Investigations on Tailored Forming of AISI 52100 as Rolling Bearing Raceway
Abstract
:1. Introduction
2. State-of-the-Art
3. Aim and Research Objectives
- Which welding parameters are necessary to functionalize bearing steel that is normally declared as not weldable?
- How do the downstream processes need to be adjusted in order to achieve a high component quality for use as rolling bearings raceways?
- What is the microstructure of the material compound after the different manufacturing steps?
- Were the relevant component properties for use as a rolling bearing component achieved?
- What are the relevant mechanisms that govern the fatigue behavior?
- What damage patterns occur when used as a rolling bearing raceway?
4. Materials and Methods
4.1. Plasma Transferred Arc Deposition Welding
4.2. Upsetting
4.3. Heat Treatment
4.4. Machining
4.5. Analytical Methods
4.5.1. Metallographic Investigations and Hardness Measurements
4.5.2. Residual Stress Measurements
4.5.3. Non-Destructive Examination
4.5.4. Bearing Fatigue Testing
5. Results and Discussion
5.1. Microstructure Evolution during Processing
5.2. Residual Stress State
5.3. Microtribological Investigations
5.4. Optical and Acoustic Microscopy
5.5. Rolling Contact Fatigue Performance
5.5.1. Screening Test
5.5.2. Pitting Tests
- Run-in procedure for 24 h at a reduced speed of 500 min−1,
- Fatigue test for the remaining 176 h at 750 min−1.
6. Conclusions
- AISI 52100 is considered as non-weldable, but it was possible to weld by means of PTA. The challenge of reducing pores during the welding process in order to increase the bearing fatigue life still remains.
- The forming process demonstrated a positive impact on the microstructure in the interface zone. Besides a grain refinement in the clad material, the Widmanstätten structure was fully recrystallized. Moreover, the porosity occurring after PTA was significantly reduced and a defect-free material transition between the base material and the cladding material was observed.
- Hardness values similar to those of industrial bearings were achieved by the applied heat treatment of quenching and tempering.
- Residual stress measurements demonstrated that no critical tensile residual stresses occurred at the surface of the hybrid bearing washers like in industrial bearing washers. High compressive residual stresses on the subsurface avoided premature failure of the bearing washers.
- By using AISI 52100 as cladding material, the load-bearing capacity of the tailored forming bearing washers was increased compared to AISI 5140 and AISI HNV3 claddings. Eighty-two percent of the calculated modified rating life for conventional bearings L10m was achieved. The slope of the determined Weibull curve indicates premature damage. By means of SAM, pores and cavities could be detected, which were probably responsible for this.
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
References
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AISI | C | Si | Mn | P | S | Cr |
---|---|---|---|---|---|---|
1022 M | 0.22 | 0.29 | 0.84 | 0.01 | 0.001 | 0.04 |
52100 | 0.97 | 0.25 | 0.31 | 0.01 | 0.004 | 1.38 |
Parameter | Value | Parameter | Value |
---|---|---|---|
Shielding gas flow (argon) | 10 L/min | Current | 180–130 A |
Plasma gas flow (argon) | 1.5 L/min | Voltage | 25–27 V |
Transport gas flow (argon) | 6 L/min | Powder material | AISI 52100 |
Welding velocity | 0.12 m/min | Particle size | 0.06–0.2 mm |
Working distance | 10 mm | Deposition rate | 0.9 kg/h |
Parameter | Value |
---|---|
Forming temperature | 1050 °C |
Furnace shielding gas | argon |
Forging force | 1700 kN |
Height reduction | 35% |
Final height | 9 mm |
Parameter | Value | Parameter | Value | ||
---|---|---|---|---|---|
Speed | n | 500–750 min−1 | Axial load | Fax | 60 kN |
Viscosity at 40 °C | ν40 | 68 mm2/s | Load equivalent | C/P | 2.87 |
Oil temperature | TOil | 95 °C | Contact load | F1 | 3.16 kN |
Viscosity ratio | 𝜅 | 0.44 | Contact pressure | pmax | 1.8 GPa |
Variable | Value | |
---|---|---|
Weibull shape parameter | β | 3.47 |
Experimental life | B10 | 3.88 × 106 revs. |
Adjusted speed | nref | 300 min−1 |
Life exponent | p | 10/3 |
Life factor | aISO | 0.14 |
Modified rating life | L10m | 4.75 × 106 revs. |
Deviation factor | B10/L10m | 0.82 |
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Share and Cite
Coors, T.; Mildebrath, M.; Büdenbender, C.; Saure, F.; Faqiri, M.Y.; Kahra, C.; Prasanthan, V.; Chugreeva, A.; Matthias, T.; Budde, L.; et al. Investigations on Tailored Forming of AISI 52100 as Rolling Bearing Raceway. Metals 2020, 10, 1363. https://doi.org/10.3390/met10101363
Coors T, Mildebrath M, Büdenbender C, Saure F, Faqiri MY, Kahra C, Prasanthan V, Chugreeva A, Matthias T, Budde L, et al. Investigations on Tailored Forming of AISI 52100 as Rolling Bearing Raceway. Metals. 2020; 10(10):1363. https://doi.org/10.3390/met10101363
Chicago/Turabian StyleCoors, Timm, Maximilian Mildebrath, Christoph Büdenbender, Felix Saure, Mohamad Yusuf Faqiri, Christoph Kahra, Vannila Prasanthan, Anna Chugreeva, Tim Matthias, Laura Budde, and et al. 2020. "Investigations on Tailored Forming of AISI 52100 as Rolling Bearing Raceway" Metals 10, no. 10: 1363. https://doi.org/10.3390/met10101363