Fretting Wear and Fretting Fatigue

Fundamental Principles and Applications

1st Edition - December 7, 2022
Editors: Tomasz Liskiewicz, Daniele Dini
Language: English
Paperback ISBN:
9 7 8 - 0 - 1 2 - 8 2 4 0 9 6 - 0
eBook ISBN:
9 7 8 - 0 - 1 2 - 8 2 4 0 9 7 - 7

Fretting Wear and Fretting Fatigue: Fundamental Principles and Applications takes a combined mechanics and materials approach, providing readers with a fundamental unders… Read more

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Fretting Wear and Fretting Fatigue: Fundamental Principles and Applications takes a combined mechanics and materials approach, providing readers with a fundamental understanding of fretting phenomena, related modeling and experimentation techniques, methods for mitigation, and robust examples of practical applications across an array of engineering disciplines. Sections cover the underpinning theories of fretting wear and fretting fatigue, delve into experimentation and modeling methods, and cover a broad array of applications of fretting fatigue and fretting wear, looking at its impacts in medical implants, suspension ropes, bearings, heating exchangers, electrical connectors, and more.

Cover image
Title page
Table of Contents
Copyright
Contributors
Preface
Section I: History and fundamental principles
Introduction
1: Brief history of the subject
Abstract
Acknowledgments
1.1: Early stages
1.2: Initial milestones in the understanding of the mechanics of fretting
1.3: Crucial steps toward a better understanding of fretting wear and fretting fatigue
1.4: State of the art at the beginning of the new millennium
References
2: Introduction to fretting fundamentals
Abstract
2.1: Fretting—complexities and synergies
2.2: Contact mechanics in fretting
2.3: Transition criteria and mapping approaches
2.4: Experimental methods
2.5: Modelling approaches
Section II: Fretting wear
Introduction
3.1: The role of tribologically transformed structures and debris in fretting of metals
Abstract
3.1.1: Overview
3.1.2: Wear in both sliding and fretting—Contrasts in the transport of species into and out of the contacts
3.1.3: The nature of oxide debris formed in fretting
3.1.4: Formation of oxide debris in fretting—The role of oxygen supply and demand
3.1.5: Tribo-sintering of oxide debris and glaze formation
3.1.6: Microstructural damage—Tribologically transformed structures in fretting
3.1.7: The critical role of debris in fretting: Godet’s third body approach
3.1.8: Godet’s third body approach revisited: Rate-determining processes in fretting wear
3.1.9: Conclusion
References
3.2: Friction energy wear approach
Abstract
3.2.1: Friction energy wear approach
3.2.2: Basics regarding friction energy wear approach
3.2.3: Influence of contact loadings regarding friction energy wear rate
3.2.4: Influence of ambient conditions
3.2.5: Surface wear modeling using the friction energy density approach
3.2.6: Conclusions
References
3.3: Lubrication approaches
Abstract
Acknowledgments
3.3.1: Introduction
3.3.2: Parameter definition
3.3.3: Oil lubrication
3.3.4: Grease lubrication
3.3.5: Mechanism for fretting wear reduction in grease lubrication
3.3.6: Conclusions
References
3.4: Impact of roughness
Abstract
3.4.1: Introduction
3.4.2: Contact of rough surfaces
3.4.3: Stress distribution in rough contact
3.4.4: Effective contact area
3.4.5: Coefficient of friction
3.4.6: Bearing capacity
3.4.7: Surface anisotropy and orientation
3.4.8: Transition between partial and gross slip
3.4.9: Impact of surface roughness on fretting wear
3.4.10: Friction in lubricated contact conditions
3.4.11: Energy dissipated at the interfaces for smooth and rough surfaces
3.4.12: Impact of surface roughness on crack initiation
3.4.13: Dynamics of surface roughness evolution in fretting contact
3.4.14: Measurement of fretting wear using surface metrology
References
3.5: Materials aspects in fretting
Abstract
3.5.1: Physical processes impacting materials in industrial fretting contacts
3.5.2: Factors affecting fretting behavior of different materials groups
3.5.3: Materials engineering approaches to the mitigation of fretting wear
3.5.4: Application of coatings to mitigate fretting wear
3.5.5: Advanced coating designs and architectures
3.5.6: Concluding remarks
References
3.6: Contact size in fretting
Abstract
3.6.1: 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 fatigue
Introduction
4.1: Partial slip problems in contact mechanics
Abstract
4.1.1: Introduction
4.1.2: Global and pointwise friction
4.1.3: Global and local elasticity solutions
4.1.4: Half-plane contacts: Fundamentals
4.1.5: Sharp-edged (complete) contact: Fundamentals
4.1.6: Partial slip of incomplete contacts
4.1.7: Dislocation-based solutions
4.1.8: Asymptotic approaches
4.1.9: Summary
Appendix 4.1.1: Eigenfunctions for the Williams’ wedge solution
Appendix 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
Abstract
4.2.1: 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
4.3: Fretting fatigue design diagram
Abstract
4.3.1: 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
Further reading
4.4: Life estimation methods
Abstract
4.4.1: 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
Further reading
4.5: Effect of surface roughness and residual stresses
Abstract
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 fretting fatigue
4.5.5: Residual stress modeling in fretting fatigue
References
4.6: Advanced numerical modeling techniques for crack nucleation and propagation
Abstract
4.6.1: 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
4.7: A thermodynamic framework for treatment of fretting fatigue
Abstract
4.7.1: 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 remarks
References
Section IV: Engineering applications affected by fretting
Introduction
5.1: Aero engines
Abstract
5.1.1: 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
Abstract
Acknowledgments
5.2.1: 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
References
5.3: Biomedical devices
Abstract
5.3.1: 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
5.3.5: In vivo fretting corrosion within the biological environment
5.3.6: Conclusions
References
5.4: Nuclear power systems
Abstract
Acknowledgments
5.4.1: 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
References
5.5: Rolling bearings
Abstract
5.5.1: 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 bearings
References
5.6: Overhead conductors
Abstract
5.6.1: Introduction
5.6.2: Traditional approaches
5.6.3: Recent results based on fatigue testing of conductors
5.6.4: Recent progress toward a multiscale fatigue analysis
References
5.7: Marine risers
Abstract
Acknowledgments
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
References
Index

Tomasz Liskiewicz

Professor Tomas 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.

Affiliations and expertise

Head, Department of Engineering, Manchester Metropolitan University, UK. Manchester Metropolitan University THE rank: 601-800th, UK

Daniele Dini

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.

Affiliations and expertise

Head, Tribology Group, Imperial College, UK

Life Sciences

Physical Sciences & Engineering

Social Sciences & Humanities

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