered.Themethod proposed in this paper can provide a feasible numerical simulation scheme for the visualization of the damage process and accurate life prediction of cable-supported bridges.

The Effect of Surface Pit Treatment on Fretting Fatigue Crack Initiation

This paper analyses the effect of surface treatment on fretting fatigue specimen by numerical simulations using Finite Element Analysis.The processed specimen refers to artificially adding a cylindrical pit to its contact surface.Then,the contact radius between the pad and the specimen is controlled by adjusting the radius of the pit.The stress distribution and slip amplitude of the contact surface under different contact geometries are compared.The critical plane approach is used to predict the crack initiation life and to evaluate the effect of processed specimen on its fretting fatigue performance.Both crack initiation life and angle can be predicted by the critical plane approach.Ruiz parameter is used to consider the effect of contact slip.It is shown that the crack initial position is dependent on the tensile stress.For same type of model,three kinds of critical plane parameters and Ruiz method provide very similar position of crack initiation.Moreover,the improved sample is much safer than the flat-specimen.

Influence of surface coating on Ti811 alloy resistance to fretting fatigue at elevated temperature

An extensive study of the composition distribution, bonding strength, hardness, and wear resistance of a 0Cr18Ni9 film deposited on a Ti811 titanium alloy surface by ion beam enhanced deposition （IBED） is presented. Shot peening was introduced to post-treat the modified surface to synergistically improve the fretting fatigue resistance of the Ti811 alloy at 350°C. The results indicate that the 0Cr18Ni9 film with high density, small grain size, low void radio, and high bonding strength can be prepared using IBED. As a result, the hardness, wear resistance, and fretting fatigue resistance of the Ti811 alloy are increased to a remarkable extent. Compared with shot peening treatment or IBED 0Cr18Ni9 film alone, the Ti811 titanium alloy with an IBED 0Cr18Ni9 film combined with shot peening shows a higher fretting fatigue resistance at 350°C. This is due to the synergistic effect of the high wear resistance of the film surface and the residual compressive stress induced by shot peening.

New approach based on continuum damage mechanics with simple parameter identification to fretting fatigue life prediction

A new continuum damage mechanics model for fretting fatigue life prediction is established. In this model, the damage evolution rate is described by two kinds of quantities. One is associated with the cyclic stress characteristics obtained by the finite element （FE） analysis, and the other is associated with the material fatigue property identified from the fatigue test data of standard specimens. The wear is modeled by the energy wear law to simulate the contact geometry evolution. A two-dimensional （2D） plane strain FE implementation of the damage mechanics model and the energy wear model is presented in the platform of ABAQUS to simulate the evolutions of the fatigue damage and the wear scar. The effect of the specimen thickness is also investigated. The predicted results of the crack initiation site and the fretting fatigue life agree well with available experimental data. Comparisons are made with the critical plane Smith- Watson-Topper （SWT） method.

Fretting Fatigue Improvement of Ti6Al4V by Coating and Shot Peening

Ion beam enhanced deposition (IBED) was employed to increase the fretting fatigue resistance of Ti6AI4V. CrN and TiN hard coatings were applied on the base material and shot peening was combined with the hard coatings to study the duplex effect on fretting fatigue resistance. The IBED coatings exhibited a good bonding strength. They did not spall off even after shot peening. However, an optimum composition of CrN showed better fretting fatigue resistance than that of TiN with the same processing parameters.

Experimental and numerical study on fretting wear and fatigue of full-scale railway axles

This study investigated the fretting wear and fatigue of full-scale railway axles.Fatigue tests were conducted on full-scale railway axles,and the fretting wear and fretting fatigue in the fretted zone of the railway axles were analysed.Three-dimensional finite element models were established based on the experimental results.Then,multi-axial fatigue parameters and a linear elastic fracture mechanics-based approach were used to investigate the fretting fatigue crack initiation and propagation,respectively,in which the role of the fretting wear was taken into account.The experimental and simulated results showed that the fretted zone could be divided into zones I-III according to the surface damage morphologies.Fretting wear alleviated the stress concentration near the wheel seat edge and resulted in a new stress concentration near the worn/unworn boundary in zone II,which greatly promoted the fretting crack initiation at the inner side of the fretted zone.Meanwhile,the stress concentration also increased the equivalent stress intensity factor range DKeq below the mating surface,and thus promoted the propagation of fretting fatigue crack.Based on these findings,the effect of the stress redistribution resulting from fretting wear is suggested to be taken into account when evaluating the fretting fatigue in railway axles.

Influence of Ultrasonic Surface Rolling Process and Shot Peening on Fretting Fatigue Performance of Ti-6Al-4V

At present,there are many studies on the residual stress field and plastic strain field introduced by surface strengthening,which can well hinder the initiation of early fatigue cracks and delay the propagation of fatigue cracks.However,there are few studies on the effects of these key factors on fretting wear.In the paper,shot-peening(SP)and ultrasonic surface rolling process(USRP)were performed on Ti-6Al-4V plate specimens.The surface hardness and residual stresses of the material were tested by vickers indenter and X-ray diffraction residual stress analyzer.Microhardness were measured by HXD-1000MC/CD micro Vickers hardness tester.The effects of different surface strengthening on its fretting fatigue properties were verified by fretting fatigue experiments.The fretting fatigue fracture surface and wear morphology of the specimens were studied and analyzed by means of microscopic observation,and the mechanism of improving fretting fatigue life by surface strengthening process was further explained.After USRP treatment,the surface roughness of Ti-6Al-4V is significantly improved.In addition,the microhardness of the specimen after SP reaches the maximum at 80μm from the surface,which is about 123%higher than that of the AsR specimen.After USRP,it reaches the maximum at 150μm from the surface,which is about 128%higher than that of AsR specimen.It is also found that the residual compressive stress of the specimens treated by USRP and SP increases first and then decreases with the depth direction,and the residual stress reaches the maximum on the sub surface.The USRP specimen reaches the maximum value at 0.18 mm,about−550 MPa,while the SP specimen reaches the maximum value at 0.1 mm,about−380 MPa.The fretting fatigue life of Ti-6Al-4V effectively improved after USRP and SP.The surface integrity of specimens after USRP is the best,which has deeper residual compressive stress layer and more refined grain.In this paper,a fretting wear device is designed to carry out fretting fatigue experiments on specimens with different surface strengthening.

Multi-Scale Analysis of Fretting Fatigue in Heterogeneous Materials Using Computational Homogenization

This paper deals with modeling of the phenomenon of fretting fatigue in heterogeneous materials using the multi-scale computational homogenization technique and finite element analysis(FEA).The heterogeneous material for the specimens consists of a single hole model(25% void/cell,16% void/cell and 10% void/cell)and a four-hole model(25%void/cell).Using a representative volume element(RVE),we try to produce the equivalent homogenized properties and work on a homogeneous specimen for the study of fretting fatigue.Next,the fretting fatigue contact problem is performed for 3 new cases of models that consist of a homogeneous and a heterogeneous part(single hole cell)in the contact area.The aim is to analyze the normal and shear stresses of these models and compare them with the results of the corresponding heterogeneous models based on the Direct Numerical Simulation(DNS)method.Finally,by comparing the computational time and%deviations,we draw conclusions about the reliability and effectiveness of the proposed method.

Performance of plasma-sprayed CuNiIn coatings and Mo coatings subjected to fretting fatigue

During atmospheric plasma spraying,a cooling process usually plays an important role in the coating quality,especially for the oxidation containment of metallic coatings.CuNiIn and Mo coatings were prepared using atmospheric plasma spraying with different cooling processes.The obtained coatings were characterized in terms of microstructure,microhardness and tensile strengths.The relation between the coating microstructure and their fretting fatigue behavior was emphasized.The results show that the sensitivity of Mo coatings to the cooling process is lower than CuNiIn coatings.The resistance to fretting fatigue is determined by the coating microhardness,correlated with the contents of oxides and pores.The fretting wear mechanisms of both the coatings are galling,third body abrasive wear and material transfer.

Aspects of Fretting Fatigue Finite Element Modelling

Fretting fatigue is a type of failure that may affect various mechanical components,such as bolted or dovetail joints,press-fitted shafts,couplings,and ropes.Due to its importance,many researchers have carried out experimental tests and analytical and numerical modelling,so that the phenomena that govern the failure process can be understood or appropriately modelled.Consequently,the performance of systems subjected to fretting fatigue can be predicted and improved.This paper discusses different aspects related to the finite element modelling of fretting fatigue.It presents common experimental configurations and the analytical solutions for cylindrical contact.Then,it discusses aspects of fretting fatigue crack initiation,such as crack location,orientation,and length,as well as stress averaging approaches.Then,it deals with the propagation stage;crack face interaction,orientation criteria,and crack growth rate are discussed.Lastly,additional aspects of recent research on fretting fatigue are reviewed:out-of-phase loading,cohesive zone modelling,wear effects,heterogeneity,and crystal orientation.Fretting fatigue is a phenomenon not well understood,and much more research is needed so that its understanding is increased and proper criteria and laws may be available for different cases.

Fatigue Delamination Characteristics of Plasma Sprayed Coatings under Fretting

The fretting wear behavior of plasma spraying CoCrW and Cr3C2-NiCr coatings were investigated. The results showed both plasma spraying coatings were inferior to K417 nickel superalloy in the fretting wear resistance. The characterized fatigue delamination of the plasma sprayed coatings was evidently different from that of the homogeneous materials. The lamellar cohesion, oxide inclusions and porosity were critical factors that controlled the fretting wear resistance. In the view of contact mechanics, the fretting wear behavior of plasma spraying coatings was characterized.

Surface Protection Methods against Fretting Fatigue for TC11 Titanium Alloy

The influence of various surface coatings, including flame sprayed Cu、 plasma sprayed Cu Ni In、 exploding sprayed WC/Co Ⅰ and plasma sprayed WC/Co Ⅱ, on fretting fatigue resistance for TC11 titanium alloy at 20℃ and 500℃ is studied. The results show that the plasma sprayed WC/Co Ⅱ coating has good protection performance and makes the fretting fatigue strength of TC11 titanium alloy raise 40% at both 20℃ and 500℃. The fretting fatigue strength of TC11 alloy with Cu coating is increased about 62% at 20℃, but the protection performance at 500℃ is not so good as that at 20℃.

基于MLBPH-FF和SVM的驾驶员疲劳检测

针对疲劳检测技术中驾驶员头部姿势变化影响图像检测效果的问题,提出一种基于多尺度LBPH傅里叶特征(MLBPH-FF)和支持向量机(SVM)的驾驶员疲劳检测方法。该方法分为训练和识别两个阶段:训练时,首先对从视频流中捕获的驾驶员人脸疲劳和非疲劳图像进行特征提取,即用不同半径的规范LBP算子计算得到多尺度的LBPH,然后拼接这些LBPH并进行傅里叶变换得到MLBPH-FF,最后把这些特征数据输入到SVM中进行训练得到SVM的模型及参数;在识别时,首先计算出待测图像样本的MLBPH-FF,然后输入到训练好的SVM中进行疲劳检测。实验结果表明,这种方法在疲劳检测方面有较好的识别率,对姿态和光照变化有较强的鲁棒性。

Inconel718榫接结构高低周微动疲劳试验研究

航空发动机涡轮叶片在实际服役环境中,受到循环往复的高/低周载荷,这是一种典型的高低周微动疲劳工况。涡轮叶片由于微动疲劳频繁引发疲劳断裂问题,严重影响着航空发动机的安全运行。为了研究热端部件材料的高低周微动疲劳问题,设计一种Inconel718榫连接模拟件,对其开展高低周复合微动疲劳试验。共设计3种不同载荷/频率的试验工况,对比不同工况下模拟件的寿命分布情况。结果表明:高周/低周载荷对榫连接结构的微动疲劳寿命有显著影响,随着高周/低周载荷或者频率的增大,涡轮叶片榫接部位微动疲劳寿命均随之降低;试验结果证明榫接结构高低周微动疲劳试验较好地还原了涡轮叶片实际服役情况;通过显示动力学有限元分析,所预测的裂纹萌生位置与试验结果中裂纹萌生位置分散性较小。

铝合金自冲铆疲劳性能及寿命预测

随着“双碳”政策的提出,轻量化已成为各行业发展的重要课题,铝合金轻量化及其连接技术研究在机械各领域备受青睐并推广。为研究铝合金自冲铆接头的力学性能,使用自冲铆连接工艺连接了6061铝合金自冲铆接头和5754铝合金自冲铆接头,对比了两种铝合金接头的几何参数、显微硬度、静力学性能和疲劳性能。结果表明,两种铝合金接头成形的几何参数相近,5754接头搭接区域的硬度和低疲劳载荷下的连接力学性能优于6061接头,但在高疲劳载荷下6061接头的连接力学性能反而更优。通过结合失效接头中黑色氧化物和疲劳载荷下的微动损伤分析结果,建立了两种铝合金接头基于Paris公式的疲劳寿命预测模型,预测结果与实验数据吻合良好。

基于微动接触力学的柱-平板结构疲劳寿命研究

在ABAQUS中对柱-平板结构的微动接触行为展开仿真模拟,分析不同法向接触力P、轴向循环载荷σ条件下,微动接触区的应力分布规律;基于临界平面的思路,结合Smith-Watson-Topper(SWT)微动损伤参数,进一步研究模型微动疲劳寿命及其影响因素。结果表明:P的改变会直接影响接触压力P0和接触半宽a;σ对轴向正应力和切应力的影响较大;SWT参数的最大值总是发生在接触区边缘,证明此处是结构的薄弱点;增加P和σ均会使疲劳寿命值降低,但过大的P和σ会减缓这种影响效果。

Effect of wear debris on fretting fatigue crack initiation

Both wear and fatigue occur in fretting condition,and they interact with one another during the whole process.Fretting fatigue is commonly analysed without considering the effect of wear in partial slip regime,although wear affects the lifetime of crack initiation.This paper investigates,for the first time,the effect of wear debris on fretting fatigue crack initiation.To investigate the effect of debris,first fretting wear characteristics in partial slip regime are analysed for loading conditions.Then,the effect of wear on fretting fatigue crack initiation is investigated using Ruiz parameters and critical plane methods without considering the debris effect.Through the results,we can see that loading conditions affect the wear profiles in different ways.Moreover,wear has a significant effect on the fatigue in partial slip regime without considering debris especially on the crack initiation location.Finally,considering wear debris in the analysis,its effect on critical plane parameters is investigated.It is found that by considering the wear debris effect,the frtting fatigue crack initiation location is shifted towards the trailing edge.The predictions of both crack initiation location and lifetime show a good agreement with the experimental data.