Astm stp 1367 2000

STP 1367

Fretting Fatigue: Current

Technology and Practices

DavidW. Hoeppner, V. Chandrasekaran,

and Charles B. Elliott III, editors

ASTM Stock Numer: STP 1367

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West Conshohocken, PA 19428-2959

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Library of Congress Cataloging-in-Publication Data

Fretting fatigue: current technology and practices/David W. Hoeppner, V.

Chandrasekaran, and Charles B. Elliott III, editors.

p. cm. -- (STP; 1367)

ASTM Stock Number: STP1367.

Includes bibliographical references and index.

ISBN 0-8031-2851-7

1. Metals--Fatigue. 2. Fretting corrosion. 3. Contact mechanics. I. Hoeppner, David W.

II. Chandrasekaran, V., 1964- II1. Elliott, Charles B., 1941- IV. International Symposium

on Fretting Fatigue (2nd: 1998: University of Utah) V. ASTM special technical publication; 1367.

TA460 .F699 2000

620.1'66--dc21 99-059181

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January 2000

Foreword

This publication, Fretting Fatigue: Current Technology and Practices, contains papers presented

at the symposium held at the University of Utah, Salt Lake City, Utah on Aug. 31, 1998. The sym￾posium was sponsored by University of Utah, United Technologies Research Center, MTS Systems

Corporation, FASIDE International, INC. and co-sponsored by Committee E8 on Fatigue and Frac￾ture. The symposium was chaired by David W. Heoppner, V. Chandrasekaran, and Charles B. Elliott

111 served as co-chairmen. They all served as STP editors of this publication.

Contents

Overview ix

BACKGROUND AND CRITICAL ISSUES RELATED TO FRETTING FATIGUE

Plastic Deformation in Fretting Processes--A Review--R. B. WATERHOUSE 3

A New Approach to the Prediction of Fretting Fatigue Life That Considers the Shifting

of the Contact Edge by Wear--T. HATTOPO, M. NAKAMURA, AND T. WATANABE 19

On the Standardization of Fretting Fatigue Test Method--Modeling Issues

Related to the Thermal Constriction Phenomenon and Prediction of Contact

Temperature---M. H. ATTIA 31

Fretting-Wear and Fretting-Fatigue: Relation Through a Mapping Concept￾s. FOUVRY, P. KAPSA, AND L. VINCENT 49

High Temperature Fretting Fatigue Behavior in an XD TM 7-base TiAI--

T. HANSSON, M. KAMARAJ, Y. MUTOH, AND B. PET'I'ERSSON 65

Applications of Fracture Mechanics in Fretting Fatigue Life Assessment--

A. E. GIANNAKOPOULOS, T. C. LINDLEY, AND S. SURESH

Spectrum Load Effects on the Fretting Behavior of Ti-6A1-4V--s. E. KINYON

AND D. W. HOEPPNER 100

FRETTING FATIGUE PARAMETER EFFECTS

The Effects of Contact Stress and Slip Distanee on Fretting Fatigue Damage

in Ti-6AI-4V/17-4PIt Contacts---D. L. ANTON, M. J. LUTIAN, L. H. FAVROW, D. LOGAN,

AND B. ANNIGERI I 19

Length Scale Considerations in Fretting Fatigue---D. NOWELL, D. A. HILLS, AND R. MOOBOLA 141

An Investigation of Friction Force in Fretting Fatigue---w. SWITEK 154

A Multiaxial Fatigue Analysis of Fretting Contact Taking into Account

the Size Effect--s. FOUVRY, P. KAPSA, AND L. VINCENT 167

Interaction of High-Cycle and Low-Cycle Fatigue on Fretting Behavior of Ti-6-4---

R. CORTEZ, S. MALL, AND J. R. CALCATERRA

Effects of Contact Load and Contact Curvature Radius of Cylinder Pad

on Fretting Fatigue in High Strength Steel--s.-K. LEE, K. NAKAZAWA, M. SUMITA,

AND N. MARUYAMA

An Experimental Investigation of Fretting Fatigue with Spherical Contact in 7075-T6

Aluminum AIIoy--B. u. WITTKOWSKY, P. R. BIRCH, J. DOMINGUEZ, AND S. SURESH

183

199

213

ENVIRONMENTAL EFFECTS

Fretting Fatigue of Some Nickel-Based Alloys in Steam Environment at 265~ -

M. H. ATTIA 231

Fretting Fatigue of 8090-T7 and 7075-T651 Aluminum Alloys in Vacuum

and Air Environments---c. B. ELLIOTT 111 AND A. M. GEORGESON 247

FRETTING FATIGUE CRACK NUCLEATION

Influence of Ambient Air on Nucleation in Fretting Fatigue---J. WOODTLI,

O VON TRZEBIATOWSKI, AND M. ROTH 257

Experimental Study of Fretting Craek Nucleation in Aerospaee Alloys with Emphasis

on Life Prediction--M. P. SZOLWINSKI, G. HARISH, P. A. MCVEIGH, AND T. N. FARRIS 267

Crack Behavior in the Early Stage of Fretting Fatigue Fracture---K. KONDOH

AND Y. MUTOH 282

MATERIAL AND MICROSTRUCTURAL EFFECTS

Influence of Microstructure on Fretting Fatigue Behavior of a Near-alpha Titanium--

T. SATOH 295

Fretting Fatigue Behavior of Ti-6AI-4V Against Ti-6AI-4V Under Flat-on-Flat Contact

with Blending Radii--A. L. HUTSON AND T. NICHOLAS 308

Fretting Fatigue Strengths of Forged and Cast AI-Si Aluminum Alloys--T. •SHIDA,

Y. MUTOH, K. YOSHII, AND O. EBIHARA 322

FRETTING DAMAGE ANALYSIS

Analysis of Fretting Damage Using Confocal Microscope---v. CHANDRASEKARAN,

Y. IN YOON, AND D. W. HOEPPNER 337

Analysis of Fretting Damage in Polymers by Means of Fretting Maps---

A. CHATEAUMINOIS, M. KHARRAT, AND A. KRICHEN 352

LIFE PREDICTION

Methodologies for Linking Nucleation and Propagation Approaches for Predicting Life

Under Fretting Fatigue--R. w. ~u, J. A. PAPE, AND D. R. SWALLA 369

EXPERIMENTAL STUDIES

Fretting Fatigue Testing Methodology Incorporating Independent Slip and Fatigue Stress

Control--L. H. FAVROW, D. WERNER, D. D. PEARSON, K. W. BROWN, M. J. LUTIAN,

B. S. ANNIGERI, AND DONALD L. ANTON 391

An Analysis of Rotating Bending Fretting Fatigue Tests Using Bridge Specimens--

M. CIAVARELLA, G. DEMELIO, AND D. A. HILLS 404

Evaluation of Fretting Stresses Through Full-Field Temperature Measurements--

G. HARISH, M. P. SZOLWINSKI, T. N. FARRIS, AND T. SAKAGAMI 423

Stage II Crack Propagation Direction Determination Under Fretting Fatigue Loading:

A New Approach in Accordance with Experimental Observations--M.-c. DUBOURG

AND V. LAMACQ 436

Development of a High-Temperature-Steam Fretting Wear Test Apparatus--

M. P. BLINN AND J. M. LIPKIN 451

SURFACE TREATMENTS

Fretting Fatigue Behavior of TiN-Coated Steel--M. OKAY, K. SHIOZAWA, AND T. ISHIKURA 465

The Effect of the Contact Conditions and Surface Treatments on the Fretting Fatigue

Strength of Medium Carbon Steel--M. KUBOTA, K. TSUTSUI, T. MAK1NO,

AND K. HIRAKAWA 477

Influence of Surface Treatments on Fretting Fatigue of Ti-6242 at Elevated Temperatures--

s. CHAKRAVARTY, J. P. DYER, J. C. CONWAY, JR., A. E. SEGALL, AND P. C. PATNAIK 491

APPLICATIONS

Fracture Mechanics Approach to the Fretting Fatigue Strength of Axle Assemblies--

T. MAKINO~ M. YAMAMOTO, AND K. HIRAKAWA 509

Fretting in Aerospace Structures and Materials--T. N. FARRIS, M. P. SZOLWINSKI,

AND G. HARISH 523

On a New Methodology for Quantitative Modeling of Fretting Fatigue---K. DANG VAN

AND M. H. MAITOURNAM 538

Indexes 553

Overview

The Second International Symposium on Fretting Fatigue was held at the University of Utah Au￾gust 31-September 2, 1998. This symposium was held to continue the exchange of information on

the subject of fretting fatigue that was accelerated within the ASTM Symposium on Standardization

of Fretting Fatigue Methods and Equipment held in San Antonio, TX on November 12-13, 1990

(see ASTM STPl159 edited by Attia and Waterhouse, ASTM, 1992) and the International Sympo￾sium on Fretting Fatigue held at the University of Sheffield in April, 1993 (see Fretting Fatigue,

ES1S Publication 18, edited by Waterhouse and Lindley, 1994). The contribution of fretting to nu￾cleating fatigue failures, often well before they were expected to occur is well known now even

though the phenomenon had not been formally identified until the 20th century. A great deal of

progress dedicated to understanding the phenomenon of fretting fatigue has occurred within the past

century. Thus, this symposium was organized to focus on the progress and to continue the extensive

interchange of ideas that has occurred-particularly within the past 50 years.

Fifty-six delegates from ten countries attended the symposium to present papers and participate in

lively discussions on the subject of fretting fatigue. The attendees included Dr. Waterhouse and Dr.

Hirakawa who did pioneering research and development from the 1960's to the present. Technical

leaders in the area of fretting fatigue were in attendance from most of the leading countries that are

currently involved in fretting fatigue research, development, and engineering design related matters

as well as failure analysis and maintenance engineering issues. ASTM Committee E08 provided the

ASTM organizational support for the symposium. The collection of papers contained in this volume

will serve as an update to a great deal of information on fretting fatigue. It contains additional contri￾butions that may prove useful in life estimation. More applications of these methods are required.

The damage mapping approach presented in some of the papers should assist the community in de￾veloping more understanding of fretting fatigue and also provide significant guidance to developing

fretting fatigue design methods, and prevention and alleviation schemes. This volume thus serves en￾gineers that have need to develop an understanding of fretting fatigue and also serves the fretting fa￾tigue community including both newcomers and those that have been involved for some time.

The Symposium was sponsored by the following organizations: 1) The Quality and Integrity En￾gineering Design Center at the Department of Mechanical Engineering at the University of Utah--

Dr. David Hoeppner--contact. 2) MTS Systems Corporation- Mr. Arthur Braun---contact. 3)

United Technologies Research Center (UTRC)- Dr. Donald Anton--contact and 4) FASIDE Inter￾national Inc.--Dr. David Hoeppner---contact.

All of the above organizations provided valuable technical assistance as well as financial support.

The Symposium was held at the University Park Hotel adjacent to the University of Utah campus.

Many of the delegates took part in pre- and post-symposium tours of area National Parks and other

sites. Sally Elliott of Utah Escapades, Part City, UT, coordinated the activities and program.

The organizing committee was formed at the conclusion of the International Symposium of Fret￾ting Fatigue held at the University of Sheffield in Sheffield, England April 19-22, 1993. The com￾mittee members were: Dr. David Hoeppner, P.E., Chair (USA), Dr. Leo Vincent (France), Dr.

Toshio Hattori (Japan), Dr. Trevor Lindley (England), and Dr. Helmi Attia (Canada). Forty papers

were presented and this volume contains 36 of those papers.

ix

X FRETTING FATIGUE: CURRENT TECHNOLOGY AND PRACTICES

At the conclusion of the symposium the planning committee for the next two symposia was

formed. Dr. Mutoh of Japan will coordinate and chair the next meeting with support from the fret￾ting fatigue community of Japan. Another symposium will be held a few years after the Japan sym￾posium in France with Dr. Vincent as coordinator and chair.

Editing and review coordination of the symposium was done with the outstanding coordination of

Ms. Annette Adams of ASTM. The editors are very grateful to her for her extensive effort in assist￾ing in concluding the paper reviews and issuing this volume in a timely manner.

The symposium opened with remarks by the symposium chair. Subsequently, Dr. Robert Water￾house gave the Distinguished Keynote Lecture. A session of six keynote papers followed the paper

of Dr. Waterhouse and is included as the Background Section in this volume.

The papers enclosed in this volume cover the following topics: Fretting fatigue parameter effects,

environmental effects, fretting fatigue crack nucleation, material and microstructural effects, fret￾ting damage analysis, fracture mechanics applied to fretting fatigue, life prediction, experimental

studies, surface treatments, and applications.

The symposium involved the presentation of methods for studying the phenomenon and for ana￾lyzing the damage that fretting produces. It is now very clear that fretting is a process that may

occur conjointly with fatigue and the fretting damage acts to nucleate cracks prematurely. More evi￾dence of this is presented in the papers presented in this volume. Although a few laboratories are ex￾pending significant efforts on the utilization of fracture mechanics to estimate both the occurrence

of fretting fatigue and its progression, there was lively discussion of when cracks are actually nucle￾ated during the fretting fatigue process. As with many of the symposia held on topics related to fa￾tigue over the past 40 years, part of the problem stems from the use of the conceptual view on "initi￾ation of cracks" rather than on the processes by which cracks nucleate (e.g., fretting), and grow in

their "short or small" stage and in their long stages where LEFM, EPFM, or FPFM are directly ap￾plicable. Even though ASTM committee E 8 has attempted to have the community use the term

crack formation or nucleation rather than initiation, this symposium had several papers that persist

in this conceptual framework and thus a great deal of discussion centered on this issue. As well,

some investigators simply substitute the word nucleation or formation for "initiation." This also re￾suited in lively discussion at the Symposium, and readers of this volume will find this aspect most

interesting. The papers will, when taken as a whole, assist the community in expanding our under￾standing of fretting fatigue a great deal. This will undoubtedly assist engineers in both the preven￾tion and control of fretting fatigue and in formulating standards to deal with experimentation related

to it in the future.

Extensive progress has been made in understanding the phenomenon of fretting fatigue. Even

though analytical techniques have emerged to assist in life estimation for fretting fatigue and the an￾alytical techniques also provide guidance for alleviation of fretting fatigue, it is still necessary to

conduct experiments to attempt to simulate the fretting fatigue behavior of joints. New experimental

techniques have emerged that allow characterization of fretting fatigue in much greater detail than

at any time previous to this and new testing techniques are emerging. A standard to assist in devel￾opment of fretting fatigue data still has not emerged, but one of the participating countries has made

an effort to attempt to develop a standard. As well, a manual of standard terminology for fretting fa￾tigue still has not emerged. ASTM E 8 was asked by the planning committee to ask their fretting fa￾tigue subcommittee to undertake to develop the list of terms and phrases and come up with a man￾ual of these within the next two years--hopefully, before the next symposium in Japan.

Several papers dealt with the application of fracture mechanics to fretting fatigue. This is not new

but some newer computational models are discussed, and these applications provide a means by

which to manage the occurrence of fretting fatigue induced cracks in practice. Thus, the crack prop￾agation portion of cracks induced by fretting is manageable as was shown in works as early as 1975.

Some papers herein provide additional insight into the application of fracture mechanics to fretting

fatigue. One of the'areas that has not received as much interest and study as it should is the area of

OVERVIEW xi

surface treatments (coatings, self-stresses, diffusion layers, and implanted layers, etc.). This is re￾grettable since one of the most important ways to prevent fretting degradation is to provide a change

in the surface behavior. Hopefully, more effort will be expended on this aspect, and more results

will be presented at the next symposium. It is suspected that the scientific community of the USA,

for example, does not view this as a new science area to be studied. If this is true and extends to

other countries, this would slow the development of fretting fatigue prevention schemes. Another

area that has not received anywhere near the attention needed, even though Waterhouse and Hoepp￾her both have emphasized the need for additional effort and study to adequately understand the phe￾nomenon, is the area of environmental effects on fretting fatigue. The review of this subject by D.

Taylor in the 1993 discussed this issue in depth but little progress seems to have occurred in this

area. This is regrettable since it is very likely that the environmental (both chemical and thermal)

contribution to fretting fatigue is substantial. Thus, more effort needs to be directed at this area in

the future.

Work in France, Japan, and two US laboratories (UTRC and the University of Utah) is progress￾ing on a more holistic, systems oriented approach to fretting fatigue. This includes damage charac￾terization during the process, the development of fretting maps and/or damage maps, attempting to

characterize the physics of the crack nucleation and propagation processes as well formulate me￾chanics based formulations of life estimation. These papers are reflected in this volume. It is clear

that additional progress will be made in the next several years to assist the engineering and science

community in understanding and dealing with fretting fatigue. The papers contained herein will as￾sist in this endeavor.

David W. Hoeppner, P.E., Ph.D.

V. Chandrasekaran, Ph.D.

Charles Elliott III, P.E. Ph.D.

University of Utah

Symposium Chairman, Co-chairmen, and STP Editors

Background and Critical Issues

Related to Fretting Fatigue

R B Waterhouse ~

Plastic Deformation in Fretting Processes - a Review

REFERENCE: Waterhouse, R. B., "Plastic Deformation in Fretting Processes--a

Review," Fretting Fatigue: Current Technology and Practices, ASTM STP 1367, D. W.

Hoeppner, V. Chandrasekaran, and C. B. Elliott, Eds., American Society of Testing and

Materials, West Conshohocken, PA, 2000.

ABSTRACT: In recent years, analytical treatments of contacting surfaces and resultant

fretting, the initiation and early propagation of fatigue cracks, have been the subject of

elastic stress analysis. However, direct observations of fretting damage in optical and

scanning electron microscopes indicates that plastic deformation of the contacting

surfaces is usually an important feature. In this respect it has some similarity with other

surface deformation processes, such as shot-peening and surface rolling, in that residual

stresses are developed or existing stresses are modified. Surface films which are there as

a result of oxidation or applied as an anti-fretting palliative can be seriously disrupted by

plastic deformations of the substrate, resulting in a "tribologically transformed layer" or

third-body intervention. Consideration of these factors can play a role in the development

of methods to counteract the effect of fretting, and is the basis of this review.

KEYWORDS: plastic deformation, adhesion, work hardening, residual stress, fretting

debris, surface films

Introduction

Recent developments in the study of fretting, and particularly fretting fatigue, have

concentrated on finite element analysis of the contact, locating the site of initiation of a

crack. If the configuration is that often used in experimental studies i.e. a square-edged

fretting pad applied to a fiat fatigue specimen, the crack initiates at a singularity created

by the sharp edge of the pad. Even with the less severe contact of a cylindrical pad these

analyses usually locate the crack at the edge of the contact region [1]. Further analysis

allows the oblique course of the crack to be predicted and its velocity calculated under

mixed-mode stress conditions. Once the crack has migrated out of the region affected by

the contact stresses, the crack propagates in a plane perpendicular to the alternating

fatigue stress.

Direct observation of fretting fatigue failures often indicates that the initial crack is

generated in the boundary between the slip region and the non-slip region in the partial

slip regime. As the slip region usually migrates further into the contact, by the time the

eventual failure occurs the crack appears to be well within the slip region. An empirical

analysis developed by Ruiz [2] predicts that this will be the case. It depends on the

1professor, Department of Materials Engineering and Materials Design, University of

Nottingham, University Park, Nottingham, NG7 2RD, United Kingdom.

Copyright* 2000 by ASTM International

3

www.astm.org

4 FRETTING FATIGUE: CURRENT TECHNOLOGY AND PRACTICES

product of the amplitude of slip 8, the shear stress x and the tensile stress in the surface o

reaching a critical value.

Close examinations of the fretted surface reveals that surface films, usually oxide, are

disrupted, intimate metal-to-metal contact occurs and local welds are formed which

result in material being plucked above the original surface [3] and even the formation of

macroscopic welds [4]. These events can be followed by the measurement of contact

resistance [5] between the surfaces and finally by topographical analysis [6] and SEM

examination [7]. These observations confirm that the disruption of the surface material

is rather more violent than appears in the FE analysis.

Direct Observation

The development of the scanning electron microscope (SEM) has proved invaluable in

examining surfaces and surface damage. Figure 1 shows damage in the early stages of

fretting fatigue in a 0.2C steel. Material has been pulled up above the original surface

and has resulted in the creation of a very visible crack. However, the optical microscope

also is still a very useful means of investigating such damage. By protecting the surface

by nickel or other plating and then sectioning, the superficial and subsurface changes can

be readily seen. Figure 2 shows evidence of plastic deformation and the initiation of a

crack in the same steel. Figure 3 is a different form of damage where shallow cracks

have joined and where a loose particle could result. Intimate intermetallic contact in the

early stage is indicated by very low electrical contact resistance and the formation of

local welds. Figure 4 is a section through the specimen and bridge foot showing that the

deformation occurs in both surfaces. Eventually a wedge of material can develop, Figure

5. The welds can be quite strong - in some cases a normal tensile force of 4kg has had to

be applied to remove the bridge. If the weld is 0.2 mm in diameter which is apparent

from such photographs and there four such welds, two on each bridge foot [8], the

strength of the welds is about 330MPa. If it is likely that one or two welds break first

and the remainder are prized off then the individual welds could be stronger and of the

same order as the strength of the steel.

Sections which have been polished but not electroplated can be examined in the SEM

to show both the surface and the underlying material, Figure 6, which shows subsurface

cavities.

Occasionally somewhat bizarre features are seen in the SEM. Figure 7 shows the

result of fretting on a pure copper specimen. A thin surface layer has broken open to

reveal a series of parallel tubular holes just below the surface and apparently parallel to

the surface. This has been termed the "zip fastener effect" and is related to the pile-up of

dislocations in the surface region [9].

Profilometer Observations

In the early days a single traverse by the profilometer would confirm the features already

seen in the SEM e.g. the undamaged plateau in the centre of the fretting scar in the

partial slip regime, Figure 8. The course of the damage as fretting proceeded could also

be assessed as in Figure 9. Nowadays, with computers, orthogonal projections of the

scar can be produced and the volume of material both raised above and missing below

WATERHOUSE ON PLASTIC DEFORMATION 5

Figure 1 - Adhesive damage in the early stages of

fretting fatigue on a 0.2C steel- slip amplitude 12kern

Figure 2 - Fretting fatigue damage on mild steel 10000 cycles x 400

6 FRETTING FATIGUE: CURRENT TECHNOLOGY AND PRACTICES

Figure 3 - Confluent fatigue cracks on mild steel x 200

Figure 4 - Local weM between miM steel surfaces 25000 cycles x 400