Fretting Wear and Fretting Fatigue

Professor Tomasz Liskiewicz is Head of Department of Engineering at Manchester Metropolitan University. He has over 20 years of international academic and engineering experience from leading research institutions in the UK, France, Canada, and Poland. His research interests focus on surface engineering and tribology of functional surfaces, with a particular interest in fretting wear phenomena. His work has been published in such journals as Applied Surface Engineering; Tribology International; Surface and Coatings Technology; Wear and Industrial & Engineering Chemistry Research. He has presented at an array of international conferences and has been involved in fretting research for 20 years, with a main focus on wear processes. He previously spent 2 years in Alberta, Canada, working as a Senior Scientist at Charter Coating, leading material testing projects for the oil and gas industry. He was elected Fellow of the Institution of Mechanical Engineers in London in 2014 and is a Fellow of the Institute of Physics in London where he acts as Chair of the Tribology Group Committee. Daniele Dini is Head of the Tribology Group at Imperial College London. Prior to joining Imperial in 2006, Professor Dini studied in the Department of Engineering at the University of Oxford, working on fretting fatigue of gas turbine components. He has been involved in work on fretting fatigue and wear for over 20 years, and currently leads the advanced modeling research team within the Tribology Group at Imperial, collaborating closely with its experimentalists. His current research portfolio supports a large team of researchers focused on studies related to the modeling of tribological systems and materials. Most of these projects are multidisciplinary and range from atomic and molecular simulation of lubricants, additives, and surfaces, to modeling of systems, such as machine and biomedical components. He has received many individual and best papers awards, sits on a number of international committees and editorial boards, is a Fellow of the UK Institute of Mechanical Engineers, and has published over 200 journal articles along with several book chapters.

• Contributors xiiiPreface xviiSection I History and fundamental principles1 Brief history of the subjectDaniele Dini and Tomasz Liskiewicz1.1 Early stages1.2 Initial milestones in the understanding of the mechanics of fretting1.3 Crucial steps toward a better understanding of fretting wear and fretting fatigue1.4 State of the art at the beginning of the new millenniumAcknowledgmentsReferences2 Introduction to fretting fundamentals2.1 Fretting—complexities and synergiesTomasz Liskiewicz and Daniele Dini2.1.1 Fretting within a wider context of tribology2.1.2 Fretting wear2.1.3 Fretting fatigue2.1.4 Mitigating fretting damageReferences2.2 Contact mechanics in frettingDaniele Dini and Tomasz Liskiewicz2.2.1 Contact geometry2.2.2 Friction and fretting regimesReferences 362.3 Transition criteria and mapping approachesTomasz Liskiewicz, Daniele Dini, and Yanfei Liu2.3.1 Transition criteria2.3.2 Mapping approachesReferences2.4 Experimental methodsTomasz Liskiewicz, Daniele Dini, and Thawhid Khan2.4.1 Early developments2.4.2 Basic test configurations2.4.3 Fretting wear tests and analytical methods2.4.4 Fretting fatigue tests and analytical methods2.4.5 Combined fretting wear and fatigue approachesReferences2.5 Modelling approachesDaniele Dini and Tomasz Liskiewicz2.5.1 Theoretical models2.5.2 Numerical modelsReferencesSection II Fretting wear3.1 The role of tribologically transformed structures and debris in fretting of metalsPhilip Howard Shipway3.1.1 Overview3.1.2 Wear in both sliding and fretting—Contrasts in the transport of species into and out of the contacts3.1.3 The nature of oxide debris formed in fretting3.1.4 Formation of oxide debris in fretting—The role of oxygen supply and demand3.1.5 Tribo-sintering of oxide debris and glaze formation3.1.6 Microstructural damage—Tribologically transformed structures in fretting3.1.7 The critical role of debris in fretting: Godet’s third body approach3.1.8 Godet’s third body approach revisited: Rate-determining processes in fretting wear3.1.9 ConclusionReferences3.2 Friction energy wear approachSiegfried Fouvry3.2.1 Friction energy wear approach3.2.2 Basics regarding friction energy wear approach3.2.3 Influence of contact loadings regarding friction energy wear rate vi Contents3.2.4 Influence of ambient conditions3.2.5 Surface wear modeling using the friction energy density approach3.2.6 ConclusionsReferences3.3 Lubrication approachesTaisuke Maruyama3.3.1 Introduction3.3.2 Parameter definition3.3.3 Oil lubrication3.3.4 Grease lubrication3.3.5 Mechanism for fretting wear reduction in grease lubrication3.3.6 ConclusionsAcknowledgmentsReferences3.4 Impact of roughnessKrzysztof J. Kubiak and Thomas G. Mathia3.4.1 Introduction3.4.2 Contact of rough surfaces3.4.3 Stress distribution in rough contact3.4.4 Effective contact area3.4.5 Coefficient of friction3.4.6 Bearing capacity3.4.7 Surface anisotropy and orientation3.4.8 Transition between partial and gross slip3.4.9 Impact of surface roughness on fretting wear3.4.10 Friction in lubricated contact conditions3.4.11 Energy dissipated at the interfaces for smooth and rough surfaces3.4.12 Impact of surface roughness on crack initiation 3.4.13 Dynamics of surface roughness evolution in fretting contact3.4.14 Measurement of fretting wear using surface metrology References 3.5 Materials aspects in fretting Thawhid Khan, Andrey Voevodin, Aleksey Yerokhin, and Allan Matthews3.5.1 Physical processes impacting materials in industrial fretting contacts 3.5.2 Factors affecting fretting behavior of different materials groups Contents vii3.5.3 Materials engineering approaches to the mitigation of fretting wear3.5.4 Application of coatings to mitigate fretting wear 3.5.5 Advanced coating designs and architectures3.5.6 Concluding remarks References 3.6 Contact size in fretting Ben D. Beake3.6.1 Introduction 3.6.2 Experimental techniques for nano-/microscale fretting and reciprocating wear testing 3.6.3 Case studies 3.6.4 Conclusions References Section III Fretting fatigue4.1 Partial slip problems in contact mechanicsDavid A. Hills and Matthew R. Moore4.1.1 Introduction4.1.2 Global and pointwise friction 4.1.3 Global and local elasticity solutions4.1.4 Half-plane contacts: Fundamentals4.1.5 Sharp-edged (complete) contact: Fundamentals4.1.6 Partial slip of incomplete contacts4.1.7 Dislocation-based solutions 4.1.8 Asymptotic approaches 4.1.9 Summary Appendix 4.1.1 Eigenfunctions for the Williams’ wedge solutionAppendix 4.1.2 Size of the permanent stick zone for a Hertz geometry with large remote tensions References 4.2 Fundamental aspects and material characterization Antonios E. Giannakopoulos and Thanasis Zisis4.2.1 Introduction 4.2.2 Mechanical models and metrics 4.2.3 The crack analogue approach 4.2.4 Modification of the crack analogue 4.2.5 Material testing and characterization 4.2.6 Looking ahead References viii Contents4.3 Fretting fatigue design diagram Yoshiharu Mutoh, Chaosuan Kanchanomai, and Murugesan Jayaprakash4.3.1 Equations for estimating fretting fatigue strength based on strength of materials approach 4.3.2 Fracture mechanics approach for fretting fatigue life prediction 4.3.3 Fretting fatigue design diagram based on stresses on the contact surface 4.3.4 Summary References 4.4 Life estimation methods Toshio Hattori4.4.1 Fretting fatigue features and fretting processes 4.4.2 Fretting fatigue crack initiation limit 4.4.3 High-cycle fretting fatigue life estimations considering fretting wear 4.4.4 Low-cycle fretting fatigue life estimations without considering fretting wear 4.4.5 Application of failure analysis of several accidents and design analyses 4.4.6 Conclusions References 4.5 Effect of surface roughness and residual stresses Jaime Domı´nguez, Jes 4.5.1 Introduction 4.5.2 Effect of surface roughness on fretting fatigue 4.5.3 Residual stresses in fretting 4.5.4 Modeling the effect of surface roughness on frettingfatigue 4.5.5 Residual stress modeling in fretting fatigue References 4.6 Advanced numerical modeling techniques for crack nucleation and propagation Nadeem Ali Bhatti, Kyvia Pereira, and Magd Abdel Wahab4.6.1 Introduction 4.6.2 Theoretical background 4.6.3 Numerical modeling 4.6.4 Crack nucleation prediction 4.6.5 Crack propagation lives estimation 4.6.6 Summary and conclusions 4.6.7 Way forward References Contents ix4.7 A thermodynamic framework for treatment of fretting fatigue Ali Beheshti and Michael M. Khonsari4.7.1 Introduction 4.7.2 Thermodynamically based CDM 4.7.3 CDM analysis of fretting fatigue crack nucleation with provision for size effect 4.7.4 Fretting subsurface stresses with provision for surface roughness 4.7.5 CDM-based prediction of fretting fatigue crack nucleation life considering surface roughness 4.7.6 Conclusion and remarksReferences Section IV Engineering applications affected by fretting5.1 Aero engines John Schofield and David Nowell5.1.1 Introduction 5.1.2 Examples of engine events 5.1.3 Areas subject to fretting 5.1.4 Mitigation measures 5.1.5 Design criteria—Academic perspective 5.1.6 Industrial applications perspective 5.1.7 Conclusions References 5.2 Electrical connectors Yong Hoon Jang, Ilkwang Jang, Youngwoo Park, and Hyeonggeun Jo5.2.1 Introduction 5.2.2 Effects of fretting on electrical contact resistance 5.2.3 Fretting in industrial applications 5.2.4 Alternative solutions for fretting in electrical contacts 5.2.5 Summary Acknowledgments References 5.3 Biomedical devices Michael G. Bryant, Andrew R. Beadling, Abimbola Oladukon, Jean Geringer, and Pascale Corne5.3.1 Introduction 5.3.2 Common biomaterials 5.3.3 The biological environment 5.3.4 Compound tribocorrosion degradation mechanisms of materials in the biological environment x Contents5.3.5 In vivo fretting corrosion within the biological environment 5.3.6 Conclusions References 5.4 Nuclear power systems M. Helmi Attia5.4.1 Introduction 5.4.2 Critical safety components of the nuclear reactor that are susceptible to fretting wear damage 5.4.3 Methodology for predicting fretting damage of nuclear structural components 5.4.4 Fretting wear of nuclear steam generator tubes—Effects of process parameters 5.4.5 Fretting Wear of nuclear fuel assembly—Effect of process parameters 5.4.6 Concluding remarks and future outlook Acknowledgments References 5.5 Rolling bearings Amir Kadiric and Rachel Januszewski5.5.1 Introduction 5.5.2 Mechanisms of false brinelling in rolling bearings 5.5.3 Test methods for assessing lubricant protection against fretting wear in bearings 5.5.4 Progression of false brinelling damage 5.5.5 Influence of lubricant properties and contact conditions on false brinelling 5.5.6 Possible measures to mitigate false brinelling risk in rolling bearings 5.5.7 Fretting in nonworking surfaces of bearingsReferences 5.6 Overhead conductors Jos 5.7.1 Introduction 5.7.2 Design methodology for fretting in flexible marine riser 5.7.3 Experimental characterization of pressure armor material 5.7.4 Global riser loading conditions and analysis 5.7.5 Local nub-groove fretting analysis 5.7.6 Fretting wear-fatigue predictions 5.7.7 Concluding remarks Acknowledgments References Index