Evaluating Rolling Contact Fatigue Damage Precursors with Rayleigh Waves in 1060 Steel
Source abstract
Abstract
The operational life of components subjected to rolling contacts such as bearings and rail wheels is limited by rolling contact fatigue (RCF). In RCF, materials undergo complex stresses and plastically deform at surface asperities or subsurface inclusions. The accumulation of plastic deformation in surface layers and subsurface inclusions eventually cause spalling and pitting, which can lead to failure of components. Nondestructive evaluation (NDE) of RCF is currently limited to cracking, however there is currently no NDE method to identify damage accumulation prior to crack initiation. Nonlinear ultrasound (NLU) has been shown to be sensitive to dislocation-based damage and thus early damage accumulation induced by fatigue. While NLU has been studied on two-dimensional curved surfaces, three-dimensional curved surfaces, typical for RCF, has not yet been studied. In this work, we apply nonlinear Rayleigh wave to evaluate RCF on a 1060 steel disc with three-dimensional curvature while the disc is mounted on the RCF setup. Custom fixtures were designed and validated with finite element modeling to repeatably generate and detect Rayleigh waves along the circumference of a disc. We measured the Rayleigh wave speed and the acoustic nonlinearity parameter, β, at progressive intervals over 80,000 total RCF cycles. The results show measurable changes in β with increasing cycles, which correlate to damage accumulation during RCF as shown by scanning electron microscopy. This work demonstrates that nonlinear Rayleigh waves are a promising NDE tool for identification of RCF-related damage on curved steel surfaces that resemble real-world rail geometries. This motivates future work to determine the exact dependence of β on RCF damage accumulation.
Source: openaire · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Ultrasonics and Acoustic Wave Propagation · Railway Engineering and Dynamics · Fatigue and fracture mechanics
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (49)
Show source-provided references
1. Olver, A.V.: The mechanism of rolling contact fatigue: an update. Proc. Inst. Mech. Eng. Part J J. Eng. Tribol. 219, 313–330 (2005). https://doi.org/10.1243/135065005X980810.1243/135065005X9808 ↗
2. Alemi, A., Corman, F., Lodewijks, G.: Condition monitoring approaches for the detection of railway wheel defects. Proc. Inst. Mech. Eng. Part F J. Rail. Rapid. Transit. 231, 961–981 (2017). https://doi.org/10.1177/095440971665621810.1177/0954409716656218 ↗
3. Magel, E.E.: Rolling contact fatigue: a comprehensive review. (2011)
4. Brizuela, J., Fritsch, C., Ibáñez, A.: Railway wheel-flat detection and measurement by ultrasound. Transp. Res. Part C Emerg. Technol. 19, 975–984 (2011). https://doi.org/10.1016/j.trc.2011.04.00410.1016/j.trc.2011.04.004 ↗
5. Montinaro, N., Epasto, G., Cerniglia, D., Guglielmino, E.: Laser ultrasonics inspection for defect evaluation on train wheel. NDT E Int. 107, 102145 (2019). https://doi.org/10.1016/j.ndteint.2019.10214510.1016/j.ndteint.2019.102145 ↗
6. Cavuto, A., Martarelli, M., Pandarese, G., Revel, G.M., Tomasini, E.P.: Experimental investigation by laser ultrasonics for high speed train axle diagnostics. Ultrasonics 55, 48–57 (2015). https://doi.org/10.1016/j.ultras.2014.08.01010.1016/j.ultras.2014.08.010 ↗
7. Kim, G., Seo, M.K., Kim, Y.. Il., Kwon, S., Kim, K.B.: Development of phased array ultrasonic system for detecting rail cracks. Sensors Actuators A Phys. 311, 112086 (2020). https://doi.org/10.1016/j.sna.2020.11208610.1016/j.sna.2020.112086 ↗
8. Du, H., Lonsdale, C., Oliver, J., Wilson, B.M., Turner, J.A.: Evaluation of railroad wheel steel with lamellar duplex microstructures using diffuse ultrasonic backscatter. J. Nondestruct. Eval. 32, 331–340 (2013). https://doi.org/10.1007/s10921-013-0186-810.1007/s10921-013-0186-8 ↗
9. Turner, J.A.: Monitoring longitudinal rail stress using diffuse ultrasonic backscatter. (2017)
10. Cantrell, J.H.: Substructural organization, dislocation plasticity and harmonic generation in cyclically stressed wavy slip metals. Proc. R Soc. A Math. Phys. Eng. Sci. 460, 757–780 (2004). https://doi.org/10.1098/rspa.2003.118110.1098/rspa.2003.1181 ↗
11. Gao, X., Qu, J.: Acoustic nonlinearity parameter induced by extended dislocations. J. Appl. Phys. (2018). https://doi.org/10.1063/1.504664010.1063/1.5046640 ↗
12. Gao, X., Qu, J.: Contribution of dislocation pileups to acoustic nonlinearity parameter. J. Appl. Phys. (2019). https://doi.org/10.1063/1.509513510.1063/1.5095135 ↗
13. Cash, W.D., Cai, W.: Dislocation contribution to acoustic nonlinearity: the effect of orientation-dependent line energy. J. Appl. Phys. (2011). https://doi.org/10.1063/1.353073610.1063/1.3530736 ↗
14. Cash, W.D., Cai, W.: Contribution of dislocation dipole structures to the acoustic nonlinearity. J. Appl. Phys. (2012). https://doi.org/10.1063/1.369936210.1063/1.3699362 ↗
15. Pfeifer, D., Kim, J.Y., Jacobs, L.J.: Nonlinear Rayleigh waves to evaluate plasticity damage in X52 pipeline material. Mech. Syst. Signal Process. 143, 106794 (2020). https://doi.org/10.1016/j.ymssp.2020.10679410.1016/j.ymssp.2020.106794 ↗
16. Walker, S.V., Kim, J.Y., Qu, J., Jacobs, L.J.: Fatigue damage evaluation in A36 steel using nonlinear Rayleigh surface waves. NDT E Int. 48, 10–15 (2012). https://doi.org/10.1016/j.ndteint.2012.02.00210.1016/j.ndteint.2012.02.002 ↗
17. Liu, M., Kim, J.Y., Jacobs, L., Qu, J.: Experimental study of nonlinear Rayleigh wave propagation in shot-peened aluminum platesFeasibility of measuring residual stress. NDT E Int. 44, 67–74 (2011). https://doi.org/10.1016/j.ndteint.2010.09.00810.1016/j.ndteint.2010.09.008 ↗
18. Thiele, S., Kim, J.Y., Qu, J., Jacobs, L.J.: Air-coupled detection of nonlinear Rayleigh surface waves to assess material nonlinearity. Ultrasonics 54, 1470–1475 (2014). https://doi.org/10.1016/j.ultras.2014.04.02010.1016/j.ultras.2014.04.020 ↗
19. Liu, S., Croxford, A.J., Neild, S.A., Zhou, Z.: Effects of experimental variables on the nonlinear harmonic generation technique. IEEE Trans. Ultrason. Ferroelectr. Freq. Control. 58, 1442–1451 (2011). https://doi.org/10.1109/TUFFC.2011.196310.1109/TUFFC.2011.1963 ↗
20. Zhang, S., Qin, L., Li, X., Kube, C.M.: Propagation of Rayleigh waves on curved surfaces. Wave Motion 94, 102517 (2020). https://doi.org/10.1016/j.wavemoti.2020.10251710.1016/j.wavemoti.2020.102517 ↗
21. Deng, M., Gao, G., Xiang, Y., Li, M.: Assessment of accumulated damage in circular tubes using nonlinear circumferential guided wave approach: a feasibility study. Ultrasonics 75, 209–215 (2017). https://doi.org/10.1016/j.ultras.2016.12.00110.1016/j.ultras.2016.12.001 ↗
22. Fu, H.: A study of sliding wear behavior of heat treated 1060 steel with pure rolling pre-conditioning. http://hdl.handle.net/2142/104922 (2019)
23. Balasubramanian, P.: Design and fabrication of a twin disc tribometer and a study of wear and friction of hardened 1060 steel under combined rolling and sliding. http://hdl.handle.net/2142/101722 (2018)
24. Aronov, V., Kalpakjian, S.: Wear kinetics of rail and wheel steels in the dry friction condition. Wear 61, 101–110 (1980). https://doi.org/10.1016/0043-1648(80)90115-510.1016/0043-1648(80)90115-5 ↗
25. Oliver, W.C., Pharr, G.M.: An improved technique for determining hardness and elastic modulus using load and displacement sensing indentation experiments. J. Mater. Res. 7, 1564–1583 (1992). https://doi.org/10.1557/JMR.1992.156410.1557/JMR.1992.1564 ↗
26. Herrmann, J., Kim, J.Y., Jacobs, L.J., Qu, J., Littles, J.W., Savage, M.F.: Assessment of material damage in a nickel-base superalloy using nonlinear Rayleigh surface waves. J. Appl. Phys. (2006). https://doi.org/10.1063/1.220480710.1063/1.2204807 ↗
27. Romer, A., Kim, J.Y., Qu, J., Jacobs, L.J.: The second harmonic generation in reflection mode: an analytical, numerical and experimental study. J. Nondestruct. Eval. 35, 1–10 (2016). https://doi.org/10.1007/s10921-015-0323-710.1007/s10921-015-0323-7 ↗
28. Achenbach, J.D.: Wave propagation in elastic solids. North-Holland, New York (1984)
29. Wiskel, J.B., Kennedy, J., Ivey, D.G., Henein, H.: Ultrasonic velocity evaluation of three grades of heat treated steel. Proc. NDT Canada 2015 Conf. 1–10 (2015)
30. Halme, J., Andersson, P.: Rolling contact fatigue and wear fundamentals for rolling bearing diagnostics - State of the art. Proc. Inst Mech. Eng. Part J J. Eng. Tribol. 224, 377–393 (2010). https://doi.org/10.1243/13506501JET65610.1243/13506501JET656 ↗
31. Pan, R., Ren, R., Chen, C., Zhao, X.: Formation of nanocrystalline structure in pearlitic steels by dry sliding wear. Mater. Charact. 132, 397–404 (2017). https://doi.org/10.1016/j.matchar.2017.05.03110.1016/j.matchar.2017.05.031 ↗
32. Kim, J.-Y., Jacobs, L.J., Qu, J., Littles, J.W.: Experimental characterization of fatigue damage in a nickel-base superalloy using nonlinear ultrasonic waves. J. Acoust. Soc. Am. 120, 1266–1273 (2006). https://doi.org/10.1121/1.222155710.1121/1.2221557 ↗
33. Cantrell, J.H.: Quantitative assessment of fatigue damage accumulation in wavy slip metals from acoustic harmonic generation. Philos. Mag. 86, 1539–1554 (2006). https://doi.org/10.1080/1478643050036535810.1080/14786430500365358 ↗
34. Shull, D.J., Kim, E.E., Hamilton, M.F., Zabolotskayac, E.A.: Diffraction effects in nonlinear Rayleigh wave beams. J. Acoust. Soc. Am. 97, 2126–2137 (1995). https://doi.org/10.1121/1.41200510.1121/1.412005 ↗
35. Rulf, B.: Rayleigh waves on curved surfaces. J. Acoust. Soc. Am. 45, 493–499 (1969). https://doi.org/10.1121/1.191140010.1121/1.1911400 ↗
36. Matsui, M., Kamiya, Y.: Evaluation of material deterioration of rails subjected to rolling contact fatigue using x-ray diffraction. Wear 304, 29–35 (2013). https://doi.org/10.1016/j.wear.2013.04.01810.1016/j.wear.2013.04.018 ↗
37. Ruud, C.O.: A review of selected non-destructive methods for residual stress measurement. NDT Int. 15, 15–23 (1982). https://doi.org/10.1016/0308-9126(82)90083-910.1016/0308-9126(82)90083-9 ↗
38. Sayers, C.M., Allen, D.R., Haines, G.E., Proudfoot, G.G.: Texture and stress determination in metals by using ultrasonic Rayleigh waves and neutron diffraction. Philos. Trans. R. Soc. London. Ser. A. 320, 187–200 (1986)10.1098/rsta.1986.0110 ↗
39. Delsanto, P.P., Clark, A. V.: Rayleigh wave propagation in deformed orthotropic materials. Rev. Prog. Quant. Nondestruct. Eval. 5 B, 1407–1414 (1986). https://doi.org/10.1121/1.39457510.1121/1.394575 ↗
40. Shintani, T., Murata, Y.: Evaluation of the dislocation density and dislocation character in cold rolled Type 304 steel determined by profile analysis of X-ray diffraction. Acta Mater. 59, 4314–4322 (2011). https://doi.org/10.1016/j.actamat.2011.03.05510.1016/j.actamat.2011.03.055 ↗
41. Kim, J.C., Cheong, S.K., Noguchi, H.: Evolution of residual stress redistribution associated with localized surface microcracking in shot-peened medium-carbon steel during fatigue test. Int. J. Fatigue. 55, 147–157 (2013). https://doi.org/10.1016/j.ijfatigue.2013.06.01010.1016/j.ijfatigue.2013.06.010 ↗
42. Sablik, M.J.: Modeling the effect of grain size and dislocation density on hysteretic magnetic properties in steels. J. Appl. Phys. 89, 5610–5613 (2001). https://doi.org/10.1063/1.135916710.1063/1.1359167 ↗
43. Bhattacharya, D.K.: Magnetic NDT for the characterization of industrial materials. Mater. Charact. Tech. - Princ. Appl. 831007, 210–227 (1999)
44. Šternberk, J., Kratochvílová, E., Gemperle, A., Faja, V., Walder, V.: Dependence of characteristics of hysteresis loops on dislocation densities for low-alloy Cr-Mo steel. Czechoslov. J. Phys. B. 35, 1259–1267 (1985)10.1007/BF01597011 ↗
45. Masoumi, M., Lima, N.B.D., Tressia, G., Sinatora, A., Goldenstein, H.: Microstructure and crystallographic orientation evolutions below the superficial white layer of a used pearlitic rail. J. Mater. Res. Technol. 8, 6275–6288 (2019). https://doi.org/10.1016/j.jmrt.2019.10.02110.1016/j.jmrt.2019.10.021 ↗
46. Beynon, J.H., Perez-unzueta, A.J.: Microstructure and wear resistance of pearlitic rail steels. Wear 164, 173–182 (1993)
47. Embury, J.D., Fisher, R.M.: The structure and properties of drawn pearlite. Acta Metall. 14, 147–159 (1966). https://doi.org/10.1016/0001-6160(66)90296-310.1016/0001-6160(66)90296-3 ↗
48. Krakhmalev, P., Fredriksson, G., Svensson, K., Yadroitsev, I., Yadroitsava, I., Thuvander, M., Peng, R.: Microstructure, solidification texture, and thermal stability of 316 L stainless steel manufactured by laser powder bed fusion. Metals (2018). https://doi.org/10.3390/met808064310.3390/met8080643 ↗
49. Cantrell, J.H.: Ultrasonic harmonic generation from fatigue-induced dislocation substructures in planar slip metals and assessment of remaining fatigue life. J. Appl. Phys. (2009). https://doi.org/10.1063/1.325422310.1063/1.3254223 ↗