Day2 Sessioniv 1 NSK Uyama

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Copyright 2011 NSK Ltd. All Rights Reserved
2011 Wind Turbine Tribology Seminar
The Mechanism of White Structure Flaking
In Rolling Bearings
November 16
th
, 2011
Renaissance Boulder Flatiron Hotel
Bloomfield, CO, USA
Hideyuki Uyama
Basic Technology Research Center,
NSK Ltd., J apan
2
Contents
1. Classification of Flaking in Bearings
Subsurface Originated, Surface Originated and White Structure Flaking
2. Bearing Failure in Wind Turbine Gearbox
3. Mechanism of Formation of White Structure
What caused White Structure?
Relation to Hydrogen Embrittlement
4. Influencing Factors on White Structure Flaking
Lubricant, Slip, Static Electricity and Material
5. Summary and Future Plan
3
4
Flaking
Flaking
(Classical theory)
Dent
Crack
Flaking
Dent
White
Structure
White
Structure
Flaking
Crack
Non-Metallic
Inclusion
Non-Metallic
Inclusion
Subsurface Originated Surface Originated White Structure
Under clean
lubrication condition
Under contaminated
lubrication condition
Specific applications
5
Distribution of shear stress
1-1 Subsurface Originated Flaking
6
Suspend the fatigue test at the early stage of flaking
1-1 Subsurface Originated Flaking
Countermeasure for
Subsurface originated flaking
Extra Pure Steel
Extra Pure Steel
Using high cleanliness steel
Using high cleanliness steel
7
Crack and flaking originated from
edge of dent on raceway surface
1-2 Surface Originated Flaking
Dent
Crack Flaking
Dent
Ball moving
direction
8
1-2 Surface Originated Flaking
Effect of retained austenite
on stress concentration
Rolling contact fatigue life under
contaminated lubrication condition
Increase of retained austenite
(Modified material and heat treatment)
Increase of retained austenite
(Modified material and heat treatment)
Countermeasure for
Surface originated flaking
9
1-3 White Structure Flaking
Ball bearing
Since 90s
Bearings for automotive electrical accessories
White Structure
( Murakami et al. , NSK Technical J ournal, No.656, 1993)
Flaking
Cross section of failure bearing for automotive alternator
10
11
Cross section
Inner ring raceway
Small flakings
White Structure
Cross section of small flaking
Flaking
(Bearing for high speed shaft)
12
Cross section of a small crack
Crack reached on surface.
White Structure
Axial crack
Long axial crack
on raceway surface of Inner ring
Small cracks around a long axial crack
(Bearing for high speed shaft)
13
Cross section of no flaking areas
Fracture origin is a White Structure.
2. Bearing Failure in Wind Turbine Gearbox (Bearing for high speed shaft)
14
Our experience and knowledge in the case of automotive bearings Is introduced
in order to resolve the issue of wind turbine bearings
Bearing failure mode in wind turbine gearbox
White Structure Flaking
Automotive electrical accessories
White Structure
Objective of This Presentation
Objective of This Presentation
White Structure
Wind turbine gearbox
=
15
3. Mechanism of Formation of White Structure
16
3-1 What Causes White Structure?
White Structure
More hydrogen was detected
in the bearing steel
with White Structure flaking.
More hydrogen was detected
in the bearing steel
with White Structure flaking.
General oil
(Long life)
Special oil
(Short life)
6206 bearing life test
0.E+00
1.E-10
2.E-10
3.E-10
4.E-10
5.E-10
0 200 400 600
Temperature ()
I
n
t
e
n
s
i
t
y

(
A
)
Special oil
General oil
Hydrogen was generated by
decomposition of the lubricant.
Hydrogen was generated by
decomposition of the lubricant.
Hydrogen contents in the steel
after testing
3. Mechanism of Formation of WS
17
H H H
Flat disk specimen
NH
4
SCN aqueous solution
Hydrogen charge method
(Soaked for 24h at 323K)
Elemental test for verification
H H H
Hydrogen measurement in steels
(1h after hydrogen charge)
< Rolling contact fatigue test >
Upper race
Thrust bearing 51305
3/8 inch balls
Lubricating oil
Lower race:
Hydrogen-precharged
specimen
Started less than 2h
after hydrogen charge
18
Uncharged
Hydrogen-
precharged
(20%NH
4
SCN)
Hydrogen-precharged
(1%NH
4
SCN)
P
max
= 3.8GPa
N = 1000min
-1
The cross section of the flaking area
(Hydrogen-precharged specimen)
White Structure was formed in hydrogen-precharged specimen.
White Structure was formed in hydrogen-precharged specimen.
Hydrogen-precharged
(0.3%NH
4
SCN)
Elemental test for verification
Results of rolling contact fatigue life tests
of hydrogen-precharged specimen
(Uyama et al., Tribology Online, Vol.6, 2011)
19
What causes White Structure?
Hydrogen
H
H
H
H
H
H
Hydrogen generation
and diffusion
H
H
H
H
H
H
H
H
H
H
H
H
H
H
White structure formation Cracking and flaking
20
Hydrogen
degradation
Relation between hardness and
delayed fracture strength
(Fukui, Tetsu-to-Hagane, Vol.55, 1969)
Effect of hydrogen charge
on fatigue strength
(Murakami et al., Zairyo, Vol.54, 2005)
Hydrogen-
precharged
Uncharged
Shortened life
Under static stress (bending) Fatigue (tension-compression)
3-2 Why hydrogen induces White Structure?
Example of hydrogen degradation of mechanical properties
Material strength without hydrogen
So-called hydrogen embrittlement
So-called hydrogen embrittlement
21
Many models about hydrogen embrittlement mechanism
Troiano (1960): Decohesion theory
Beachem(1972): Hydrogen Assisted Cracking
Oriani (1974)
Birnbaum (1983): Hydrogen enhanced localized plasticity, HELP
Lynch (1988)
Nagumo (2001): Increase of vacancy .and so on
3-2 Why hydrogen induces White Structure?
Hydrogen
Hydrogen
Dislocation mobility
Dislocation mobility
Localized plasticity
Localized plasticity
Under tension stress
Enhanced crack initiation and propagation
Enhanced crack initiation and propagation
Under shear stress
Effects on rolling contact fatigue are unknown
Effects on rolling contact fatigue are unknown
22
Ultra fine grained structure
Dislocation cell structure
DEC
(Dark Etched
Constituent)
WEC
(White Etched
Constituent)
4.310
6
cycles 2.310
7
cycles
100nm 100nm
TEM image
TEM image
Martensitic lath structure
Before testing
(Mitamura et al., Material Science Forum, Vol.539-543, 2007)
Under high contact stress and high temperature (case of no hydrogen)
3-3 Microstructural change in rolling contact fatigue
23
210
6
cycles 310
6
cycles
910
6
cycles
SEM image SEM image SEM image
Lined structure
White Structure
3-4 Hydrogen effect on microstructural change
White Structure
Microstructural change of a hydrogen-precharged specimen
24
Microstructural change of a hydrogen-precharged specimen
Ultra fine grained
Structure
(Fatigued structure)
(Non fatigued structure)
The area adjacent to White Structure was martensitic lath structure,
which is the same structure as new bearing.
Localized microstructural changes occurred from the
hydrogen in the rolling contact fatigue process.
The area adjacent to White Structure was martensitic lath structure,
which is the same structure as new bearing.
Localized microstructural changes occurred from the
hydrogen in the rolling contact fatigue process.
0.5m
White
Structure
Crack
TEM image
White Structure
Cut out by FIB
(Focused ion beam)
25
(Very early stage)
Cut out by FIB
(Focused ion beam)
Lined structure
TEM image
SEM image
Lined structure
Ultra fine grained
Structure
(Fatigued structure)
(Non fatigued structure)
Localized micro structural changes occurred from the
hydrogen even at a very early stage in the fatigue process
Localized micro structural changes occurred from the
hydrogen even at a very early stage in the fatigue process
Microstructural change of hydrogen-precharged specimen
26
Why does hydrogen induce White Structure?
Hydrogen enhances localized plasticity.
(HELP theory on hydrogen embrittlement)
Localized microstructural changes quickly
occur in rolling contact fatigue.
27
4. Influencing Factors on White Structure Flaking
28
4-1 Type of Lubricant 4. Influencing Factors of White Structure Flaking
White Structure
Hydrogen generation depends on
the type of lubricant
General oil
(Long life)
Special oil
(Short life)
6206 bearing life test (Oil bath)
0.E+00
1.E-10
2.E-10
3.E-10
4.E-10
5.E-10
0 200 400 600
Temperature ()
I
n
t
e
n
s
i
t
y

(
A
)
Special oil
General oil
Hydrogen contents in the steel
after testing
Countermeasure for
Automotive bearings
Modification of lubricant is effective.
(Change base oil or additives)
Modification of lubricant is effective.
(Change base oil or additives)
29
Flaking
White Structure is formed
at the large slip area on the raceway.
White Structure is formed
at the large slip area on the raceway.
4-2 Slip 4. Influencing Factors of White Structure Flaking
Relation between position of microstructural change and slip
(Tanaka, Motion & Control, No.19, 2006)
Effect of differential slip
6206 ball bearing tested in the special oil
Observed
cross section
30
H
H
H
Hydrogen diffuse
into steel
H H H
Ball moving
direction
Poor oil film
Local metal-to-metal contact
Formation of fresh surface
Slip
Decomposition of
lubricant cause
hydrogen generation.
Fresh surface
Ball moving
direction
4-2 Slip 4. Influencing Factors of White Structure Flaking
Decreasing slip is effective.
Decreasing slip is effective.
It is often difficult to change
bearing designs or operating conditions.
Countermeasure for automotive bearings
31
Alternator bearing
Frictional electrification
between pulley and belt
(Rubber belt)
Simulation test machine
for automotive alternator bearing
4-3 Static Electricity 4. Influencing Factors of White Structure Flaking
Automotive electrical accessory
Rubber belt
(Iso et al., Motion & Control, No.19, 2006)
Simulation test for automotive electrical accessory
32
Results of alternator simulation tests
White Structure flaking can be prevented by controlling the static electricity.
White Structure flaking can be prevented by controlling the static electricity.
Hydrogen measurement results after testing
Ceramic
balls
Insulated
pulley
33
Modified grease
for removal of static electricity
(Compound nano-carbon particle)
Modified grease
for removal of static electricity
(Compound nano-carbon particle)
Grease A
+
Nano-carbon
Grease containing nano-carbon particle
Standard grease
34
4-4 Material 4. Influencing Factors of White Structure Flaking
Effects of alloy elements
(Fujita et al., Motion & Control, No.19, 2006)
Effect of chromium content in steel
on White Structure flaking life
Relation between chromium content
and hydrogen diffusion rate
White Structure flaking
can be improved
by changing the alloy.
White Structure flaking
can be improved
by changing the alloy.
35
4-4 Material 4. Influencing Factors of White Structure Flaking
Modified material (changing alloy elements)
Modified material (changing alloy elements)
SHJ 5 (Through-hardened steel)
Test bearing: 6206
Oil bath lubrication
Test bearing: 6303
Grease lubrication
SHX3 (Carbonized steel)
(Fujita et al., Motion & Control, No.19, 2006)
However, SHX3 and SHJ5 can not be applied to large size bearings
due to productivity.
Developed material
SUJ2
(SAE52100)
SHX3
SUJ2
(SAE52100)
SHJ5
For automotive bearings
36
(1)It is understood that bearing failures in wind turbine gearboxes may be
classified as a White Structure flaking.
(2)White Structure flaking was induced by hydrogen, which diffuses into the
bearing steel.
(3)White Structure corresponded with localized microstructural changes.
It indicates that hydrogen induced localized plasticity is present in the
rolling contact fatigue process.
(4)Type of lubricant, slip, static electricity, and material influenced White
Structure flaking.
5. Summary and Future Plan
Summary
37
Thank you.

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