Multiscale modelling and simulation of subsurface carbide deformation during the formation of white etching areas

One of the main failure indications in rolling bearings subjected to rolling contact fatigue (RCF) is premature subsurface cracking accompanied by white etching areas (WEAs). The cracks that are linked with WEAs are called white etching cracks (WECs). The formation mechanisms of WEAs/WECs are still highly debatable according to international state of art. Often SAE 52100 steel is used for bearing rings. Its microstructure consists of a martensitic or bainitic matrix and homogeneously distributed chromium rich cementite precipitations. There are two main hypotheses based on what forms first, the cracks or WEAs (hypothesis 1 & 2 respectively). There are many numerical studies that examine non-metallic inclusions as a source of cracks that leads to WEAs (hypothesis 1), but none that considers carbides as the source of severe plastic deformation subjected to RCF that leads to WEAs and, eventually WECs (hypothesis 2). In this study, the testing was conducted on a ZF-type modified RCF test rig with hydrogen charged samples to reproduce WEAs/WECs formation. Later the influence of the microstructural features of the carbides on the steel matrix, during the formation of WEAs was investigated by microstructural investigations and multiscale finite element modelling. It was found that carbides can contribute to severe local plastic deformation which leads to formation of WEAs. Thus, it also supported the likelihood of hypothesis 2. Additionally, the surface traction and microstructural characteristics of carbides are correlated with the wide range of WEAs formation depths and timescales.