Accumulated damage process of thermal sprayed coating under rolling contact by acoustic emission technique

Jia XU, Zhen-yu ZHOU, Zhong-yu PIAO

PDF(633 KB)
PDF(633 KB)
Front. Mech. Eng. ›› 2016, Vol. 11 ›› Issue (3) : 227-232. DOI: 10.1007/s11465-016-0395-9
RESEARCH ARTICLE

Accumulated damage process of thermal sprayed coating under rolling contact by acoustic emission technique

Author information +
History +

Abstract

The accumulated damage process of rolling contact fatigue (RCF) of plasma-sprayed coatings was investigated. The influences of surface roughness, loading condition, and stress cycle frequency on the accumulated damage status of the coatings were discussed. A ball-on-disc machine was employed to conduct RCF experiments. Acoustic emission (AE) technique was introduced to monitor the RCF process of the coatings. AE signal characteristics were investigated to reveal the accumulated damage process. Result showed that the polished coating would resist the asperity contact and remit accumulated damage. The RCF lifetime would then extend. Heavy load would aggravate the accumulated damage status and induce surface fracture. Wear became the main failure mode that reduced the RCF lifetime. Frequent stress cycle would aggravate the accumulated damage status and induce interface fracture. Fatigue then became the main failure mode that also reduced the RCF lifetime.

Keywords

accumulated damage / spray coating / rolling contact fatigue / acoustic emission

Cite this article

Download citation ▾
Jia XU, Zhen-yu ZHOU, Zhong-yu PIAO. Accumulated damage process of thermal sprayed coating under rolling contact by acoustic emission technique. Front. Mech. Eng., 2016, 11(3): 227‒232 https://doi.org/10.1007/s11465-016-0395-9

References

[1]
Xu B, Wang H, Ma G. Advanced surface engineering technologies for remanufacturing forming. Rare Metal Materials and Engineering, 2012, (S1): 1–5 (in Chinese)
[2]
Xu B, Fang J, Dong S, . Heat-affected zone microstructure evolution and its effects on mechanical properties for laser cladding FV520B stainless steel. Acta Metallurgica Sinica, 2016, 52(1): 1–9 (in Chinese)
[3]
Zivelonghi A, Weitkamp T, Larrue A. Open porosity and 3D pore architecture in plasma-sprayed tungsten. Scripta Materialia, 2016, 115: 66–70
CrossRef Google scholar
[4]
Zhang C, Wang J, Geng X. Tungsten oxide coatings deposited by plasma spray using powder and solution precursor for detection of nitrogen dioxide gas. Journal of Alloys and Compounds, 2016, 668: 128–136
CrossRef Google scholar
[5]
Ahmed R. Contact fatigue failure modes of HVOF coatings. Wear, 2002, 253(3‒4): 473–487
CrossRef Google scholar
[6]
Stewart S, Ahmed R. Contact fatigue failure modes in hot isostatically pressed WC-12%Co coatings. Surface and Coatings Technology, 2003, 172(2‒3): 204–216
CrossRef Google scholar
[7]
Stewart S, Ahmed R, Itsukaichi T. Contact fatigue failure evaluation of post-treated WC-NiCrBSi functionally graded thermal spray coatings. Wear, 2004, 257(9‒10): 962–983
CrossRef Google scholar
[8]
Stewart S, Ahmed R, Ituskaichi T. Rolling contact fatigue of post-treated WC-NiCrBSi thermal spray coatings. Surface and Coatings Technology, 2005, 190(2‒3): 171–189
CrossRef Google scholar
[9]
Fujii M, Ma J, Yoshida A, . Influence of coating thickness on rolling contact fatigue of alumina ceramics thermally sprayed on steel roller. Tribology International, 2006, 39(11): 1447–1453
CrossRef Google scholar
[10]
Fujii M, Yoshida A, Ma J, . Rolling contact fatigue of alumina ceramics sprayed on steel roller under pure rolling contact condition. Tribology International, 2006, 39(9): 856–862
CrossRef Google scholar
[11]
Zhang X, Xu B, Xuan F, . Fatigue resistance of plasma-sprayed CrC-NiCr cermet coatings in rolling contact. Applied Surface Science, 2008, 254(13): 3734–3744
CrossRef Google scholar
[12]
Zhang X, Xu B, Tu S, Rolling contact fatigue mechanism of a plasma-sprayed and laser-remelted Ni alloy coating. Fatigue & Fracture of Engineering Materials & Structures, 2009, 32(2): 84–96
CrossRef Google scholar
[13]
Kang J, Xu B, Wang H, . Competing failure mechanism and life prediction of plasma sprayed composite ceramic coating in rolling-sliding contact condition. Tribology International, 2014, 73: 128–137
CrossRef Google scholar
[14]
Kang J, Xu B, Wang H, . Influence of contact stress on rolling contact fatigue of composite ceramic coatings plasma sprayed on a steel roller. Tribology International, 2014, 73: 47–56
CrossRef Google scholar
[15]
Piao Z, Xu B, Wang H, . Investigation of fatigue failure prediction of Fe-Cr alloy coatings under rolling contact based on acoustic emission technique. Applied Surface Science, 2011, 257(7): 2581–2586
CrossRef Google scholar
[16]
Piao Z, Xu B, Wang H, . Investigation of RCF failure prewarning of Fe-based coating by online monitoring. Tribology International, 2014, 72: 156–160
CrossRef Google scholar
[17]
Piao Z, Xu B, Wang H, . Investigation of acoustic emission source of Fe-based sprayed coating under rolling contact. International Journal of Fatigue, 2013, 47: 184–188
CrossRef Google scholar
[18]
Li G, Zhang Z, Wang H, . Acoustic emission monitoring and failure mechanism analysis of rolling contact fatigue for Fe-based alloy coating. Tribology International, 2013, 61: 129–137
CrossRef Google scholar
[19]
Piao Z, Xu B, Wang H, Investigation of rolling contact fatigue lives of Fe-Cr alloy coatings under different loading conditions. Surface and Coatings Technology, 2010, 204(9‒10): 1405–1411
CrossRef Google scholar
[20]
Piao Z, Xu B, Wang H, . Influence of surface roughness on rolling contact fatigue behavior Fe-Cr alloy coatings. Journal of Materials Engineering and Performance, 2013, 22(3): 767–773
CrossRef Google scholar

Acknowledgment

This study was financially supported by the Distinguished Young Scholars of National Natural Science Foundation of China (Grant No. 51125023), the 973 Project (Grant No. 2011CB013405), the National Natural Science Foundation of China (Grant Nos. 51305397 and 51375457), and the Open Foundation of the State Laboratory of Fluid Power Transmission and Control (GZKF-201411) (Grant Nos. 2014C31099 and EM2015042003).

RIGHTS & PERMISSIONS

2016 Higher Education Press and Springer-Verlag Berlin Heidelberg
AI Summary AI Mindmap
PDF(633 KB)

Accesses

Citations

Detail

Sections
Recommended

/