Greco, Aaron C. | Engineering Papers

DOE OSTI2023

The effect of current and lambda on white-etch-crack failures

White etching cracks (WECs) have been associated with premature failure of wind turbine roller bearings. Various drivers for the generation of WECs have been identified such as loading conditions, slip, steel quality, lubrication, hydrogen embrittlement, corrosion fatigue cracking, and stray electrical currents passing through the surface. Here, in this work, a benchtop test rig utilizing a three-ring-on-roller test configuration was used to investigate the effect of electrical current and operation in different lubricating regimes, defined by lambda (λ), on high-quality bearing steel samples tested in a commercially available power transmission EP gear lubricant. It was observed that there is an inverse correlation between the magnitude of electric current applied to the ring/ roller system and time-to-failure. Higher current magnitudes lead to shorter time-to-failure than lower current magnitudes, with macropitting as the main failure mode. Sub-surface investigation revealed the presence of WECs in all cases. For the same current magnitude, tests conducted in boundary and mixed lubrication regimes showed that time-to-failure increased as lambda increased, and the tests resulted in WEC related macropits, whereas tests conducted in near-hydrodynamic regime resulted in surface damage with no macropit. It was also noted that a shift toward near-hydrodynamic lubrication resulted in a distinct surface distress on the roller surface. Furthermore, there seems to be a transition in the mixed regime during which the surface distress occurred. The damage on the surface of the test samples resembled non-spatially, periodic, groove-like corrugations and, in some cases, crater-like depressions. Sub-surface imaging, performed by sequential sectioning, revealed the presence of WECs in all cases, and broad, branching cracks that were more prevalent under the more severe boundary conditions.

17 WIND ENERGY↗

DOE OSTI2020

Pitting resistant carbon coatings

A hydrogenated diamond-like coating (“H-DLC”) for metallic substrates provides improved reliability. The H-DLC is relatively soft and elastic. Unlike hard and/or inelastic coatings in the prior art, the present coatings do not exhibit a loss of adhesion (delamination). A bonding layer may be used between the metallic substrate and the H-DLC. H-DLC coatings can, for example, be used in bearings and gears to reduce the occurrence of micropits and, ultimately, product failure.

Erylimaz, Osman L.↗

DOE OSTI2020

Correlations between thermal history and keyhole porosity in laser powder bed fusion

Additive manufacturing has the potential to revolutionize the production of metallic components as it yields near net shape parts with complex geometries and minimizes waste. At the present day, additively manufactured components face qualification and certification challenges due to the difficulty in controlling defects. This has driven a significant research effort aimed at better understanding and improving processing controls – yielding a plethora of in-situ measurements aimed at correlating defects with material quality metrics of interest. In this work, we develop machine-learning methods to learn correlations between thermal history and subsurface porosity for a variety of print conditions in laser powder bed fusion. Un-normalized surface temperatures (in the form of black-body radiances) are obtained using high-speed infrared imaging and porosity formation is observed in the sample cross-section through synchrotron x-ray imaging. To demonstrate the predictive power of these features, we present four statistical machine-learning models that correlate temperature histories to subsurface porosity formation in laser fused Ti-6Al4V powder.

36 MATERIALS SCIENCE↗