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Residual Stresses and Fretting Fatigue: A. Benrabah, C. Langlade, A.B. Vannes
Residual Stresses and Fretting Fatigue: A. Benrabah, C. Langlade, A.B. Vannes
267–273
Abstract
Controlled residual stress field, induced by conventional and ultrasonic shot peening in some reference materials has been measured
using X-ray diffraction. Its influence on the tribological behavior of these treated samples has been studied and its evolution during the
fretting tests has been followed and related to the observed wear mechanisms. q 1999 Elsevier Science S.A. All rights reserved.
0043-1648r99r$ - see front matter q 1999 Elsevier Science S.A. All rights reserved.
PII: S 0 0 4 3 - 1 6 4 8 Ž 9 8 . 0 0 3 4 2 - 1
268 A. Benrabah et al.r Wear 224 (1999) 267–273
Table 1 Table 2
Materials characteristics Residual stress measured on the different unworn samples
Composition 32CrMoVa13 30NiCrMo16 sf s 08 sf s908 s 13 or
C 0.29–0.36 0.26–0.33
ŽMPa. ŽMPa. t ŽMPa.
Si 0.1–0.4 0.1–0.4 A1 Before cutting y520"30 y520"30 0.5"4
Mn 0.4–0.7 0.2–0.6 After cutting y480"30 y475"30 0.5"4
S - 0.02 - 0.02 A2-1 Before cutting y535"30 y530"30 2"4
P - 0.025 - 0.025 After cutting y460"20 y460"20 2"4
Cr 2.8–3.3 1.2–1.5 A2-2 Before cutting y520"25 y515"30 4"5
Ni - 0.3 3.3–4.3 After cutting y430"30 y420"20 4"5
Mo 0.7–1.2 0.3–0.6 B y535"35 y550"35 2"4
Va 0.15–0.35 –
Thermal treatment quenchedq quenchedq
tempered tempered
Hardness ŽHV500 . 395"5 405"25
R 0.2 ŽMPa. 979 1044 balls in a titanium container. Samples, balls and container
Tensile Yield Strength 975 900 were then submitted to ultrasonic vibrations at 20,000 Hz.
ŽMpa. at 10 7 cycles
The induced shot peening creates microcracks similar to
those observed when using conventional treatment.
Two types of 52100 balls have been used:
52100 steel ŽTable 1 for materials characteristics.. Samples case A2-1: balls with small diameter ŽB 1 mm.
have a controlled roughness of R a s 0.04 mm. The plane case A2-2: balls with medium diameter ŽB 3 mm.
samples to be tested were made of: Both conditions give an overlapping rate of more than
- Case A: 30 = 30 = 10 mm3 parallelepipeds made of 200%.
32CrMoVa13 Žsee Table 1. polished to achieve an
initial roughness of R a s 0.3 Ž"0.05. mm. 2.2.2. Sample B
- Case B: 10 = 10 = 10 mm 3 cubes made of These samples were conventionally shot peened Žsimilar
30NiCrMo16 Žsee Table 1. with an initial roughness of to case A1.. However in these cases, cubes of 1 = 1 = 1
R a s 0.88 Ž"0.05. mm mm3 dimension were cut prior to the shot peening process
Both types of samples were shot peened to create in order to avoid any risk of stress relaxation.
controlled residual stresses. Fig. 1 summarizes the different samples’ treatments.
After rapid verification using herztian hardness test w5x, a
2.2.1. Samples A Young’s modulus E of 220 GPa and a Poisson’s coeffi-
Case A1: Discs of 100 mm in diameter and 10 mm cient of 0.3 were chosen for the stress calculation.
thickness were treated on one face using conventional shot
peening Žballs of 0.6 mm in diameter. leading to an 2.3. Characterization
ALMEN intensity ŽAFNOR NFL 06832 standard. of 0.2–
0.3 mm. Parallelepipeds were then extracted from these X-rays diffraction analyses have been performed on
treated discs. each sample before and after fretting test to evaluate the
Case A2: Ultrasonic shot peening was used in these superficial residual stress. For this, we followed the con-
cases. In this process, samples were placed with 52100 ventional sin2c method w6,7x on a DOSOPHATEX appara-
tus ŽCourbon, St. Etienne, France. using the K a line of a
Cr anticathode Ž211 line.. This produces a Bragg angle of
Fig. 4. Evolution of the residual stresses in the fretting wear scar Žwith
Fn s800 N, N s1000 cycles and Ds"12 mm..
3. Results and discussion
3.1. Preliminary results and Õalidation 3.1.3. Validation of our experimental stress measurement
method
Fig. 4 presents the typical results obtained on samples
3.1.1. Pre-testing characterization after fretting tests. The limits of the contact area can
Prior to any fretting tests, the stress concentration was clearly be defined and the evolutions measured in both
evaluated on the different shot peened samples; results are directions are quite similar.
presented in Table 2. Fig. 2 illustrated the typical values
obtained in the case B. 3.2. Influence of the shot peening treatment on the fretting
behaÕior
3.1.2. Residual stress measurement after fretting testing
The contact geometry was chosen to facilitate the stress It may first be noticed that whatever the tested materi-
measurement in the wear scar Žrectangular area 0.8 = 0.8 als, numerous previous studies have shown that, for each
mm2 .. Fig. 3 presents a sketch of the experimental proce- couple of experimental and controlled parameters Ž Fn , D .,
dure which was followed to evaluate the superficial stress two different mechanical behaviors may be obtained.
after friction. It shows a high rate of overlapping between
two successive areas of measurements. It should be noticed
that each measure gives a mean value of the residual stress
inside the analyzed area so that very localized variations
may not be very accurately detected. It should also be
noted that almost no fluctuation or dispersion is observed
which means that no orientation effect is induced by the
surface treatment. However Table 2 clearly shows that the
sample cutting in cases A leads to an isotropic stress
relaxation of about 15%.
Fig. 5. Ža. RCFM’s obtained on two different steels before and after
Fig. 3. Sketch of the experimental procedure followed to evaluate the clasical shot peening, Žb. RCFM’s obtained on 32CrMoVa13 steel after
residual stresses field in the fretting wear scar. ultrasonic shot peening using two different balls diameters.
270 A. Benrabah et al.r Wear 224 (1999) 267–273
Table 3
Measured roughness in micron as a function of the shot peening process
R a Žmm. R t Žmm. R z Žmm.
Case B 1.8"0.4 10"2 8.5"0.5
Case A1 1.4"0.4 6.5"0.5 5.5"0.5
Case A2-1 0.37"0.01 1.6"0.1 1.3"0.1
Case A2-2 1.5"0.4 8"2 6"0.5
Fig. 7. Evolution of the residual stresses in the wear scar for different shot peened samples with different roughnesses.
A. Benrabah et al.r Wear 224 (1999) 267–273 271
Fig. 9. Evolution of the residual stresses measured on 32CrMoVa13 steel Fig. 10. Evolution of the residual stresses measured on 30NiCrMo16 steel
at the center and at the limit of the wear scar as a function of the number at the center and at the limit of the wear scar as a function of the number
of cycles Žlogarithmic scale.. of cycles Žlogarithmic scale..
272 A. Benrabah et al.r Wear 224 (1999) 267–273
3.3.2.1. Phase 1. corresponding to short test duration Fig. 12. Evolution of D LŽ%. measured at the contact center on 32CrMo-
Ž- 10,000 cycles. reveals stress relaxation of about 20%. Va13 steel.
Whoever, when carefully considering D s and D Li , this
phase I in the 08 direction can be subdivided into several
steps: These particles originate from a TTS at the subsurface.
N - 300 cycles ŽFig. 14.: significant reduction of D s This TTS is made of nanocrystalline ferrite supersaturated
and D Li in the 08 direction, no variation in the 908 axis. in additional elements. Non-oriented and dislocation rich,
N ) 1000 cycles: correlated evolutions of D s and D Li it is very hard and therefore very brittle. Microcracking of
similar in both directions. This particular behavior of D Li this TTS leads to the detachment of particles which can
during the very first cycles can be explained by consider- later be oxidized Žred powder.. From our present results,
ing the material damage. Numerous studies w2,3,13x have the following points may be highlighted.
clearly established that these two types of steel, when The increase of D L i is related to the TTS formation
submitted to fretting conditions such as those chosen in which creates coherent microdomains. This TTS transfor-
this study, undergo wear damage by particle detachment. mation concerns the entire contact area and is macroscopi-
cally dependent on the friction direction during the first
1000 cycles ŽFig. 13.. This point was uncovered in the
previous works w2,14x due to the absence of crystallo-
graphic texture at the submicroscopic scale which tends to
screen it.
Compared to the stress and strain induced by the shot
peening process at the material subsurface, the formation
of the TTS reduces the equivalent specific volume. As the
internal stresses are linked to the elastic accommodation
between the equivalent deformations in the different mi-
crodomains, the TTS also modifies the equilibrium in the
first order residual stresses and leads to the stress relax-
ation evidenced in this work w15x. This phenomenon is
rather a ‘dynamic crystallization’ w13,14x than a structural
restoration.
Fig. 11. Evolution of the residual stresses measured on both steels at the
center of the wear scar as a function of the number of cycles Žlinear Fig. 13. Evolution of D LŽ%. measured at the contact center on 30NiCr-
scale.. Mo16 steel.
A. Benrabah et al.r Wear 224 (1999) 267–273 273
4. Conclusions
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