Since the fatigue life of high strength steels, e.g., roller bearing steel 100Cr6, depends on microstructural defects, an improvement of their defect tolerance can enhance the performance of components. To improve the defect tolerance, the retained austenite content can be increased. Thus, in this work the high cycle and very high cycle fatigue behavior of two modified laboratory variants of 100Cr6, which have an increased content (1.5 wt%) of Al and Si, respectively, were analyzed since these alloying elements lead to higher fractions of austenite. Moreover, an industrially available variant with 0.6 wt% Si was analyzed as a reference. All steels were investigated in the bainitic condition and had austenite contents of about 20 vol-%. However, the distribution and chemical composition of the austenite differed. The presented results demonstrate that the effect of retained austenite on defect tolerance is caused by i) the increased ductility and ii) the local deformation-induced phase transformation. To strengthen the effects of the austenitic phase, a finer distribution as well as a lower austenite stability are useful. Consequently, to evaluate the effect of retained austenite on the fatigue behavior the content, the distribution and the chemical composition of the austenitic phase must be considered.

The fatigue lifetime of high‐strength 100Cr6 steels can be improved by an increased content of retained austenite that can be induced by Al and Si alloying. The related deformation‐induced retention of the austenite–martensite transformation during cyclic loading increases their local strain hardening capacity. However, for those 100Cr6 steels containing retained austenite, sufficient dimensional stability must be ensured. In this study, two standard 100Cr6 steels alloyed either with 1.5 wt% Al or 1.5 wt% Si (to diminish carbide formation and accordingly promote austenite retention) are laboratory melted and processed to adjust a microstructure of bainite, retained austenite, and carbides. The segregation simulation in the as‐cast condition and the corresponding microstructures in the forging and heat‐treating conditions are investigated. The inheritance of chemical heterogeneity leads to structural heterogeneity on both the nano‐ (nm) and micro (μm) scales. This heterogeneity is much more pronounced in the Al‐alloyed steel, which can be attributed to inheritance from the as‐cast state. While the results of the quasistatic tensile tests are comparable for both alloys, the cyclic load increase tests indicate a higher fatigue strength of the Si‐alloyed steel, which can be explained with the more homogenous microstructure and the finer distribution of the retained austenite.

In the existing design guidelines for rolling bearings, there is no direct evaluation of the influence of the surface morphology on the achievable fatigue life under mixed lubrication conditions. This work focuses on the influence of different surface finishing processes, i.e., fine grinding, rough grinding, and hard turning, on the fatigue life of inner rings of radial cylindrical roller bearings. In addition to fatigue life experiments at a four-bearing test rig, detailed analyses of the finishing-induced surface morphology as well as calculations of the stress condition caused by the different surface topographies were conducted. To characterize the surface morphology, the local mechanical properties were determined using cyclic micro-indentation tests and the residual stresses were measured by X-ray diffraction. For the stress calculations, a multiscale simulation composed of a multi-body model at the macro-level and a half-space contact model at the micro-level was used. The results obtained in fatigue life experiments, surface morphology characterization, and stress calculations were combined. From this for the hard turning a high potential to increase the fatigue life of roller bearings under mixed lubrication conditions was examined.

Since highly loaded components, such as roller bearings, tend to have relatively high lifetime scatter caused by microstructural defects, an increased defect tolerance of the material can improve the performance as well as the reliability of these highly stressed components. To increase the defect tolerance of the roller bearing steel 100Cr6, two different laboratory melts with either 1.5 wt.-% Al or 1.5 wt.-% Si in addition to the standard composition were developed. After an adapted heat treatment, both steels exhibited a bainitic microstructure with a relatively high content of retained austenite with more than 20 vol.-%. Considering the effects of the retained austenite, a defined mechanical stability is essential to avoid excessive deformation-induced transformation from the retained austenite into & alpha;& PRIME;-martensite, which can lead to shape deviations in components. However, besides the increased deformability of the austenitic phase, local phase transformations in the vicinity of defects can increase the defect tolerance. The fatigue tests performed at ambient temperature (AT) and at T = 100 degrees C, show a higher fatigue strength of the Si-alloyed steel due to a refined microstructure and revealed for both steels a relatively high austenite stability, since no macroscopic phase transformation was observed. The high austenite stability can be explained by a relatively high carbon content of the austenitic phase. However, in contrast to the Al-alloyed steel, a decrease in the fatigue strength and in the defect tolerance due to the increased temperature were observed for the Si-alloyed steel, which indicates a more pronounced phase transformation at AT. The lower carbon content and the finer distribution of the retained austenite, when compared to the Al alloyed steel, are supposed to be the reason. While a smaller carbon content decreases the phase stability, the refined austenite distribution results in a higher probability of retained austenite presence in the vicinity of a defect.

In highly loaded components, such as roller bearings, early failures may occur due to microstructural defects. Thus, a higher defect tolerance of the material can improve the fatigue lifetime. To produce steels with high defect tolerance, innovative alloying concepts, and a sound knowledge of the influence of heat treatment parameters on the resultant mechanical properties is indispensable. Consequently, two bearing steels based on 100Cr6 with different silicon contents were investigated to achieve relatively high retained austenite (RA) fractions, which are assumed to increase the defect tolerance at cyclic loading. To understand the relation between bainitic heat treatment and mechanical characteristics, the resultant RA fractions, Vickers hardness, microhardness, and cyclic hardening exponent (CHT) e(II), which correlates to defect tolerance of metallic materials, were determined for differently heat-treated conditions. Based on the statistical design of experiments and measurements obtained with X-ray diffraction and cyclic indentation testing, regression calculations were conducted. Pertaining to the results of the regression analyses, the heat treatment parameterizations of these steels were specifically determined for certain desired property combinations within the boundaries investigated. Therefore, the temperatures used in the austenitizing and bainitizing procedures have shown the highest influence on the mechanical characteristics and the RA fraction of both steels.

For a reliable design of structural components, valid information about the fatigue strength of the material used is a prerequisite. As the determination of the fatigue properties, and especially the fatigue limit σw, requires a high experimental effort, efficient approaches to estimate the fatigue strength are of great interest. Available estimation approaches using monotonic properties, e.g., Vickers hardness (HV), and in some cases the cyclic yield strength, only allow a rough estimation of σw. The approaches solely based on monotonic properties lead to substantial deviations of the estimated σw in relation to the experimentally determined fatigue limit as they do not consider the cyclic deformation behavior. In this work, an estimation approach was developed, which is based on a correlation analysis of the fatigue limit σw, HV, and the cyclic hardening potential obtained in instrumented cyclic indentation tests (CIT). For this, eleven conditions from five different low-alloy steels were investigated. The CIT enable an efficient and quantitative determination of the cyclic hardening potential, i.e., the cyclic hardening exponentCHT eII, and thus, the consideration of the cyclic deformation behavior in an estimation approach. In this work, a strong correlation of σw with the product of HV and |eII| was observed. In relation to an existing estimation approach based solely on HV, considering the combination of HV and |eII| enables the estimation of σw with an enormously increased precision.

Finishing processes result in changes of near‐surface morphology, which strongly influences the fatigue behavior of components. Especially, roller bearings show a high dependency of the lifetime on surface roughness and the residual stress state in the subsurface volume. To analyze the influence of different finishing processes on the near‐surface morphology, including the residual stress state, roller bearing rings made of AISI 52100 are finished in this work using hard turning, rough grinding, and fine grinding. In addition, fatigue specimens made of AISI 52100 and finished by cryogenic hard turning are investigated. For each condition, the residual stresses are determined at different distances from the surface, showing pronounced compressive stresses for all conditions. While the ground roller bearing rings show highest compressive residual stresses at the surface, the hard turned bearing ring and the cryogenic hard turned fatigue specimens reveal maximum compressive stresses in the subsurface volume. Moreover, cyclic indentation tests (CITs) are conducted in the different subsurface volumes, showing a higher cyclic plasticity in relation to the respective initial state, which is assumed to be caused by finishing‐induced compressive residual stresses. Thus, the presented results indicate a high potential of CITs to efficiently characterize the residual stress state.