A common cause for premature bearing failures in wind turbine gearboxes are the so-called White Etching Cracks (WEC). These undirected, three-dimensional cracks are bordered by regions of altered ...microstructure and ultimately lead to a cracking or spalling of the raceway. An accelerated WEC test was carried out on a FE8 test rig using cylindrical roller thrust bearings made of martensitic 100Cr6 steel. The resulting WECs were investigated with several characterisation techniques. Ultrasonic measurements showed the WEC were mainly located in the region of the overrolled surface in which negative slip occurs, which agrees with hypotheses based on an energetic approach for a prognosis. SEM orientation contrast imaging of the area around WEC revealed an inhomogeneous structure with varied grain sizes and a large amount of defects. Microstructure characterization around the WEA using EBSD showed significant grain refinement. Atom probe tomography showed the microstructure in the undamaged zone has a plate-like martensitic structure with carbides, while no carbides were detected in the WEA where the microstructure consisted of equiaxed 10nm grains. A three dimensional characterisation of WEC network was successfully demonstrated with X-ray computerized tomography, showing crack interaction with unidentified inclusion-like particles.
•Accelerated laboratory WEC test successfully carried out.•Electron backscatter diffraction of WEC region.•3D characterization of nanocrystalline WEA using atom probe tomography.•3D characterisation of WEC network using X-ray tomography.
•Cracks in wind turbine bearings were investigated after several years of service.•WEC propagation is mostly transgranular without relation to microstructure features.•Carbide particles are observed ...to decompose at a late stage of WEM formation.•Both sharp transition and gradual transition between WEM and matrix are observed.
White etching cracks and other microstructural features have been investigated in two 100Cr6 steel bearings failed after several years of service in wind turbines. It is found that cracks in these bearings propagate predominantly through prior austenite grains in the tempered martensite structure. Both sharp and gradual transitions between the tempered martensite structure and white etching matter adjacent to the cracks are observed. Furthermore, it is suggested that structural refinement of carbide particles present in the microstructure of the wind turbine bearings occurred at a late stage of white etching matter formation.
WEC is an aggressive and unpredictable failure mode affecting bearings in particular in the wind energy sector. This paper focuses on the most common used method for WEC laboratory accelerated ...testing, the FE8 type test rigs using martensitic through hardened 100Cr6 cylindrical roller thrust bearings, analyzing the load conditions, test results and damage quantification. The surface and sub-surface stress conditions as well as the surface frictional loading were analyzed using a half-space model. Simulations and experiments were conducted under different load conditions, including tests with different number of rollers and tests using dynamic load and speed. Tests under constant loads show a low load influence and prove that a WEC failure can occur both prematurely and after exceeding the rated lifetime. Dynamic conditions did not accelerate WEC failure, and only rollers (not washers) were affected by WEC under dynamic loading conditions. Damage characterization was performed using optical microscopy and ultrasound scanning. Advanced image analysis based on characterization of defect regions in the ultrasound scans was used for quantifying the subsurface damage. Tests showed WEC failure could be achieved consistently, however there were seemingly large random variations in the observed damage.
White Etch Cracking (WEC) is a severe and unpredictable failure mode affecting bearings in various industrial sectors. In this work, accelerated WEC laboratory tests have been performed using FE8 ...type test rigs with ceramic rollers to test the WEC resistance of different bearing materials, materials quality and roughness. It is demonstrated that the test method can reliably and consistently provoke WEC in commercially available washers. Tests using washers with different roughness values did not show significant changes in the time to failure. Tests of through hardened bearing steel with a low content of inclusions resulted in a significantly longer time to failure compared to the baseline. Through hardened washers with a black oxide coating did not improve the WEC life as the coating was worn away during testing. Tests with two types of carbo-nitrided washers gave significantly longer time to failure, of which one type in particular showed high resistance towards WEC formation.
•Tests of White Etching Crack resistance for several bearing materials was conducted.•Bearing steel with low inclusion content showed improved performance.•Carbo-nitrided steels showed significant improved performance.•Black oxide coating was worn off during testing and did not improve performance.•Lower roughness did not show improved performance.
For high temperature applications, 9-12 wt-%Cr steels in fossil fired power plants rely upon precipitate strengthening from (V,Nb)N MX nitrides for long term creep strength. During prolonged exposure ...at service temperature, another nitride precipitates: Cr(V,Nb)N Z phase. The Z phases lowly replace MX, eventually causing a breakdown in creep strength. The present paper reviews the Z phase and its behaviour in 9-12 wt-%Cr steels including thermodynamic modelling, crystal structure, nucleation process and precipitation rate as a function of chemical composition. The influence of Z phase precipitation upon long term creep strength is assessed from several different 9-12wt-%Cr steel grades and alloy design philosophies.
The paper deals in depth with characterizing bead-on-plate welds on EN-GJS-500-14 base metal, utilizing two filler metals: a pure Ni wire and a NiFe wire containing 45 wt pct Ni. The welds were ...conducted using the same heat input to ensure comparability in microstructure analysis. The microstructural observations were carried out using optical and scanning electron microscopies, X-ray tomography, X-ray diffraction analysis, and microhardness testing. Thermodynamic simulations using the non-equilibrium Scheil solidification model provide insights into the solidification process and the underlying metallurgical factors associated with the observed microstructural evolution. The observations revealed that the pure Ni wire deposited a softer fusion zone with graphite precipitation, while cementite precipitated in the fusion zone of NiFe alloy. The formation of martensite structures with different morphologies was the predominant microstructural evolution in the heat-affected zone of both welds. The partially melted zone of the pure Ni weld is narrower than the NiFe weld because more diffusion of Ni avoids widening the brittle structures in the partially melted zone. An unmixed zone in the form of a peninsula was exclusively observed in the fusion zone of the NiFe weld because of inadequate diffusion of Ni into the liquified materials along the fusion boundary.
Rail wheel contact at switches and crossings (S&Cs) induces impact stresses along with rolling contact stresses, resulting in plastic deformation and eventually crack formation. Damaged and deformed ...wing rails of a manganese steel crossing are studied and the microstructure, hardness and 3D crack network within the steel are characterized. It is found that the surface of the rail receives the maximum deformation resulting in a hardened top layer. The deformation is manifested by a high density of twins and dislocation boundaries in the microstructure. A complex crack network is revealed in high resolution by X-ray tomography.
•For Manganese steel, damage in the wing rail is similar to that in the nose rail.•The depth of work hardening reaches a depth of 10 mm and 600Hv at the surface.•It can be assumed the impact from the wheel causes the crack formation.•3D mapping of the crack network reveal presence of surface and sub-surface cracks.•The crack network appears similar to that of normal straight track pearlitic steel.
Preoperative risk stratification is essential in tailoring endometrial cancer treatment, and biomarkers predicting lymph node metastasis and aggressive disease are aspired in clinical practice. DNA ...ploidy assessment in hysterectomy specimens is a well-established prognostic marker. DNA ploidy assessment in preoperative curettage specimens is less studied, and in particular in relation to the occurrence of lymph node metastasis.
Curettage image cytometry DNA ploidy in relation to established clinicopathological variables and outcome was investigated in 785 endometrial carcinoma patients prospectively included in the MoMaTEC multicentre trial.
Diploid curettage status was found in 72.0%, whereas 28.0% were non-diploid. Non-diploid status significantly correlated with traditional aggressive postoperative clinicopathological features, and was an independent predictor of lymph node metastasis among FIGO stage I-III patients in multivariate analysis (OR 1.94, P=0.033). Non-diploid status was related to shorter disease-specific survival (5-year DSS of 74.4% vs 88.8% for diploid curettage, P<0.001). When stratifying by FIGO stage and lymph node status, the prognostic effect remained. However, in multivariate regression analysis, preoperative histological risk classification was a stronger predictor of DSS than DNA ploidy.
Non-diploid curettage is significantly associated with aggressive clinicopathological phenotype, lymph node metastasis, and poor survival in endometrial cancer. The prognostic effect was also observed among subgroups with (presumably) less aggressive traits, such as low FIGO stage and negative lymph node status. Our results indicate curettage DNA ploidy as a possible supplement to existing parameters used to tailor surgical treatment.
According to classical theories precipitate interfaces are described by their degree of coherency with the matrix, which affects their strengthening contribution. Investigations of nitride ...precipitate interfaces in 12% Cr steels with transmission electron microscopy have shown the nitrides to be enveloped in an amorphous shell a few nm thick, thus leaving them without any coherency with the matrix. The amorphous nature of the shells could be ascertained with high resolution microscopy and dark field techniques. When extracted from the ferrite matrix the amorphous shells were observed to crystallize during electron beam exposure. The amorphous shells were observed around Ta- and Nb-based nitrides, which are considered to have a high interfacial energy with the ferrite matrix. They were not observed around V-based nitrides which have a Baker-Nutting relationship with low-misfit to the matrix.
Switches and crossings are an integral part of any railway network. Plastic deformation associated with wear and rolling contact fatigue due to repeated passage of trains cause severe damage leading ...to the formation of surface and sub-surface cracks which ultimately may result in rail failure. Knowledge of the internal stress distribution adds to the understanding of crack propagation and may thus help to prevent catastrophic rail failures. In this work, the residual strains inside the bulk of a damaged nose of a manganese railway crossing that was in service for five years has been investigated by using differential aperture synchrotron X-ray diffraction. The main purpose of this paper is to describe how this method allows non-destructive measurement of residual strains in selected local volumes in the bulk of the rail. Measurements were conducted on the transverse surface at a position about 6.5 mm from the rail running surface of a crossing nose. The results revealed the presence of significant compressive residual strains along the running direction of the rail.
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