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NREL Argonne
October, 2014-10-30
Dr.Walter Holweger
ST/HZA-ST
Basics Tribology
Aeorospace
Renewable Energies
Application Engineering
OPEN
for
Surface Technologies
overall
Basics Tribology
Dr. Joanna Procelewska
Dr. Yasmin Korth
Dr. Walter Holweger
Dr. Jrgen Gierl
Mr. Ivan Grozev
Automotive
Industrial
Internal/External Partners
Academia
Other
October 2014
2
COMMUNICATION
and
COOOPERATION
Factors that lead toward White Etching Cracks as stated and summarized
Solutions
Acknowledgements
11/6/2014
Page 3
11/6/2014
Page 4
Datamining
Cross Table Results on approx. 3000 WT
worldwide
DAMAGE RATE
=
HIGH
if
ELECTRICAL ISSUES
Frequency converters
and
INHERENT DYNAMICS
Gears, Brakes
And others
e.g. rotor blades, height
are
present
Gearbox
Generator
Clutches
Brakes
If so how can one make this robust against the WEC formation ?
Wheel Bearings
Automotive
Wind Power
Washing Machines
Cement Mills
within the SAE 52100 but also the SAE 4320 family
Bainite
Case Hardeners
(SAE 4320)
P robabilit y - W eibull
99
Probability -Weibull
Bude rus Charge 81237
Weibull-2P
ML E SRM MED FM
F=9/S=11
Data Points
Susp Points
Proba bility L ine
Classical
material fatigue ?
90
50
U nreliability, F( t)
10
Jrg Loos
Scha effle r Technologies AG & Co KG
20.11.2013
16:12:01
1
10
100
Time, ( t)
b= 0,6 279 , h= 16 72 ,3 55 0
1000
10000
Wahrscheinlichkeit-Weibull
Probability
- Weibull
99,000
Wahrscheinlichkeit-Weibull
CB@90% 2-seitig [T]
Folio1\Dayco 8 lang + Haas-Ref.
Weibull-2P
MLE SRM MED FM
F=26/S=4
Datenpunkte
Susp Punkte
Linie Wahrscheinlichkeit
Oberer VB-I
Unterer VB-I
90,000
Unzuverlssigkeit, F(t)
50,000
steep ascent
10,000
5,000
Jrg Loos
Schaeffler KG
30.09.2009
14:56:37
1,000
100,000
1000,000
Zeit, (t)
Folio1\Dayco 8 lang + Haas-Ref.:
Folio1\ECO S Best of Sthle:
b=3,7992, h=570,6468
b=3,2856, h=435,9363
2000,000
SUMMARY
there is no way to apply the DIN ISO 281 formula and it's
implications
L10 = a (C/P)n
Specific
Contact
Dynamics
Electrical
issues
Lubrication
.
even more
and
unkown
aspects
all kind of through hardeners ( 1 % p.w. Carbon) but also Case Hardeners are susceptible
independant from macroscopic residual stress and covering retained austenite from
030 % al stress
11/6/2014
Page 13
Test Rig I
Slip Mode
SLIP + LUBRICATION
SLIP - LUBRICATION
unkown Aspects
unkown aspects
Bearing
Speed
Loading
FAG 81212
750 U/min
60 kN
(1900 / 2100 MPa)
Lubrication Low ref Oil
Specific
Contact
Dynamics
11/6/2014
Page 14
Electrical
issues
Lubrication
.
even more
and
unkown
aspects
Ausgewhlter
Arbeitspunkt
Kapazitive Impulsstrme
I in A
U in V
Ausgewhlter
Arbeitspunkt
Slave Bearing
Test Bearing
21.09.12
Slave Bearing
Test Bearing
DGBB 6206
Low Ref Oil
9000 rpm
2800 MPa
-+
Bearing
Lubrication
Test Bearings
Speed
Loading
DGBB 6206
Wind Mill Oil ISO VG 320
plus critical additives
9000 rpm
2800 MPa
Specific
Contact
Dynamics
11/6/2014
Page 15
Electrical
issues
Lubrication
.
even more
and
unkown
aspects
WEC
No WEC
1 MHz
300 kHz
Specific
Contact
Dynamics
Time (minutes
Electrical
issues
Time (minutes
Lubrication
.
even more
and
unkown
aspects
Short pulse impacts ( higher than the rolling frequencies) to cause adiabatic
shear bands are unlike to be prime drivers in WEC even though they might assist to it
11/6/2014
Page 16
Standard Materials
Without Dark Oxide
Decrease in robustness
Through Hardeners
Increase in robustness