Fretting

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Fretting refers to wear and sometimes corrosion damage of loaded surfaces in contact while they encounter small oscillatory movements tangential to the surface. Fretting is caused by adhesion of contact surface asperities, which are subsequently broken again by the small movement. This breaking causes wear debris to be formed.

Contents

If the debris and/or surface subsequently undergo chemical reaction, i.e., mainly oxidation, the mechanism is termed fretting corrosion. Fretting degrades the surface, leading to increased surface roughness and micropits, which reduces the fatigue strength of the components. The amplitude of the relative sliding motion is often in the order of micrometers to millimeters, but can be as low as 3 nanometers. [1]

Typically fretting is encountered in shrink fits, bearing seats, bolted parts, splines, and dovetail connections.

Materials

Steel

Fretting damage in steel can be identified by the presence of a pitted surface and fine 'red' iron oxide dust resembling cocoa powder. Strictly this debris is not 'rust' as its production requires no water. The particles are much harder than the steel surfaces in contact, so abrasive wear is inevitable; however, particulates are not required to initiate fret.

Aluminium

Fretting in Aluminium causes black debris to be present in the contact area due to the fine oxide particles.

Products affected

Fretting examples include wear of drive splines on driveshafts, wheels at the lug bolt interface, and cylinder head gaskets subject to differentials in thermal expansion coefficients.

There is currently a focus on fretting research in the aerospace industry. [2] The dovetail blade-root connection and the spline coupling of gas turbine aero engines experience fretting. [3]

Another example in which fretting corrosion may occur are the pitch bearings of modern wind turbines, which operate under oscillation motion to control the power and loads of the turbine. [4]

Fretting can also occur between reciprocating elements in the human body. Especially implants, for example hip implants, are often affected by fretting effects. [5] [6]

Fretting electrical/electronic connectors

Source: [7]

Fretting also occurs on virtually all electrical connectors subject to motion (e.g. a printed circuit board connector plugged into a backplane, i.e. SOSA/VPX). Commonly most board to board (B2B) electrical connectors are especially vulnerable if there is any relative motion present between the mating connectors. A mechanically rigid connection system is required to hold both halves of a B2B motionless (often impossible). Wire to board (W2B) connectors tend to be immune to fretting because the wire half of the connector acts as a spring absorbing relative motion that would otherwise transfer to the contact surfaces of the W2B connector. Very few exotic B2B connectors exist that address fretting by: 1) incorporating springs into the individual contacts or 2) using a Chinese finger trap design to greatly increase the contact area. A connector design that contacts all 4-sides of a square pin instead of just one or 1 or 2 can delay the inevitable fretting some amount. Keeping contacts clean and lubricated also offers some longevity.

Contact fretting can change the impedance of a B2B connector from milliohms to ohms in just minutes when vibration is present. The relatively soft and thin gold plating used on most high quality electrical connectors is quickly worn through exposing the underlying alloy metals and with fretting debris the impedance rapidly increases. Contrary to common sense, high contact forces on the mated connector pair (thought to help lower impedance and increase reliability) can actually make the rate of fretting even worse.

Fretting in rolling element bearings

Different areas of typical false brinelling and fretting corrosion damage in a ball bearing Fretting And FalseBrinelling Schwack Byckov.png
Different areas of typical false brinelling and fretting corrosion damage in a ball bearing

In rolling element bearings fretting may occur when the bearings are operating in an oscillating motion. Examples of applications are blade bearings in wind turbines, helicopter rotor pitch bearings, and bearings in robots. If the bearing movement is limited to small motions the damage caused may be called fretting or false brinelling depending on mechanism encountered. [8] [9] The main difference is that false brinelling occurs under lubricated and fretting under dry contact conditions. Between false brinelling and fretting corrosion, a time-dependent relation has been proposed. [10]

Fretting fatigue

Fretting decreases fatigue strength of materials operating under cycling stress. This can result in fretting fatigue, whereby fatigue cracks can initiate in the fretting zone. Afterwards, the crack propagates into the material. Lap joints, common on airframe surfaces, are a prime location for fretting corrosion. This is also known as frettage or fretting corrosion. [11]

Factors affecting fretting

Fretting resistance is not an intrinsic property of a material, or even of a material couple. There are several factors affecting fretting behavior of a contact: [12]

Mitigation

The fundamental way to prevent fretting is to design for no relative motion of the surfaces at the contact. Surface roughness plays an important role as fretting normally occurs by the contact of the asperities of the mating surfaces. Lubricants are often employed to mitigate fretting because they reduce friction and inhibit oxidation. This may however, also cause the opposite effect as a lower coefficient of friction may lead to more movement. [13] Thus, a solution must be carefully considered and tested. In the aviation industry, coatings are applied to cause a harder surface and/or influence the friction coefficient.

Soft materials often exhibit higher susceptibility to fretting than hard materials of a similar type. The hardness ratio of the two sliding materials also has an effect on fretting wear. [14] However, softer materials such as polymers can show the opposite effect when they capture hard debris which becomes embedded in their bearing surfaces. They then act as a very effective abrasive agent, wearing down the harder metal with which they are in contact.

See also

Related Research Articles

<span class="mw-page-title-main">Friction</span> Force resisting sliding motion

Friction is the force resisting the relative motion of solid surfaces, fluid layers, and material elements sliding against each other. Types of friction include dry, fluid, lubricated, skin, and internal.

A lubricant is a substance that helps to reduce friction between surfaces in mutual contact, which ultimately reduces the heat generated when the surfaces move. It may also have the function of transmitting forces, transporting foreign particles, or heating or cooling the surfaces. The property of reducing friction is known as lubricity.

<span class="mw-page-title-main">Ball bearing</span> Type of rolling-element bearing

A ball bearing is a type of rolling-element bearing that uses balls to maintain the separation between the bearing races.

<span class="mw-page-title-main">Bearing (mechanical)</span> Mechanism to constrain relative movement to the desired motion and reduce friction

A bearing is a machine element that constrains relative motion to only the desired motion and reduces friction between moving parts. The design of the bearing may, for example, provide for free linear movement of the moving part or for free rotation around a fixed axis; or, it may prevent a motion by controlling the vectors of normal forces that bear on the moving parts. Most bearings facilitate the desired motion by minimizing friction. Bearings are classified broadly according to the type of operation, the motions allowed, or the directions of the loads (forces) applied to the parts.

<span class="mw-page-title-main">Lubrication</span> The presence of a material to reduce friction between two surfaces.

Lubrication is the process or technique of using a lubricant to reduce friction and wear and tear in a contact between two surfaces. The study of lubrication is a discipline in the field of tribology.

<span class="mw-page-title-main">Wear</span> Damaging, gradual removal or deformation of material at solid surfaces

Wear is the damaging, gradual removal or deformation of material at solid surfaces. Causes of wear can be mechanical or chemical. The study of wear and related processes is referred to as tribology.

Tribology is the science and engineering of understanding friction, lubrication and wear phenomena for interacting surfaces in relative motion. It is highly interdisciplinary, drawing on many academic fields, including physics, chemistry, materials science, mathematics, biology and engineering. The fundamental objects of study in tribology are tribosystems, which are physical systems of contacting surfaces. Subfields of tribology include biotribology, nanotribology and space tribology. It is also related to other areas such as the coupling of corrosion and tribology in tribocorrosion and the contact mechanics of how surfaces in contact deform. Approximately 20% of the total energy expenditure of the world is due to the impact of friction and wear in the transportation, manufacturing, power generation, and residential sectors.

<span class="mw-page-title-main">Plain bearing</span> Simplest type of bearing, comprising just a bearing surface and no rolling elements

A plain bearing, or more commonly sliding contact bearing and slide bearing, is the simplest type of bearing, comprising just a bearing surface and no rolling elements. Therefore, the journal slides over the bearing surface. The simplest example of a plain bearing is a shaft rotating in a hole. A simple linear bearing can be a pair of flat surfaces designed to allow motion; e.g., a drawer and the slides it rests on or the ways on the bed of a lathe.

<span class="mw-page-title-main">Rolling-element bearing</span> Bearing which carries a load with rolling elements placed between two grooved rings

In mechanical engineering, a rolling-element bearing, also known as a rolling bearing, is a bearing which carries a load by placing rolling elements between two concentric, grooved rings called races. The relative motion of the races causes the rolling elements to roll with very little rolling resistance and with little sliding.

<span class="mw-page-title-main">False brinelling</span>

False brinelling is a bearing damage caused by fretting, with or without corrosion, that causes imprints that look similar to brinelling, but are caused by a different mechanism. False brinelling may occur in bearings which act under small oscillations or vibrations.

<span class="mw-page-title-main">Galling</span> Form of wear caused by adhesion between sliding surfaces

Galling is a form of wear caused by adhesion between sliding surfaces. When a material galls, some of it is pulled with the contacting surface, especially if there is a large amount of force compressing the surfaces together. Galling is caused by a combination of friction and adhesion between the surfaces, followed by slipping and tearing of crystal structure beneath the surface. This will generally leave some material stuck or even friction welded to the adjacent surface, whereas the galled material may appear gouged with balled-up or torn lumps of material stuck to its surface.

<span class="mw-page-title-main">Stick–slip phenomenon</span>

The stick–slip phenomenon, also known as the slip–stick phenomenon or simply stick–slip, is a type of motion exhibited by objects in contact sliding over one another. The motion of these objects is usually not perfectly smooth, but rather irregular, with brief accelerations (slips) interrupted by stops (sticks). Stick–slip motion is normally connected to friction, and may generate vibration (noise) or be associated with mechanical wear of the moving objects, and is thus often undesirable in mechanical devices. On the other hand, stick–slip motion can be useful in some situations, such as the movement of a bow across a string to create musical tones in a bowed string instrument.

<span class="mw-page-title-main">Precession (mechanical)</span> Mechanical displacement of an axis

Precession is the process of a round part in a round hole, rotating with respect to each other, wherein the inner part begins rolling around the circumference of the outer bore, in a direction opposite of rotation. This is caused by too much clearance between them and a radial force on the part that constantly changes direction. The direction of rotation of the inner part is opposite to the direction of rotation of the radial force.

Dry lubricants or solid lubricants are materials that, despite being in the solid phase, are able to reduce friction between two surfaces sliding against each other without the need for a liquid oil medium.

Brinelling is the permanent indentation of a hard surface. It is named after the Brinell scale of hardness, in which a small ball is pushed against a hard surface at a preset level of force, and the depth and diameter of the mark indicates the Brinell hardness of the surface. Brinelling is permanent plastic deformation of a surface, and usually occurs while two surfaces in contact are stationary and the material yield strength has been exceeded.

<span class="mw-page-title-main">Tribocorrosion</span> Material degradation due to corrosion and wear.

Tribocorrosion is a material degradation process due to the combined effect of corrosion and wear. The name tribocorrosion expresses the underlying disciplines of tribology and corrosion. Tribology is concerned with the study of friction, lubrication and wear and corrosion is concerned with the chemical and electrochemical interactions between a material, normally a metal, and its environment. As a field of research tribocorrosion is relatively new, but tribocorrosion phenomena have been around ever since machines and installations are being used.

Pitch bearing Component connecting a turbine blade to the hub allowing pitch variation

The pitch bearing, also named blade bearing, is a component of modern wind turbines which connect the rotor hub and the rotor blade. The bearing allows the required oscillation to control the loads and power of the wind turbine. The pitch system brings the blade to the desired position by adapting the aerodynamic angle of attack. The pitch system is also used for emergency breaks of the turbine system.

Extreme tribology refers to tribological situations under extreme operating conditions which can be related to high loads and/or temperatures, or severe environments. Also, they may be related to high transitory contact conditions, or to situations with near-impossible monitoring and maintenance opportunities. In general, extreme conditions can typically be categorized as involving abnormally high or excessive exposure to e.g. cold, heat, pressure, vacuum, voltage, corrosive chemicals, vibration, or dust. The extreme conditions should include any device or system requiring a lubricant operating under any of the following conditions:

<span class="mw-page-title-main">White etching cracks</span> Deformation mechanism in steel

White etching cracks (WEC), or white structure flaking or brittle flaking, is a type of rolling contact fatigue (RCF) damage that can occur in bearing steels under certain conditions, such as hydrogen embrittlement, high stress, inadequate lubrication, and high temperature. WEC is characterised by the presence of white areas of microstructural alteration in the material, which can lead to the formation of small cracks that can grow and propagate over time, eventually leading to premature failure of the bearing. WEC has been observed in a variety of applications, including wind turbine gearboxes, automotive engines, and other heavy machinery. The exact mechanism of WEC formation is still a subject of research, but it is believed to be related to a combination of microstructural changes, such as phase transformations and grain boundary degradation, and cyclic loading.

<span class="mw-page-title-main">Rolling contact fatigue</span> Deformation mechanism

Rolling Contact Fatigue (RCF) is a phenomenon that occurs in mechanical components relating to rolling/sliding contact, such as railways, gears, and bearings. It is the result of the process of fatigue due to rolling/sliding contact. The RCF process begins with cyclic loading of the material, which results in fatigue damage that can be observed in crack-like flaws, like white etching cracks. These flaws can grow into larger cracks under further loading, potentially leading to fractures.

References

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