Fretting Wear and Fretting Fatigue

<p>Contributors xiii</p> <p>Preface xvii</p> <p>Section I History and fundamental principles</p> <p>1 Brief history of the subject</p> <p>Daniele Dini and Tomasz Liskiewicz</p> <p>1.1 Early stages</p> <p>1.2 Initial milestones in the understanding of the mechanics of fretting</p> <p>1.3 Crucial steps toward a better understanding of fretting wear and fretting fatigue</p> <p>1.4 State of the art at the beginning of the new millennium</p> <p>Acknowledgments</p> <p>References</p> <p>2 Introduction to fretting fundamentals</p> <p>2.1 Fretting—complexities and synergies</p> <p>Tomasz Liskiewicz and Daniele Dini</p> <p>2.1.1 Fretting within a wider context of tribology</p> <p>2.1.2 Fretting wear</p> <p>2.1.3 Fretting fatigue</p> <p>2.1.4 Mitigating fretting damage</p> <p>References</p> <p>2.2 Contact mechanics in fretting</p> <p>Daniele Dini and Tomasz Liskiewicz</p> <p>2.2.1 Contact geometry</p> <p>2.2.2 Friction and fretting regimes</p> <p>References 36</p> <p>2.3 Transition criteria and mapping approaches</p> <p>Tomasz Liskiewicz, Daniele Dini, and Yanfei Liu</p> <p>2.3.1 Transition criteria</p> <p>2.3.2 Mapping approaches</p> <p>References</p> <p>2.4 Experimental methods</p> <p>Tomasz Liskiewicz, Daniele Dini, and Thawhid Khan</p> <p>2.4.1 Early developments</p> <p>2.4.2 Basic test configurations</p> <p>2.4.3 Fretting wear tests and analytical methods</p> <p>2.4.4 Fretting fatigue tests and analytical methods</p> <p>2.4.5 Combined fretting wear and fatigue approaches</p> <p>References</p> <p>2.5 Modelling approaches</p> <p>Daniele Dini and Tomasz Liskiewicz</p> <p>2.5.1 Theoretical models</p> <p>2.5.2 Numerical models</p> <p>References</p> <p>Section II Fretting wear</p> <p>3.1 The role of tribologically transformed structures and debris in fretting of metals</p> <p>Philip Howard Shipway</p> <p>3.1.1 Overview</p> <p>3.1.2 Wear in both sliding and fretting—Contrasts in the transport of species into and out of the contacts</p> <p>3.1.3 The nature of oxide debris formed in fretting</p> <p>3.1.4 Formation of oxide debris in fretting—The role of oxygen supply and demand</p> <p>3.1.5 Tribo-sintering of oxide debris and glaze formation</p> <p>3.1.6 Microstructural damage—Tribologically transformed structures in fretting</p> <p>3.1.7 The critical role of debris in fretting: Godet’s third body approach</p> <p>3.1.8 Godet’s third body approach revisited: Rate-determining processes in fretting wear</p> <p>3.1.9 Conclusion</p> <p>References</p> <p>3.2 Friction energy wear approach</p> <p>Siegfried Fouvry</p> <p>3.2.1 Friction energy wear approach</p> <p>3.2.2 Basics regarding friction energy wear approach</p> <p>3.2.3 Influence of contact loadings regarding friction energy wear rate </p> <p>vi Contents</p> <p>3.2.4 Influence of ambient conditions</p> <p>3.2.5 Surface wear modeling using the friction energy density approach</p> <p>3.2.6 Conclusions</p> <p>References</p> <p>3.3 Lubrication approaches</p> <p>Taisuke Maruyama</p> <p>3.3.1 Introduction</p> <p>3.3.2 Parameter definition</p> <p>3.3.3 Oil lubrication</p> <p>3.3.4 Grease lubrication</p> <p>3.3.5 Mechanism for fretting wear reduction in grease lubrication</p> <p>3.3.6 Conclusions</p> <p>Acknowledgments</p> <p>References</p> <p>3.4 Impact of roughness</p> <p>Krzysztof J. Kubiak and Thomas G. Mathia</p> <p>3.4.1 Introduction</p> <p>3.4.2 Contact of rough surfaces</p> <p>3.4.3 Stress distribution in rough contact</p> <p>3.4.4 Effective contact area</p> <p>3.4.5 Coefficient of friction</p> <p>3.4.6 Bearing capacity</p> <p>3.4.7 Surface anisotropy and orientation</p> <p>3.4.8 Transition between partial and gross slip</p> <p>3.4.9 Impact of surface roughness on fretting wear</p> <p>3.4.10 Friction in lubricated contact conditions</p> <p>3.4.11 Energy dissipated at the interfaces for smooth and rough surfaces</p> <p>3.4.12 Impact of surface roughness on crack initiation </p> <p>3.4.13 Dynamics of surface roughness evolution in fretting contact</p> <p>3.4.14 Measurement of fretting wear using surface metrology </p> <p>References </p> <p>3.5 Materials aspects in fretting </p> <p>Thawhid Khan, Andrey Voevodin, Aleksey Yerokhin, and Allan Matthews</p> <p>3.5.1 Physical processes impacting materials in industrial fretting contacts </p> <p>3.5.2 Factors affecting fretting behavior of different materials groups </p> <p>Contents vii</p> <p>3.5.3 Materials engineering approaches to the mitigation of fretting wear</p> <p>3.5.4 Application of coatings to mitigate fretting wear </p> <p>3.5.5 Advanced coating designs and architectures</p> <p>3.5.6 Concluding remarks </p> <p>References </p> <p>3.6 Contact size in fretting </p> <p>Ben D. Beake</p> <p>3.6.1 Introduction </p> <p>3.6.2 Experimental techniques for nano-/microscale fretting and reciprocating wear testing </p> <p>3.6.3 Case studies </p> <p>3.6.4 Conclusions </p> <p>References </p> <p>Section III Fretting fatigue</p> <p>4.1 Partial slip problems in contact mechanics</p> <p>David A. Hills and Matthew R. Moore</p> <p>4.1.1 Introduction</p> <p>4.1.2 Global and pointwise friction </p> <p>4.1.3 Global and local elasticity solutions</p> <p>4.1.4 Half-plane contacts: Fundamentals</p> <p>4.1.5 Sharp-edged (complete) contact: Fundamentals</p> <p>4.1.6 Partial slip of incomplete contacts</p> <p>4.1.7 Dislocation-based solutions </p> <p>4.1.8 Asymptotic approaches </p> <p>4.1.9 Summary </p> <p>Appendix 4.1.1 Eigenfunctions for the Williams’ wedge solution</p> <p>Appendix 4.1.2 Size of the permanent stick zone for a Hertz geometry with large remote tensions </p> <p>References </p> <p>4.2 Fundamental aspects and material characterization </p> <p>Antonios E. Giannakopoulos and Thanasis Zisis</p> <p>4.2.1 Introduction </p> <p>4.2.2 Mechanical models and metrics </p> <p>4.2.3 The crack analogue approach </p> <p>4.2.4 Modification of the crack analogue </p> <p>4.2.5 Material testing and characterization </p> <p>4.2.6 Looking ahead </p> <p>References </p> <p>viii Contents</p> <p>4.3 Fretting fatigue design diagram </p> <p>Yoshiharu Mutoh, Chaosuan Kanchanomai, and Murugesan Jayaprakash</p> <p>4.3.1 Equations for estimating fretting fatigue strength based on strength of materials approach </p> <p>4.3.2 Fracture mechanics approach for fretting fatigue life prediction </p> <p>4.3.3 Fretting fatigue design diagram based on stresses on the contact surface </p> <p>4.3.4 Summary </p> <p>References </p> <p>4.4 Life estimation methods </p> <p>Toshio Hattori</p> <p>4.4.1 Fretting fatigue features and fretting processes </p> <p>4.4.2 Fretting fatigue crack initiation limit </p> <p>4.4.3 High-cycle fretting fatigue life estimations considering fretting wear </p> <p>4.4.4 Low-cycle fretting fatigue life estimations without considering fretting wear </p> <p>4.4.5 Application of failure analysis of several accidents and design analyses </p> <p>4.4.6 Conclusions </p> <p>References </p> <p>4.5 Effect of surface roughness and residual stresses </p> <p>Jaime Domı´nguez, Jes<U> <p>4.5.1 Introduction </p> <p>4.5.2 Effect of surface roughness on fretting fatigue </p> <p>4.5.3 Residual stresses in fretting </p> <p>4.5.4 Modeling the effect of surface roughness on fretting</p> <p>fatigue </p> <p>4.5.5 Residual stress modeling in fretting fatigue </p> <p>References </p> <p>4.6 Advanced numerical modeling techniques for crack nucleation and propagation </p> <p>Nadeem Ali Bhatti, Kyvia Pereira, and Magd Abdel Wahab</p> <p>4.6.1 Introduction </p> <p>4.6.2 Theoretical background </p> <p>4.6.3 Numerical modeling </p> <p>4.6.4 Crack nucleation prediction </p> <p>4.6.5 Crack propagation lives estimation </p> <p>4.6.6 Summary and conclusions </p> <p>4.6.7 Way forward </p> <p>References </p> <p>Contents ix</p> <p>4.7 A thermodynamic framework for treatment of fretting fatigue </p> <p>Ali Beheshti and Michael M. Khonsari</p> <p>4.7.1 Introduction </p> <p>4.7.2 Thermodynamically based CDM </p> <p>4.7.3 CDM analysis of fretting fatigue crack nucleation with provision for size effect </p> <p>4.7.4 Fretting subsurface stresses with provision for surface roughness </p> <p>4.7.5 CDM-based prediction of fretting fatigue crack nucleation life considering surface roughness </p> <p>4.7.6 Conclusion and remarks</p> <p>References </p> <p>Section IV Engineering applications affected by fretting</p> <p>5.1 Aero engines </p> <p>John Schofield and David Nowell</p> <p>5.1.1 Introduction </p> <p>5.1.2 Examples of engine events </p> <p>5.1.3 Areas subject to fretting </p> <p>5.1.4 Mitigation measures </p> <p>5.1.5 Design criteria—Academic perspective </p> <p>5.1.6 Industrial applications perspective </p> <p>5.1.7 Conclusions </p> <p>References </p> <p>5.2 Electrical connectors </p> <p>Yong Hoon Jang, Ilkwang Jang, Youngwoo Park, and Hyeonggeun Jo</p> <p>5.2.1 Introduction </p> <p>5.2.2 Effects of fretting on electrical contact resistance </p> <p>5.2.3 Fretting in industrial applications </p> <p>5.2.4 Alternative solutions for fretting in electrical contacts </p> <p>5.2.5 Summary </p> <p>Acknowledgments </p> <p>References </p> <p>5.3 Biomedical devices </p> <p>Michael G. Bryant, Andrew R. Beadling, Abimbola Oladukon, Jean Geringer, and Pascale Corne</p> <p>5.3.1 Introduction </p> <p>5.3.2 Common biomaterials </p> <p>5.3.3 The biological environment </p> <p>5.3.4 Compound tribocorrosion degradation mechanisms of materials in the biological environment </p> <p>x Contents</p> <p>5.3.5 In vivo fretting corrosion within the biological environment </p> <p>5.3.6 Conclusions </p> <p>References </p> <p>5.4 Nuclear power systems </p> <p>M. Helmi Attia</p> <p>5.4.1 Introduction </p> <p>5.4.2 Critical safety components of the nuclear reactor that are susceptible to fretting wear damage </p> <p>5.4.3 Methodology for predicting fretting damage of nuclear structural components </p> <p>5.4.4 Fretting wear of nuclear steam generator tubes—Effects of process parameters </p> <p>5.4.5 Fretting Wear of nuclear fuel assembly—Effect of process parameters </p> <p>5.4.6 Concluding remarks and future outlook </p> <p>Acknowledgments </p> <p>References </p> <p>5.5 Rolling bearings </p> <p>Amir Kadiric and Rachel Januszewski</p> <p>5.5.1 Introduction </p> <p>5.5.2 Mechanisms of false brinelling in rolling bearings </p> <p>5.5.3 Test methods for assessing lubricant protection against fretting wear in bearings </p> <p>5.5.4 Progression of false brinelling damage </p> <p>5.5.5 Influence of lubricant properties and contact conditions on false brinelling </p> <p>5.5.6 Possible measures to mitigate false brinelling risk in rolling bearings </p> <p>5.5.7 Fretting in nonworking surfaces of bearings</p> <p>References </p> <p>5.6 Overhead conductors </p> <p>Jos <p>5.7.1 Introduction </p> <p>5.7.2 Design methodology for fretting in flexible marine riser </p> <p>5.7.3 Experimental characterization of pressure armor material </p> <p>5.7.4 Global riser loading conditions and analysis </p> <p>5.7.5 Local nub-groove fretting analysis </p> <p>5.7.6 Fretting wear-fatigue predictions </p> <p>5.7.7 Concluding remarks </p> <p>Acknowledgments </p> <p>References </p> <p>Index </p></U>