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

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

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

[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

[5] Ahmed R. Contact fatigue failure modes of HVOF coatings. Wear, 2002, 253(3‒4): 473–487

[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

[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

[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

[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

[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

[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

[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

[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

[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

[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

[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

[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

[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

[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

[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

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