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White Etching Cracks

NREL Argonne
October, 2014-10-30
Dr.Walter Holweger
ST/HZA-ST

Basics Tribology

Basics Tribology at Argonne (USA), NREL, 2014


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Dr. Joanna Procelewska
Dr. Yasmin Korth
Dr. Walter Holweger
Dr. Jrgen Gierl
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Dr.Walter Holweger ST/HZA-ST Basics Tribology

COMMUNICATION
and
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Basics Tribology at Argonne (USA), NREL, 2014

About White Etching Cracks - Overview

Factors that lead toward White Etching Cracks as stated and summarized

Solutions

Current Root Cause Investigations

Acknowledgements

11/6/2014
Page 3

ST/HZA-ST Basics Tribology Dr. Walter Holweger

Basics Tribology at Argonne (USA), NREL, 2014


About White Etching Cracks - Overview
Source : Evans, M.-H.: White structure flaking (WSF) in wind turbines gearbox bearings: effects of butterflies and white etching
cracks (WECs), Material Science and Technology, Vol. 28, No. 1 (2012)

11/6/2014
Page 4

ST/HZA-ST Basics Tribology Dr. Walter Holweger

Basics Tribology Basics Tribology at Argonne (USA), NREL, 2014


Findings from Field

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

Basics Tribology Basics Tribology at Argonne (USA), NREL, 2014


Is within the WT Gear Box Components the Bearing the recipe of the WEC damage ?
Could one built a low ref drive train other t in order to test solutions ?
Rotor shaft

Gearbox

Generator

Clutches

Brakes
If so how can one make this robust against the WEC formation ?

What is an appropriate WEC Root Cause then ?

Basics Tribology Basics Tribology at Argonne (USA), NREL, 2014


Some WEC findings

.they occur in various applications, e.g...

Wheel Bearings

Automotive

Wind Power
Washing Machines

Cement Mills

Basics Tribology Basics Tribology at Argonne (USA), NREL, 2014


They occur independent from the type of the bearing

Point-/ Line Contact

within the SAE 52100 but also the SAE 4320 family

100Cr6 (SAE 52100)


Martensite

Bainite

Retained Austenite from 1- 30 %

Case Hardeners
(SAE 4320)

Basics Tribology Basics Tribology at Argonne (USA), NREL, 2014

Weibull according to RCF


Re lia Soft Weibull++ 7 - www.Relia Soft.com

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)

non metallic inclusions

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

Basics Tribology Basics Tribology at Argonne (USA), NREL, 2014

Weibull according to WEC Failure


ReliaSoft Weibull++ 7 - www.ReliaSoft.com

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

Folio1\ECO S Best of Sthle


Weibull-2P
MLE SRM MED FM
F=33/S=0
Datenpunkte
Linie Wahrscheinlichkeit
Oberer VB-I
Unterer VB-I

steep ascent

10,000

This does not implicate that WEC


occurs earlier compared to classical
Rolling Contact Fatigue
WEC may occur at any time

5,000

Failure free period

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

Basics Tribology at Argonne (USA), NREL, 2014

Irregular White Structure Flaking (WEC) is distinct to Rolling Contact Fatigue

Additional Load is required to get WEC


as there are

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

ST/HZA-ST Basics Tribology Dr. Walter Holweger

Basics TribologyBasics Tribology at Argonne (USA), NREL, 2014

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

ST/HZA-ST Basics Tribology Dr. Walter Holweger

.
even more
and
unkown
aspects

Basics Tribology at Argonne (USA), NREL, 2014


L11-Test Rig II
Voltage
Probe

w/o Voltage Probe


U in V

Ausgewhlter
Arbeitspunkt
Kapazitive Impulsstrme
I in A

U in V

Ausgewhlter
Arbeitspunkt

Slave Bearing
Test Bearing

21.09.12

Keine kapazitiven Impulsstrme

Slave Bearing
Test Bearing

Matthias Go, ST/HZA-ETVF1

ELECTRICAL ISSUES + LUBRICATION


unkown aspects
SLIP - LUBRICATION
unkown Aspects
all of them are subsurface initiated at an
early stage of load cycles
Bearing
Lubrication
Speed
Loading

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

ST/HZA-ST Basics Tribology Dr. Walter Holweger

.
even more
and
unkown
aspects

Basics Tribology Basics Tribology at Argonne (USA), NREL, 2014

Incidential high frequency impacts recorded by Piezo Impulse Spectrometry


during an FE8 Test Runs
Average Energy

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

ST/HZA-ST Basics Tribology Dr. Walter Holweger

Basics Tribology at Argonne (USA), NREL, 2014

SOLUTIONS related to White Etching Cracks


Based on a ground population of
> 400 000 bearings over 9 years

Standard Materials
Without Dark Oxide

..0 .. 30 % randomly distributed

Decrease in robustness

less than 1 % .. random

Through Hardeners

Plus Dark Oxide


Schaeffler (Durotect B)

Increase in robustness

in terms of the numbers


of bearings installed :
> 99 % Reliability

Thank you for attention

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