Bearing steel technologies : 12th volume : progress in bearing steel metallurgical testing and quality assurance

THIS COMPILATION OF Selected Technical Papers, STP1623, Bearing Steel Technologies: 12th Volume, Progress in Bearing Steel Metallurgical Testing and Quality Assurance, contains peer-reviewed papers that were presented at a symposium held May 15-17, 2019, in Denver, CO, USA. The symposium was jointly sponsored by ASTM International Committee A01 on Steel, Stainless Steel and Related Alloys, and Subcommittee A01.28 on Bearing and Power Transmission Steels. Symposium Chair and STP Editor: John M. Beswick Montfoort, The Netherlands TABLE OF CONTENTS Overview Review on Crack Initiation and Premature Failures in Bearing Applications Influence of Steel Cleanliness on RCF and WEC Formation Rolling Contact Fatigue Transformations in Aero Steels: The Effect of Temperature on Microstructural Decay Quantitative Ultrasonic Characterization of Subsurface Inclusions in Tapered Roller Bearings Design and Validation of a Modular Rolling Contact Fatigue/Rolling-Sliding Contact Fatigue Testing Machine Investigation of Fatigue Behavior around Nonmetallic Inclusion Using a Newly Developed Rolling Contact Fatigue Test Method Lubricant-Induced White Etching Cracks: Mechanism and Effects of Surface Finishing Surface Damage in Rolling Bearings and the Impact on Rolling Contact Fatigue Effect of MnS on the Micropitting Behavior of Through Hardened Bearing Steel during Rolling Contact Fatigue Influence of Material, Heat Treatment, and Microstructure in Resisting White Etching Crack Damage Selective Laser Melting (SLM) of M50NiL---Enabling Increased Degrees of Freedom in New Design Concepts Manufacturing of Large-Diameter Rolling Element Bearings by Steel-Steel Multimaterial Systems Ultrasonic Evaluation of Tailored Forming Components Improved Processing Techniques for Inclusion-Free Steel for Bearing and Mechanical Component Applications Performance and Reliability of Powder Metallurgy Steels for Aerospace Bearings The Use of SEM-EDS and PDA-OES Techniques to Help the Development of the Production of Bearing Steel Advances in Billet Cast Carbon Steel Quality for High-Performance Rolling Bearings Improvements in GCr15 (52100) High Carbon Bearing Steel Steelmaking and Their Effect on Inclusions, Segregation, and Fatigue Properties Temperature-Resistant, Corrosion-Tolerant Carburizing Bearing Steel for Aero-Engine Applications High Performance Ferrium Steels for Aerospace Gearing and Bearing Applications Hybrid Steel and Its Potential for Bearing Applications Effect of Carbide Segregation on Mode I Fatigue Resistance Properties of the Bearing Tool Steel Roll Blade Die Relevance of Fracture Mechanics in Rolling Bearing: Functional Property Determination and Steel Quality Assurance VIM-VAR Steelmaking for Bearing Steel Grades Melt Methods and Their Effects on Cleanliness for Bearing Performance Spall Propagation Characteristics of Life-Tested VIM-VAR M50 and Pyrowear 675 Bearing Steels Spall Propagation Characteristics of As-Manufactured Aerospace Bearing Steels Testing to Reveal Tribology Mechanisms for Advancing Bearing Steels Adhesive Wear Performance of Pyrowear 675 in All-Metal and Hybrid Configuration Accelerated Life Testing of Pyrowear 675 Material at 218C (425F) Using a Ball-on-Rod Rolling Contact Fatigue Tester Title Page Copyright Page Foreword Contents Overview Review on Crack Initiation and Premature Failures in Bearing Applications Introduction Occurrence of White Etching Areas in Bearing Steel Metallurgical Characterization GENERAL PICTURE OF WEA MICROSTRUCTURE HARDNESS OF WEA CRACKS ORIGINATING AT INCLUSIONS (BUTTERFLIES) CRACKS OBSERVED IN CLASSICAL ROLLING CONTACT FATIGUE LIFE CRACK INITIATION PRECEDING WEA DAMAGE DEVELOPMENT DURING ACCELERATED FATIGUE VERSUS RCF Discussion Conclusions ACKNOWLEDGMENTS References Influence of Steel Cleanliness on RCF and WEC Formation Introduction STEEL CLEANLINESS AND IMPROVEMENT IN MANUFACTURING INFLUENCE OF MATERIAL CLEANLINESS ON ROLLING CONTACT FATIGUE INFLUENCE OF MATERIAL CLEANLINESS ON WHITE ETCHING CRACK FORMATION Experimental CHARACTERIZATION OF STEEL 100CR6 (EQUIVALENT TO SAE 52100) BATCHES INCLUDING THE CLEANLINESS ASSESSMENT RCF TESTING WEC TESTING Results ROLLING CONTACT FATIGUE TESTS ON L17 WITH SURFACE SEPARATION AND 2,900 MPA HERTZIAN PRESSURE ROLLING CONTACT FATIGUE TESTS ON L17 WITH SURFACE SEPARATION AND 3,500 MPA HERTZIAN PRESSURE ROLLING CONTACT FATIGUE TESTS ON L17 WITH MIXED FRICTION AND 2,630 MPA WHITE ETCHING CRACK FORMATION ON FE8 Discussion RCF TESTING WEC TESTING Conclusion References Rolling Contact Fatigue Transformations in Aero Steels: The Effect of Temperature on Microstructural Decay Introduction Properties and Microstructural Alterations Dislocation-Assisted Carbon Migration MICROSTRUCTURAL ALTERATIONS IN BEARINGS CARBON FLUX DRIVEN BY GLIDING OF DISLOCATIONS Modelling Microstructural Alterations in Aerospace Bearings CORRELATION OF YIELD STRENGTH WITH HARDNESS CASE STUDY: MODELLING OF MICROSTRUCTURAL ALTERATIONS IN M50 SHORTCOMINGS AND FUTURE DEVELOPMENT Conclusions ACKNOWLEDGMENT References Quantitative Ultrasonic Characterization of Subsurface Inclusions in Tapered Roller Bearings Introduction Experimental Configuration for Surface Wave Measurements Ultrasonic Calibration Methods Effect of Part Curvature and Associated Corrections Finite Element Modeling SurfaceWave Model Conclusions References Design and Validation of a Modular Rolling Contact Fatigue/Rolling-Sliding Contact Fatigue Testing Machine Introduction RSCF Machine Considerations BALL-ON-ROD TESTING MACHINES SINGLE-MOTOR DRIVE TWO-MOTOR DRIVE Testing Machine Design Goals Overview of Testing Machine OVERALL ARCHITECTURE GEOMETRY CONTROL INTERFACE DRIVE SETUP FORCE CONTROL OIL LUBRICATION SYSTEM FAILURE DETECTION Machine Overview Preliminary Testing Results PRETESTING CHARACTERIZATION TESTING POSTTESTING CHARACTERIZATION Summary ACKNOWLEDGMENTS References Investigation of Fatigue Behavior around Nonmetallic Inclusion Using a Newly Developed Rolling Contact Fatigue Test Method Introduction PreviousWorks Experimental Procedure Result RCF CRACKING BEHAVIOR AROUND CAVITY RCF CRACKING BEHAVIOR AROUND INTERFACIALLY BONDED AL2O3 RCF CRACKING BEHAVIOR AROUND INTERFACIALLY DEBONDED AL2O3 Discussion Conclusion References Lubricant-Induced White Etching Cracks: Mechanism and Effects of Surface Finishing Introduction Experiments Results Discussion Conclusions ACKNOWLEDGMENTS References Surface Damage in Rolling Bearings and the Impact on Rolling Contact Fatigue Introduction Approach EXPERIMENTAL SIMULATION Experimental Results LIFE TESTING WITH PREDAMAGED RACEWAYS TEST LOAD OF 11.2 KN DAMAGE APPEARANCE TEST LOAD OF 14.5 KN Simulation Results PREDAMAGING OVERROLLING RATING LIFE PREDICTION Discussion IMPACT OF INDENTATION SIZE AND SHAPE SIMULATION AND RATING LIFE PREDICTION SUMMARY AND CONCLUSION References Effect of MnS on the Micropitting Behavior of Through Hardened Bearing Steel during Rolling Contact Fatigue Introduction Materials and Methods Results and Discussion DAMAGED AREA ANALYSIS SCANNING ELECTRON MICROSCOPY WITH THREE-DIMENSIONAL SLICE AND VIEW IMAGING Summary ACKNOWLEDGMENTS References Influence of Material, Heat Treatment, and Microstructure in Resisting White Etching Crack Damage Introduction Experimental Details Results WEC RESISTANCE OF 52100 AND 3310 CASE-CARBURIZED (CC) STEEL WEC RESISTANCE OF ALTERNATIVELY HEAT-TREATED 3310-CC STEEL WEC RESISTANCE OF 3310-CC AND 4140-CC STEELS Discussion COMPARISON OF 52100-MTH AND 3310-CC COMPARISON OF 3310-CC AND 3310-CC MODIFIED HT COMPARISON OF 3310-CC AND 4140-CC Conclusions ACKNOWLEDGMENTS References Influence of Heat Treatment Conditions on the Dimensional Stability of SAE 52100 Introduction and State of the Art Experimental Test Plan METHODOLOGY AND HEAT TREATMENTS EXPERIMENTAL TECHNIQUES Influence of Heat Treatment Parameters on Dimensional Variations INFLUENCE OF THE AUSTENITIZING CONDITIONS INFLUENCE OF COOLING CONDITIONS CONCLUSIONS Interpretation by Qualifying and Quantifying the Phase Evolutions INFLUENCE OF THE AUSTENITIZING CONDITIONS INFLUENCE OF THE COOLING CONDITIONS INFLUENCE OF STEP QUENCHES CONTROLLED COOLING CONDITIONS DISCUSSION ON THE MICROSTRUCTURAL EVOLUTION IN RELATION TO THE EXPERIMENTAL DIMENSIONAL VARIATIONS Focus on Carbon Disappearing from Solid Solution during Quench USE OF XRD DATA TO ESTIMATE THE DISTRIBUTION OF CARBON BETWEEN THE PHASES SUGGESTION OF A PHENOMENON BASED ON A FURTHER ANALYSIS OF THE DILATOMETRY, TEP DATA, AND XRD DATA LOCATION OF CARBON IN THE AS-QUENCHED MICROSTRUCTURE Microstructural Scenario Proposal to Explain the Dimensional Variation Dependence on Initial Heat Treatment Parameters DIMENSIONAL CONTRIBUTIONS AND THEIR INFLUENCE FACTOR UNDERSTANDING THE INFLUENCE OF THE AUSTENITIZING CONDITIONS ON THE DIMENSIONAL VARIATIONS UNDERSTANDING THE INFLUENCE OF THE QUENCH CONDITIONS ON THE DIMENSIONAL VARIATIONS Conclusions ACKNOWLEDGMENTS References Complexity of Dimensional Stability of Case-Hardened Bearing Components Introduction Bearing Tests Ring Exposure Tests Dilatometry Tests Conclusions and FutureWork ACKNOWLEDGMENTS References Selective Laser Melting (SLM) of M50NiL—Enabling Increased Degrees of Freedom in New Design Concepts Introduction M50NiL Powder—Chemical Composition Porosity of M50NiL SLM—Parameter Study Mechanical Properties—Tension Tests Heat Treatment and Microstructure of M50NiL AM Rolling Contact Fatigue (RCF) Testing New Design Solution Possible with SLM Theoretical Analysis of the Cooling Channel Manufacturing Route Summary References Manufacturing of Large-Diameter Rolling Element Bearings by Steel-Steel Multimaterial Systems Introduction Rolling Bearings and Material Selection Focus of this Paper and Methodology Process Chain for Load-Adapted Large-Diameter Rolling Bearings MANUFACTURING OF MULTIMATERIAL WORKPIECES Forming through Ring Rolling FINISHING BY HEAT TREATMENT AND MACHINING Manufacturing and Testing of Tailored Forming Bearings PREVIOUS INVESTIGATIONS UTILIZATION OF BEARING STEEL THROUGH TAILORED FORMING DESIGN OF TAILORED FORMING BEARINGS PTA WELDING ON A LABORATORY SCALE FINISHING OF ANALOGOUS COMPONENTS ROLLING BEARING TESTS REGARDING OPERATING AND FATIGUE BEHAVIOR Summary and Outlook ACKNOWLEDGMENT References Ultrasonic Evaluation of Tailored Forming Components Introduction SCANNING ACOUSTIC MICROSCOPY—TEST PRINCIPLES SCANNING ACOUSTIC MICROSCOPY RESULTS—MEASUREMENT ON TAILORED FORMING THRUST BEARING WASHERS SCANNING ACOUSTIC MICROSCOPY RESULTS—MEASUREMENT ON TAILORED FORMING HYBRID SHAFTS Results and Discussion ACKNOWLEDGMENTS References Improved Processing Techniques for Inclusion-Free Steel for Bearing and Mechanical Component Applications Introduction Background Materials and Methods Results and Discussions MICROSTRUCTURE: CAST ELECTRODE POWDER FABRICATION: ATOMIZATION OF CAST ANODE POWDER CONSOLIDATION: HOT ISOSTATIC PRESS Discussion Summary ACKNOWLEDGMENTS References Performance and Reliability of Powder Metallurgy Steels for Aerospace Bearings Introduction and Context Powder Metallurgy and Microcleanliness NATURE OF THE INCLUSIONS LINK WITH THE PROCESS AND PROCESS CONTROL Powder Metallurgy ASP 2055 Forgeability and Heat Treatment ASP 2055 FORGEABILITY ASP 2055—HEAT TREATMENT AND MICROSTRUCTURE ASP 2055 Performance SUBSURFACE PROPERTIES CORE PROPERTIES Promising Investigation Methods SCANNING MICROWAVE MICROSCOPY Conclusion ACKNOWLEDGMENTS References The Use of SEM-EDS and PDAOES Techniques to Help the Development of the Production of Bearing Steel Introduction Experiments and Methods PROCESS ROUTE EXPERIMENTS, SAMPLING, AND SAMPLE PREPARATION SAMPLE ANALYSIS Results and Discussion LOLLIPOP HOMOGENEITY CORRELATION BETWEEN THE CHARACTERIZATION METHODS SIZE AND AMOUNT OF INCLUSIONS CHEMICAL COMPOSITION OF INCLUSIONS INCLUSION MORPHOLOGY INCLUSION MODIFICATION MECHANISM Conclusion References Advances in Billet Cast Carbon Steel Quality for High-Performance Rolling Bearings Introduction Analytical Methods The Steelmaking Process Experimental Trial Conditions TRIAL 1: CALCIUM VERSUS NON-CALCIUM IN CARBON STEELMAKING TRIAL 2: DEGASSING AND SOFT STIRRING Results and Discussion TRIAL 1: CALCIUM VERSUS NONCALCIUM TRIAL 2: DEGASSING AND SOFT STIRRING Conclusions ACKNOWLEDGMENTS References Improvements in GCr15 (52100) High Carbon Bearing Steel Steelmaking and Their Effect on Inclusions, Segregation, and Fatigue Properties Introduction Improvement of Steel Cleanliness PROCESS ROUTE AND STEEL MICROCLEANLINESS INCLUSION REMOVAL DURING CASTING Homogeneity of Steel SUPERHEAT DURING CASTING SOFT REDUCTION DURING CASTING Conclusions ACKNOWLEDGMENT References Temperature-Resistant, Corrosion-Tolerant Carburizing Bearing Steel for Aero-Engine Applications Background Alloy Design First Melt Series Second Melt Series Third Melt Series Next Steps Conclusions ACKNOWLEDGMENTS References High Performance Ferrium Steels for Aerospace Gearing and Bearing Applications Introduction Computational Materials Design Background for Ferrium Gear Steel Alloys ICME APPROACH FERRIUM GEAR STEEL DEVELOPMENT Design and Development of Ferrium N63TM Stainless, Nitridable Bearing Steel ALLOY DESIGN CRITERIA ALLOY DESIGN CONCEPTS PROPERTY VALIDATION ON COMMERCIAL SCALE PRODUCTION Discussion ACKNOWLEDGMENTS References Hybrid Steel and Its Potential for Bearing Applications Introduction Segregation Study and Primary Carbide Formation Heat Treatment Microstructure and Precipitate Species Experimental Procedure and Investigated Materials CHEMICAL COMPOSITION AND HEAT TREATMENTS ROTATING BENDING FATIGUE HIGH-TEMPERATURE TENSILE TEST HYDROGEN EMBRITTLEMENT CORROSION TEST Rotating Bending Fatigue High-Temperature Applications Resistance to Hydrogen Embrittlement Corrosion Resistance Summary ACKNOWLEDGMENTS References Effect of Carbide Segregation on Mode I Fatigue Resistance Properties of the Bearing Tool Steel Roll Blade Die Introduction Methodology MATERIAL MODE I FATIGUE TESTING METALLURGICAL CHARACTERIZATION Results MODE I FATIGUE TEST RESULTS FRACTOGRAPHY METALLURGICAL CHARACTERIZATION Discussion Conclusions References Relevance of Fracture Mechanics in Rolling Bearing: Functional Property Determination and Steel Quality Assurance Introduction Experimental Details and Results EFFECT OF MICROINCLUSIONS ON KIC AND DKTH INFLUENCE OF THROUGH HARDENING HEAT TREATMENT ON KIC AND DKTH IN 1C-1.5CR STEELS STEELMAKING EFFECTS ON FRACTURE TOUGHNESS PM-HIP VERSUS VIM-VAR M50 THROUGH HARDENED HIGH-SPEED STEEL FRACTURE TOUGHNESS CARBURIZED HSS FRACTURE TOUGHNESS Materials Selection Based on Fracture Mechanics in Rolling Bearing Design Notched Impact Toughness Properties Discussion Conclusions ACKNOWLEDGMENTS References VIM-VAR Steelmaking for Bearing Steel Grades Introduction Vacuum Induction Melting VIM: Process Outline VIM Control Parameters and Furnace Design Features MATERIAL COMPOSITION VACUUM TEMPERATURE STEEL CLEANNESS VIM: Risks and Limitations Vacuum Arc Remelting VAR: Process Outline VAR Control Parameters and Furnace Design Features ELECTRODE QUALITY MELT RATE ARC GAP VACUUM LEVEL VAR: Risks and Limitations VIM-VAR Bearing Steels INCLUSION ASSESSMENT PRODUCT OXYGEN SEGREGATION Conclusion ACKNOWLEDGMENTS References Melt Methods and Their Effects on Cleanliness for Bearing Performance Introduction Experimental Methods Results Discussion Summary References Spall Propagation Characteristics of Life-Tested VIM-VAR M50 and Pyrowear 675 Bearing Steels Introduction Experimental TEST BEARING MATERIALS TEST RIG AND PROCEDURE Results and Discussion Conclusions ACKNOWLEDGMENTS References Spall Propagation Characteristics of As-Manufactured Aerospace Bearing Steels Introduction Experimental TEST BEARING MATERIAL TEST RIG AND PROCEDURE Results and Discussion Conclusions ACKNOWLEDGMENTS References Testing to Reveal Tribology Mechanisms for Advancing Bearing Steels Introduction and Background Approach Test Specimen Bearing Steels Abrasive Wear Resistance TRL 3 Tests for Subsurface and Near-Surface Fatigue Regions and Mechanisms for Shear Accommodation and Tangential Stress TRL 3 Load Capacity Testing for Superficial Tribology Attributes Effect of Oil Formulation on Superficial Tribology Performance Effect of Bearing Steels on Superficial Tribology Performance Mechanisms, Phenomena, and Contact Conditions Mechanisms and Phenomena for High Nitrogen Stainless Steel AMS 5898 Discussion Outlook Conclusions ACKNOWLEDGMENTS References Adhesive Wear Performance of Pyrowear 675 in All-Metal and Hybrid Configuration Introduction Experimental Setup MATERIALS TEST MATRIX AND PROCEDURE Results and Discussion ALL-METAL COMBINATIONS HYBRID COMBINATIONS DISCUSSION Conclusions ACKNOWLEDGMENTS References Accelerated Life Testing of Pyrowear 675 Material at 218C (425F) Using a Ball-on-Rod Rolling Contact Fatigue Tester Introduction Experimental TEST RIG AND PROCEDURE TEST MATERIALS Results and Discussion Summary and Conclusions ACKNOWLEDGMENTS References Author Index Subject Index THIS COMPILATION OF Selected Technical Papers, STP1623, contains peer-reviewed papers that were presented at a symposium held May 15-17, 2019, in Denver, CO, USA. The symposium was jointly sponsored by ASTM International Committee A01 on Steel, Stainless Steel and Related Alloys, and Subcommittee A01.28 on Bearing and Power Transmission Steels. John M. Beswick __Montfoort, The Netherlands__ Overview Influence of Steel Cleanliness on RCF and WEC Formation Quantitative Ultrasonic Characterization of Subsurface Inclusions in Tapered Roller Bearings Investigation of Fatigue Behavior around Nonmetallic Inclusion Using a Newly Developed Rolling Contact Fatigue Test Method Surface Damage in Rolling Bearings and the Impact on Rolling Contact Fatigue Influence of Material, Heat Treatment, and Microstructure in Resisting White Etching Crack Damage Manufacturing of Large-Diameter Rolling Element Bearings by Steel-Steel Multimaterial Systems Improved Processing Techniques for Inclusion-Free Steel for Bearing and Mechanical Component Applications The Use of SEM-EDS and PDA-OES Techniques to Help the Development of the Production of Bearing Steel Improvements in GCr15 (52100) High Carbon Bearing Steel Steelmaking and Their Effect on Inclusions, Segregation, and Fatigue Properties High Performance Ferrium Steels for Aerospace Gearing and Bearing Applications Effect of Carbide Segregation on Mode I Fatigue Resistance Properties of the Bearing Tool Steel Roll Blade Die VIM-VAR Steelmaking for Bearing Steel Grades Spall Propagation Characteristics of Life-Tested VIM-VAR M50 and Pyrowear 675 Bearing Steels Testing to Reveal Tribology Mechanisms for Advancing Bearing Steels Accelerated Life Testing of Pyrowear 675 Material at 218C (425F) Using a Ball-on-Rod Rolling Contact Fatigue Tester