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contact fatigue
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Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 January 2015
DOI: 10.31399/asm.tb.spsp2.t54410499
EISBN: 978-1-62708-265-5
..., carbonitriding, and nitrocarburizing. The discussion on carburizing addresses several interrelated factors, including processing principles, alloying, surface oxidation, residual stresses, bending fatigue, contact fatigue, and fracture. carbonitriding carburizing ferritic nitrocarburizing flame...
Abstract
Mechanical components often require surface treatments to meet application demands. This chapter describes several surface hardening treatments for steel and their effect on microstructure, composition, and properties. It discusses flame hardening, induction heating, carburizing, nitriding, carbonitriding, and nitrocarburizing. The discussion on carburizing addresses several interrelated factors, including processing principles, alloying, surface oxidation, residual stresses, bending fatigue, contact fatigue, and fracture.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 September 2005
DOI: 10.31399/asm.tb.gmpm.t51250311
EISBN: 978-1-62708-345-4
..., namely dimensional, surface finish texture, metallurgical, and residual stress. The following section presents the tests that simulate gear action, namely the rolling contact fatigue test, the single-tooth fatigue test, the single-tooth single-overload test, and the single-tooth impact test. Finally...
Abstract
Mechanical tests are performed to evaluate the durability of gears under load. The chapter first discusses the processes involved in the computations of stress for test parameters of gear. Next, the chapter reviews the four areas of specimen characterization of a test program, namely dimensional, surface finish texture, metallurgical, and residual stress. The following section presents the tests that simulate gear action, namely the rolling contact fatigue test, the single-tooth fatigue test, the single-tooth single-overload test, and the single-tooth impact test. Finally, the chapter describes the test procedures for surface durability (pitting), root strength (bending), and scoring (or scuffing) testing.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 1999
DOI: 10.31399/asm.tb.cmp.t66770135
EISBN: 978-1-62708-337-9
..., toughness, and fatigue resistance. It likewise explains how carbon affects case hardenability, surface hardness, and case toughness and how case depth influences residual stresses and bending and contact fatigue. It also discusses the effect of quenching methods and addresses the issue of distortion...
Abstract
The design of case-hardened components is an iterative process, requiring the consideration of multiple interrelated factors. This chapter walks readers through the steps involved in selecting an appropriate material and assessing the influence of alloy composition and cooling rate on core properties including hardenability, microstructure, tensile and yield strength, ductility, toughness, and fatigue resistance. It likewise explains how carbon affects case hardenability, surface hardness, and case toughness and how case depth influences residual stresses and bending and contact fatigue. It also discusses the effect of quenching methods and addresses the issue of distortion.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 1999
DOI: 10.31399/asm.tb.cmp.t66770171
EISBN: 978-1-62708-337-9
...; 50KhNi: 0.5% C, 0.6% Mn, 0.6% Cr, 1.2% Ni, <0.3% Cr; ShKh15:1.0% C, 1.5% Cr, <0.3% Ni, <0.25% Cu. (b) Distortions in crystal lattice in α solid solution Contact fatigue life of case-hardened 16CD4 steel Table 7.19 Contact fatigue life of case-hardened 16CD4 steel Additional...
Abstract
This chapter familiarizes readers with tempering and refrigeration treatments and their effect on case-carburized parts. It explains how tempering makes such parts easier to machine, more structurally and dimensionally stable, and more durable in certain applications. It identifies key process parameters and provides test data showing how they affect hardness, yield strength, bending and contact fatigue, and fracture toughness. It also addresses potential problems stemming from process-related factors such as the presence of hydrogen and the effects of aging and grinding. In regard to refrigeration, the chapter explains that it is not uncommon for subzero treatments to be included in the production of carburized parts whether as a standard procedure or optional step. Subzero cooling promotes the transformation of retained austenite to martensite, thereby increasing surface hardness and reducing the propensity of quenched carburized steels to burn and crack during surface grinding. The chapter includes numerous data plots and tables showing how the various treatments influence hardness, wear resistance, tensile properties, and fatigue and fracture behaviors.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 30 November 2013
DOI: 10.31399/asm.tb.uhcf3.t53630189
EISBN: 978-1-62708-270-9
...Characteristics of contact stress fatigue Table 2 Characteristics of contact stress fatigue Characteristic Surface pitting Subsurface pitting Subcase fatigue Location of origin Surface, often at “micropits” Short distance below surface, usually at a nonmetallic inclusion Near...
Abstract
The wear caused by contact stress fatigue is the result of a wide variety of mechanical forces and environments. This chapter discusses the characteristics of four types of contact stress fatigue on mating metal surfaces: surface, subsurface, subcase, and cavitation. Features and corrective actions for these contact stress fatigue are discussed. The chapter also lists some possible ways to reduce the cavitation fatigue problem.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 September 2005
DOI: 10.31399/asm.tb.gmpm.t51250293
EISBN: 978-1-62708-345-4
... contact (pitting or spalling), rolling contact, thermal fatigue Impact Tooth bending, tooth shear, tooth chipping, case crushing, torsional shear Wear Abrasive, adhesive Stress rupture Internal, external In an analysis of more than 1500 studies, the three most common failure modes, which...
Abstract
This chapter summarizes the various kinds of gear wear and failure and how gear life in service is estimated and discusses the kinds of flaws in material that may lead to premature gear fatigue failure. The topics covered are alignment, gear tooth, surface durability and breakage of gear tooth, life determined by contact stress and bending stress, analysis of gear tooth failure by breakage after pitting, and metallurgical flaws that reduce the life of gears. The chapter briefly reviews some components in the design and structure of each gear and/or gear train that must be considered in conjunction with the teeth to enhance fatigue life.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 March 2006
DOI: 10.31399/asm.tb.fdsm.t69870237
EISBN: 978-1-62708-344-7
... effects, foreign particles, and stresses generated by rolling contact. crack growth crack initiation dislocations fatigue mechanism plasticity rolling contact Introduction There has always been an aura of mystery regarding why metals, and materials in general, fail in fatigue...
Abstract
This chapter focuses on the processes and mechanisms involved in fatigue. It begins with a review of some of the early theories of fatigue and the tools subsequently used to obtain a better understanding of the fatigue process. It then explains how plasticity plays a major role in creating dislocations, breaking up grains into subgrains, and causing microscopic imperfections to coalesce into larger flaws. It also discusses the factors that contribute to the development and propagation of fatigue cracks, including surface deterioration, volumetric and environmental effects, foreign particles, and stresses generated by rolling contact.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 1999
DOI: 10.31399/asm.tb.cmp.t66770051
EISBN: 978-1-62708-337-9
... of the austenitization temperature of heating before quenching in the ratio of structural components and the composition of the matrix of the case-hardened layer on the contact fatigue Table 3.2 Effect of the austenitization temperature of heating before quenching in the ratio of structural components...
Abstract
This chapter discusses the formation of free carbides and their effect on case-carburized components. It explains how alloying elements influence the composition and structure of carbide phases produced at cooling rates typical of carburizing process. It describes the morphology and distribution of the various types of carbides formed and explains how they affect mechanical properties such as hardness, residual stresses, fatigue and fracture behaviors, and wear resistance. It also provides guidance for determining what processing conditions to avoid and when and why parts should be rejected.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 1999
DOI: 10.31399/asm.tb.cmp.t66770077
EISBN: 978-1-62708-337-9
..., which approximates to the “knee” of the S-N curve. Source: Ref 28 Fig. 4.22 Effect of austenitizing temperature on hardness, amount of retained austenite, and contact fatigue strength of 90KhGNMFL steel under a 3.43 GPa (350 kgf/mm 2 ) load. Source: Ref 32 Fig. 4.23 Effect...
Abstract
This chapter addresses the issue of retained austenite in quenched carburized steels. It explains why retained austenite can be expected at the surface of case-hardened components, how to estimate the amount that will be present, and how to effectively stabilize or otherwise control it. It presents detailed images and data plots showing how retained austenite appears and how it influences hardness, tensile properties, residual stresses, fatigue and fracture behaviors, and wear resistance.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 September 2005
DOI: 10.31399/asm.tb.gmpm.t51250257
EISBN: 978-1-62708-345-4
... of gear failure analysis. contact fatigue failure analysis fatigue failure gears macropitting micropitting rolling-contact fatigue scuffing spalling stress rupture subcase fatigue thermal fatigue wear GEARS can fail in many different ways, and except for an increase in noise level...
Abstract
Gears can fail in many different ways, and except for an increase in noise level and vibration, there is often no indication of difficulty until total failure occurs. This chapter begins with the classification of gear failure modes, followed by sections discussing the characteristics of various fatigue failures. Then, it provides information on the modes of impact fractures, wear, scuffing, and stress rupture. Next, the chapter describes the causes of gear failures and discusses the processes involved in conducting the failure analysis. Finally, the chapter presents examples of gear failure analysis.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 September 2005
DOI: 10.31399/asm.tb.gmpm.t51250227
EISBN: 978-1-62708-345-4
.... Nitriding produces a wear- and fatigue-resistant surface on gear teeth and is used in applications where gears are not subjected to high shock loads or contact stress. It is useful for gears that need to maintain their surface hardness at elevated temperatures. Gears used in industrial, automotive...
Abstract
Nitriding is a surface hardening heat treatment that introduces nitrogen into the surface of steel while it is in the ferritic condition. Gas nitriding using ammonia as the nitrogen-carrying species is the most commonly employed process and is emphasized in this chapter. Nitriding produces a wear- and fatigue-resistant surface on gear teeth and is used in applications where gears are not subjected to high shock loads or contact stress. It is useful for gears that need to maintain their surface hardness at elevated temperatures. Gears used in industrial, automotive, and aerospace applications are commonly nitrided. This chapter discusses the processes involved in gas, controlled, and ion nitriding.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 1999
DOI: 10.31399/asm.tb.cmp.t66770199
EISBN: 978-1-62708-337-9
... 4028 Shot peened 62.2 36 1.1 0.044 2265 329 1035 150 (a) Converted from HRA. (b) Distance to 510 HV Fig. 8.25 Relationship between fatigue limit at 10 7 cycles and contact stress for case-hardened 20Kh2N4A test pieces (7.5 mm diam, 1.1 to 1.5 mm case depth). Source: Ref...
Abstract
Mechanical treatments such as grinding and shot peening are often employed in the production of case-carburized parts. Grinding, besides restoring precision, removes carbide films, internal oxidation, and high-temperature transformation products. Shot peening strengthens component surfaces and induces a stress state that increases fatigue resistance. This chapter describes both processes as well as roller burnishing. It explains how these treatments are applied and how they influence the microstructure, properties, and behaviors of case-hardened components. It also addresses process challenges, particularly in regard to grinding.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2012
DOI: 10.31399/asm.tb.ffub.t53610461
EISBN: 978-1-62708-303-4
... (a) Up, toward top; down, toward root. (b) Negative sliding: rolling and sliding are in opposite directions. (c) Positive sliding: rolling and sliding are in the same direction. Source: Ref 7 Characteristics of contact-stress fatigue Table 2 Characteristics of contact-stress fatigue...
Abstract
This chapter discusses the causes and effects of wear along with prevention methods. It covers abrasive, erosive, erosion-corrosion, grinding, gouging, adhesive, and fretting wear. It also discusses various forms of contact-stress fatigue, including subsurface-origin fatigue, surface-origin fatigue, subcase-origin fatigue (spalling fatigue), and cavitation fatigue.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 1999
DOI: 10.31399/asm.tb.cmp.t66770001
EISBN: 978-1-62708-337-9
... to are bending-fatigue strength, contact-fatigue resistance, hardness, and wear resistance. These properties were chosen because it is to promote one or more of these properties that the carburizing treatment is employed. A gear tooth is a good example in which each of these must be considered. Some significance...
Abstract
This chapter provides a brief but practical overview of the case carburizing process. It discusses the benefits and challenges of the process and compares and contrasts it with other hardening methods. It explains how design allowables and safety factors compensate for unknowns and familiarizes readers with the steps involved in determining case depth and verifying that case carbon requirements have been met.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 October 2011
DOI: 10.31399/asm.tb.mnm2.t53060385
EISBN: 978-1-62708-261-7
..., sliding, and combined effect Fig. 16.9 Crack origin subsurface in a gear tooth section due to rolling-contact fatigue. Progression was parallel to surface and inward away from surface. Not etched. Original magnification: 60× Fig. 16.10 Typical morphology of fatigue spall in rolling...
Abstract
Durability is a generic term used to describe the performance of a material or a component made from that material in a given application. In order to be durable, a material must resist failure by wear, corrosion, fracture, fatigue, deformation, and exposure to a range of service temperatures. This chapter covers several types of component and material failure associated with wear, temperature effects, and crack growth. It examines temperature-induced, brittle, ductile, and fatigue failures as well as failures due to abrasive, erosive, adhesive, and fretting wear and cavitation fatigue. It also discusses preventative measures.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 September 2005
DOI: 10.31399/asm.tb.gmpm.t51250039
EISBN: 978-1-62708-345-4
... fatigue fracture gears iron-base alloys magnesium alloys rolling contact fatigue surface-hardening steels through hardening wrought steel GEAR MATERIALS can be broadly classified into two groups: nonmetallic and metallic materials. Nonmetallics are the plastics, both thermoplastic...
Abstract
This chapter describes important requirements for ferrous and nonferrous alloys used for gears. Wrought surface-hardening and through-hardening carbon and alloy steels are the most widely used of all gear materials and are emphasized in this chapter. The processing characteristics of gear steels and the bending fatigue strength and properties of carburized steels are reviewed. In addition to wrought steels, the chapter provides information on the other iron-base alloys that are used for gears, namely cast carbon and alloy steels, gray and ductile cast irons, powder metallurgy irons and steels, stainless steels, and tool steels. In terms of nonferrous alloys, the chapter addresses copper-base alloys, die cast aluminum alloys, zinc alloys, and magnesium alloys.
Book Chapter
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 1999
DOI: 10.31399/asm.tb.cmp.t66770011
EISBN: 978-1-62708-337-9
... 3 5 1 155 93 81 6 880 758 733 12 2400 2290 2180 Fig. 1.25 Contact fatigue life in relation to the amount of material removed from carburized SAE 8620 samples prior to testing. The hatched band represents the depth of internal oxidation beneath the original surface...
Abstract
Gas carburizing is known to promote internal oxidation in steel which can adversely affect certain properties. This chapter discusses the root of the problem and its effect on component lifetime and performance. It explains that gas-carburizing atmospheres contain water vapor and carbon dioxide, providing oxygen that reacts with alloying elements, particularly manganese, chromium, and silicon. It examines the composition and distribution of oxides produced in different steels and assesses the resulting composition gradients. It describes how these changes influence the development of high-temperature transformation products as well as microstructure, hardenability, and carbon content and properties such as fatigue and fracture behaviors, hardness, and wear resistance. It also explains how to manage internal oxidation through material design, process control, and other measures.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 2018
DOI: 10.31399/asm.tb.msisep.t59220519
EISBN: 978-1-62708-259-4
... S.A., RJ, Brazil. Fig. 15.31 Radial section of a railway wheel. Region immediately below the tread. Fine pearlite. Etchant: nital 2%. Cracks caused by contact fatigue. Courtesy of MRS Logística S.A., RJ, Brazil. Fig. 15.12 AISI 4145 steel quenched and tempered. Tempered martensite...
Abstract
This chapter examines the microstructure of special bar quality (or engineering) steels and how it is influenced by carbon content, tempering temperature, and prior austenitic grain size. It explains how some of the changes are difficult to detect and require special etching and/or measurement techniques. It provides information on many types of engineering steel, including medium and high-carbon steels used in rail applications. It also examines the effect of nickel-phosphorus coatings on stainless steel and phosphate coatings used to reduce friction during thread rolling and other such procedures.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 September 2008
DOI: 10.31399/asm.tb.fahtsc.t51130177
EISBN: 978-1-62708-284-6
...Comparison of carburizing and carbonitriding processes Table 1 Comparison of carburizing and carbonitriding processes Process Comments Carburizing Hard, highly wear-resistant surface (medium case depths), excellent contact load potential, good bending fatigue strength, good seizure...
Abstract
This chapter provides information on various contributors to failure of carburized and carbonitrided components, with the primary focus on carburized components. The most common contributors covered include component design, selection of proper hardenability, increased residual stress, dimensional stability, and generation of quenching and grinding cracks. They also include insufficient case hardness and improper core hardness, influence of surface carbon content and grain size, internal oxidation, structure of carbides, and inclusion of noncarbide. Details on micropitting, macropitting, case crushing, pitting corrosion, and partial melting are also provided.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 September 2008
DOI: 10.31399/asm.tb.fahtsc.t51130111
EISBN: 978-1-62708-284-6
...-contact fatigue appears like wear in early stages Multiple intergranular fissures covered with reaction scale Grain faces may show porosity Metallographic inspection, 50 to 1000× (cross section) Grain distortion and flow near fracture Irregular, transgranular fracture Little...
Abstract
This chapter briefly outlines some of the basic aspects of failure analysis, describing some of the basic steps and major concerns in conducting a failure analysis. A brief review of failure types from fracture, distortion, wear-assisted failure, and environmentally assisted failure (corrosion) is also provided.