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TECHNICAL PAPERS

Some Studies on Life Prediction of Thermal Sprayed Coatings Under Rolling Contact Conditions

[+] Author and Article Information
B. Y. Sarma, M. M. Mayuram

Department of Mechanical Engineering, Indian Institute of Technology, Madras, Chennai, 600 036 India

J. Tribol 122(3), 503-510 (Oct 13, 1999) (8 pages) doi:10.1115/1.555393 History: Received May 06, 1998; Revised October 13, 1999
Copyright © 2000 by ASME
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References

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Komvopoulos,  K., 1989, “Elastic-Plastic Finite Element Analysis of Indented Layered Media,” ASME J. Tribol., 111, pp. 430–439.
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Tobe S., Kodama, S., Sekiguchi, K., 1988 “Rolling Fatigue Behavior of Plasma Coated Steel,” Proceedings of Surface Engineering International Conference, Japan Thermal Spray Society, Tokyo, Japan, pp. 35–44.
Hadfield,  M., Tobe,  S., and Stolarski,  T., 1994, “Subsurface Crack Investigation on Delaminated Ceramic Elements,” Tribol. Int., 27, No. 5, pp. 359–367.
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Sarma, B. Y., 1997 “Some studies on life prediction of Thermal Sprayed Coatings under rolling contact condition” M.S., thesis, Department of Mechanical Engineering, Indian Institute of Technology, Madras.
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Figures

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(a) Test setup (schematic) (b) Test and standard rollers-geometry and dimensions
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(a) Distribution of shear stresses at surface level with change in coating thickness (b) Distribution of shear stresses at sub-surface level with change in coating thickness (c) Variation in orthogonal shear stress distribution at various depths (d) Variation in shear stresses across the depth at the load point
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(a) Pit growth and life to single pit formation for 0.20 mm coating at 822 MPa contact stress (b) Pit growth and life to single pit formation for 0.20 mm coating at 960 MPa contact stress (c) Pit growth and life to single pit formation for 0.45 mm coating at 845 MPa contact stress (d) Pit growth and life to single pit formation for 0.45 mm coating at 1086 MPa contact stress
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(a) S-N (contact stress-safe life) curve for 0.20 mm coating (b) S-N (contact stress-safe life) curve for 0.45 mm coating
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(a) Spalling life (analytical and experimental) prediction results for 0.20 mm coating (b) Spalling life (analytical and experimental) prediction results for 0.45 mm coating
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SEM photographs of failed roller with 0.45 thick coating at 400 N/mm contact load

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