Accumulated damage process of thermal sprayed coating under rolling contact by acoustic emission technique

doi:10.1007/s11465-016-0395-9

Front. Mech. Eng.

2016, Vol. 11

Issue (3) : 227-232 https://doi.org/10.1007/s11465-016-0395-9

RESEARCH ARTICLE

Accumulated damage process of thermal sprayed coating under rolling contact by acoustic emission technique

Jia XU¹,Zhen-yu ZHOU¹,Zhong-yu PIAO^2,^*(

)

¹. Key Laboratory of Special Purpose Equipment and Advanced Processing Technology (Zhejiang University of Technology), Ministry of Education and Zhejiang Province, Hangzhou 310014, China
². Key Laboratory of Special Purpose Equipment and Advanced Processing Technology (Zhejiang University of Technology), Ministry of Education and Zhejiang Province, Hangzhou 310014, China; The State Key Laboratory of Fluid Power Transmission and Control, Hangzhou 310027, China

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Abstract

The accumulated damage process of rolling contact fatigue (RCF) of plasma-sprayed coatings was investigated. The influences of surface roughness, loading condition, and stress cycle frequency on the accumulated damage status of the coatings were discussed. A ball-on-disc machine was employed to conduct RCF experiments. Acoustic emission (AE) technique was introduced to monitor the RCF process of the coatings. AE signal characteristics were investigated to reveal the accumulated damage process. Result showed that the polished coating would resist the asperity contact and remit accumulated damage. The RCF lifetime would then extend. Heavy load would aggravate the accumulated damage status and induce surface fracture. Wear became the main failure mode that reduced the RCF lifetime. Frequent stress cycle would aggravate the accumulated damage status and induce interface fracture. Fatigue then became the main failure mode that also reduced the RCF lifetime.

Keywords accumulated damage spray coating rolling contact fatigue acoustic emission

Corresponding Author(s): Zhong-yu PIAO

Online First Date: 22 July 2016 Issue Date: 31 August 2016

Cite this article:

Jia XU,Zhen-yu ZHOU,Zhong-yu PIAO. Accumulated damage process of thermal sprayed coating under rolling contact by acoustic emission technique[J]. Front. Mech. Eng., 2016, 11(3): 227-232.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-016-0395-9
https://academic.hep.com.cn/fme/EN/Y2016/V11/I3/227

Tab.1 Operating parameters of the PS process

Fig.1 Typical AE signal responses of the ground coating under rolling contact under 100 N

Fig.2 Typical AE signal responses of the polished coating under rolling contact under 100 N

Fig.3 Surface cracks of the polished coating after the mutation of AE signal. (a) Initiation cracks; (b) local fracture

Fig.4 Delamination morphology of the polished coating

Fig.5 Typical AE signal responses of the coating under 200 N

Fig.6 Cross-sectional morphologies of the coating under 200 N after the mutation of AE signal. (a) Bottom of wear trace; (b) edge of wear trace

Fig.7 Typical AE signal responses of the coating under a high stress cycle frequency

Fig.8 Cross-sectional morphology of the coating under a high stress cycle frequency after the mutation of AE signal

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