Design of engineering components is concerned with their strength and durability characteristics. While design for strength is influenced by the bulk material characteristics, the design for durability is dependant on the surface characteristics. Majority of the component failures are surface originated. Surface engineering could play a vital role in minimizing such failures. Thermal sprayed coatings, one of the versatile surface coating techniques, can be applied to components of machinery surfaces to avoid such failures. The present paper presents a methodology for contact stress evaluation of surface coated elements, adopting a layered structure approach, and thereby analytically predict their spalling life. Further data on cycles to single pit formation, and spalling of spray fused coatings obtained from experimental testing are presented for assessing the applicability of life prediction models to layered structures such as sprayed coatings. Experimental investigations were conducted on spray fused coatings using a twin disk RCF test setup. The surface and subsurface contact stress distribution have been obtained analytically by Smith–Liu equations along with first order model perturbation method (FOMP), to account for the variation of elastic modulus constants of the layered structure. Applying Lundberg-Palmgren and Tallian life prediction models, the spalling life of these coatings has been predicted analytically and compared with experimental life values. [S0742-4787(00)02502-9]
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July 2000
Technical Papers
Some Studies on Life Prediction of Thermal Sprayed Coatings Under Rolling Contact Conditions
B. Y. Sarma, Research Scholar,
B. Y. Sarma, Research Scholar
Department of Mechanical Engineering, Indian Institute of Technology, Madras, Chennai, 600 036 India
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M. M. Mayuram, Asst. Professor
M. M. Mayuram, Asst. Professor
Department of Mechanical Engineering, Indian Institute of Technology, Madras, Chennai, 600 036 India
Search for other works by this author on:
B. Y. Sarma, Research Scholar
Department of Mechanical Engineering, Indian Institute of Technology, Madras, Chennai, 600 036 India
M. M. Mayuram, Asst. Professor
Department of Mechanical Engineering, Indian Institute of Technology, Madras, Chennai, 600 036 India
Contributed by the Tribology Division for publication in the JOURNAL OF TRIBOLOGY. Manuscript received by the Tribology Division May 6, 1998; revised manuscript received October 13, 1999. Associate Technical Editor: T. C. Ovaert.
J. Tribol. Jul 2000, 122(3): 503-510 (8 pages)
Published Online: October 13, 1999
Article history
Received:
May 6, 1998
Revised:
October 13, 1999
Citation
Sarma, B. Y., and Mayuram, M. M. (October 13, 1999). "Some Studies on Life Prediction of Thermal Sprayed Coatings Under Rolling Contact Conditions ." ASME. J. Tribol. July 2000; 122(3): 503–510. https://doi.org/10.1115/1.555393
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