NREL Wind Turbine Tribology Seminar 2014

October 29-31, 2014 Argonne, IL, USA

A. Ruellan1.2.3, F. Ville1, X. Kleber2, B. Liatard3
1 Universit

de Lyon, CNRS - INSA-Lyon, LaMCoS, UMR 5259, France

de Lyon, CNRS - INSA-Lyon, MATEIS, UMR 5510, France
3 NTN-SNR, European R&D center, Annecy, France
2 Universit

Tribological analysis of White Etching Crack (WEC)

failures in rolling element bearings

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

Outline
1. Introduction

2. WEC reproduction on bearing test rigs

3. Understanding WEC formation mechanisms

4. Multiple influent tribochemical and mechanical drivers

5. Laboratory reproduction on a Twin-Disc machine

6. Conclusion

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

Outline
1. Context
Wind turbine bearing rolling contact fatigue (RCF)

Introduction

White Etching Cracks (WEC) characterization

Major difficulties in observing and understanding WEC

2. WEC reproduction on bearing test rigs

3. Understanding WEC formation mechanisms

4. Multiple influent tribochemical and mechanical drivers

5. Laboratory reproduction on a Twin-Disc machine

6. Conclusion

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

1.1 Wind turbine bearing rolling contact fatigue

[1] Goch et al., 2012

Wind turbine are in constant expansion

Introduction

Expected lifetime: 20 years Premature failures: 5 6 years

Gearbox: 20% but 80% of maintenance cost[1]

Gearbox

Generator

Coupling
Hub & pitch system

Brake

Main shaft & bearings

Yaw system

1/19

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

1.1 Wind turbine bearing rolling contact fatigue

[2] Stadler et al., 2013; [3] Gegner, 2011

Wind turbine are in constant expansion

Introduction

Desired lifetime: 20 years First failures: 5 6 years

Gearbox: 20% but 80% of maintenance cost[1]

with huge rolling element bearings

Dimensions far beyond historical know-hows and fatigue benchmarking impossible
Unconventional and severe operating conditions[1-3]

Misalignement
Housing deformation

Transient overloads
15,000/y

1/19

Mixed lubrication
20 2000rpm

Extreme environment

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

1.2 White Etching Cracks (WEC) characterization

Wind turbine are in constant expansion

Introduction

Desired lifetime: 20 years First failures: 5 6 years

Gearbox: 20% but 80% of maintenance cost[1]

with huge rolling element bearings

Dimensions far beyond historical know-hows and fatigue benchmarking impossible
Severe operating conditions[2]

that still suffer from expensive unexpected tribological failure modes[2-5] :

White Etching Cracks (WEC):

also named IrWEA, WSF (flaking), radial cracking[2-9]

raceway

Atypical discrete and wide 3D

branching crack networks
Propagate subsurface but often
punctually linked to the surface
Very thin cracks bordered by white
etching microstructure (2% Nital)
Optical micrograph (Nital 2%)
2/19

[4] Tallian. NREL, 2005; [5] Errichello et al.,2013; [6] Greco et al., 2013; [7] Evans, 2012; [8] West et al., 2013 ; [9] Graca et al., 2013

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

1.2 White Etching Cracks (WEC) characterization

Wind turbine are in constant expansion

Introduction

Desired lifetime: 20 years First failures: 5 6 years

Gearbox: 20% but 80% of maintenance cost[1]

with huge rolling element bearings

Dimensions far beyond historical know-hows and fatigue benchmarking impossible
Severe operating conditions[2]

that still suffer from expensive unexpected tribological failure modes[2-5] :

White Etching Cracks (WEC):

also named IrWEA, WSF (flaking), radial cracking[2-9]

raceway

Atypical discrete and wide 3D

branching crack networks
Propagate subsurface but often
punctually linked to the surface
Very thin cracks bordered by white
etching microstructure (2% Nital)
Optical micrograph (Nital 2%)
2/19

[4] Tallian. NREL, 2005; [5] Errichello et al.,2013; [6] Greco et al., 2013; [7] Evans, 2012; [8] West et al., 2013 ; [9] Graca et al., 2013

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

1.3 Some difficulties in observing and understanding WEC

WEC morphology depends on the type and position of cross section vs. contact

Introduction

z1

z2
WEC
DEA

z1 z2

z3

z3

Industrial application: relatively frequent but with no evident common denominator[all]

3/19

Grades
Heat treatment

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

1.3 Some difficulties in observing and understanding WEC

WEC morphology depends on the type and position of cross section vs. contact

Introduction

z1

z2
WEC
DEA

z1 z2

z3

z3

Industrial application: relatively frequent but with no evident common denominator[all]

3/19

Grades
Need for a thorough tribological analysis of WEC reproductions on test rigs
Heat treatment

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

Outline

WEC reproduction

1. Context

2. WEC reproduction on bearing test rigs

The effect of artificial hydrogen charging
Thrust bearings - FAG-FE-8

Radial ball bearing - NTN-SNR Machine S

Triggered by common tribomechanical kinematic

3. Understanding WEC formation mechanisms

4. Multiple influent tribochemical and mechanical drivers

5. Laboratory reproduction on a Twin-Disc machine

6. Conclusion

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

2.1 The effect of artificial hydrogen charging

WEC reproduction

WEC reproduction on test rigs

4/19

[10] Ruellan et al. 2014

EASY: Hydrogen precharged specimens

Neutral

Hydrogen

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

2.1 The effect of artificial hydrogen charging

WEC reproduction

WEC reproduction on test rigs

[10] Ruellan et al. 2014

EASY: Hydrogen precharged specimens

BUT: Hydrogen charging seems to alter WEC initiation[10]
Hydrogenated: WEC at center of contact
Neutral: WEC at raceway shoulder
104h

WEC

WEC
2mm
1011h

DER
DER
WEC

WEC
4/19

2mm

1 mm

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

2.1 The effect of artificial hydrogen charging

WEC reproduction

WEC reproduction on test rigs

[10] Ruellan et al. 2014

EASY: Hydrogen precharged specimens

BUT: Hydrogen charging seems to alter WEC initiation[10]
Hydrogenated: WEC at center of contact
Neutral: WEC at raceway shoulder

1. WEC formation mechanisms not yet fully understood in neutral

2. Hydrogen embrittlement but how does hydrogen penetrate?
analysis of reproductions without artificial hydrogen charging

H
non-H

4/19

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

2.2 WEC reproduction on thrust bearings non H-precharged

WEC reproduction

CRTB - FAG-FE8 test rig (from literature)[14-16]

Neutral environment
100Cr6 martensitic steel
Speeds: 750 rpm 3 m/s

Thrust load

Moderate contact stresses: 1.9 GPa

Oil temperature: 100C
Mixed lubrication: 0.1[15] < < 1.1[14,16]
Test Bearings

WEC on rollers[15] or washers[14,16] (~12x106 cycles):

Raceway borders 12.5% SRR
Required highly additivated PAO based lubricant combining
specific additives (Calcium Sulfonates) [14,16]
Mixed lubrication fresh surface formation [15]

WEC

WEC with no apparent link to surface[15]

V

5/19

[14] Holweger et al., 2014; [15] Evans et al., 2014; [16] Franke et al., 2013

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

2.3 WEC reproduction on radial ball bearings non H-precharged

WEC reproduction

Radial ACBB - NTN-SNR endurance test rig[10]

[10] Ruellan et al., 2014

Neutral environment
Top quality 100Cr6 martensitic steel
Speeds: 2250 rpm 2.4 m/s
Usual contact stresses: 3.4GPa

Oil temperature: ambient

Full jet lubrication: ~4.2
Test Bearings
OD

Contact force and angle

DEA

OD

1 mm
6/19

2 mm

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

2.3 WEC reproduction on radial ball bearings non H-precharged

WEC reproduction

Radial ACBB - NTN-SNR endurance test rig[10]

[10] Ruellan et al., 2014

Neutral environment
Top quality 100Cr6 martensitic steel
Speeds: 2250 rpm 2.4 m/s
Usual contact stresses: 3.4GPa

Oil temperature: ambient

Full jet lubrication: ~4.2
Test Bearings

WEC on inner rings (85x106 cycles):

OD

Raceway
Raceway borders
20% SRR

Mineral oil with no specific additives aforementioned

(Ca-S)
Contact
force and angle
WEC linked to incipient surface microcracks at raceway
OD Raceway topview

DEA

OD

1 mm
6/19

50 m

2 mm

WEC

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

2.4 Triggered by common tribomechanical kinematics

Dimensionless P.U/P.Umax ACBB:LC1

WEC reproduction

High sliding energy criteria at contact borders

PV
CRTB
NTN-SNR
PV
PV
PV
DGBB
FE8
- ACBB
CRTB
Fujita

WEC

1,5

WEC
WEC
WEC
1,0

WEC

0,5

No-WEC
0,0
-1

-0,5

ACBB:LoadCase1 -WEC

ACBB:LoadCase2 -WEC

ACBB:LoadCase3

ACBB:LoadCase4

ACBB:LoadCase5

CRTB:FE8 -WEC

DGBB: Fujita et al. 2.8GPa -WEC

OD

CRTB: NTN-SNR FB3 1GPa -NoWEC

1 mm
7/19

0,5

Dimensionless major semi-axis distance to contact center: y/c

[10] Ruellan et al., 2014

[13] Fujita et al., 2005

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

Formation mechanisms

Outline
1. Context

2. WEC reproduction on bearing test rigs

3. Understanding WEC formation mechanisms

Surface affected tribochemical cracking classical RCF
Surface affected initiation
Tribochemical propagation

4. Multiple influent tribochemical and mechanical drivers

5. Laboratory reproduction on a Twin-Disc machine

6. Conclusion

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

Formation mechanisms

3.1 WEC: surface affected tribochemical cracking

8/19

WEC are different from classical RCF

[13] Fujita et al., 2005

Increased WEC risk for lower contact stresses[13]

Premature and deep branched propagation beyond and regardless the contact mechanical
stresses: similar dimensions in WT and usual bearings despite the Hertzian zone

Lubricant penetration in thin and deep cracks [9,10]

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

Formation mechanisms

3.1 WEC: surface affected tribochemical cracking

WEC are different from classical RCF

Increased WEC risk for lower contact stresses[13]

Premature and deep branched propagation beyond and regardless the contact mechanical
stresses: similar dimensions in WT and usual bearings despite the Hertzian zone

Lubricant penetration in thin and deep cracks [9,10]

Triggered to tribofilm formation in the CRTB[16] and confirmed for the ACBB IR:
WEC reproducibility lowered with enhanced cage clearance
Standard cage clearance

WEC
Center

Raceway topview

9/19

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

Formation mechanisms

3.1 WEC: surface affected tribochemical cracking

WEC are different from classical RCF

Increased WEC risk for lower contact stresses[13]

Premature and deep branched propagation beyond and regardless the contact mechanical
stresses: similar dimensions in WT and usual bearings despite the Hertzian zone

Lubricant penetration in thin and deep cracks [9,10]

Triggered by tribofilm formation in the CRTB[16] and confirmed for the ACBB IR:
WEC reproducibility lowered with enhanced cage clearance
Enhanced cage clearance

WEC
Center

Raceway topview

200 m
9/19

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

Formation mechanisms

3.1 WEC: surface affected tribochemical cracking

WEC are different from classical RCF

Increased WEC risk for lower contact stresses[13]

Premature and deep branched propagation beyond and regardless the contact mechanical
stresses: similar dimensions in WT and usual bearings despite the Hertzian zone

Lubricant penetration in thin and deep cracks [9,10]

Triggered by tribofilm formation in the CRTB[16] and confirmed for the ACBB IR:
WEC reproducibility lowered with enhanced cage clearance

WEC mainly affected by surface and tribochemical parameters:

lubrication, slippage and not by bulk material and contact stresses as classical RCF

9/19

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

Formation mechanisms

3.2 WEC surface affected initiation

10/19

Initiation: 1st step via nascent surface formation

* 10-20m in depth

1. Fresh metal surface at raceway

Incipient wear: mixed lubrication
Patchy tribofilm: detergents, local thermal effects, impact loading

2. Surface* axial crack flanks and lubricant penetration[3]

High tensile stress: slippage kinematics, mixed lubrication
Near surface* discontinuities: inclusions, machining defects
Lubricant degradation: high shear, PV, local thermal effects

OD

OD
U1

U2

Incipient wear

U1

U2

traction

Thrust bearings
[10] Ruellan et al., 2014

Radial bearings[10]

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

Formation mechanisms

3.2 WEC surface affected initiation

11/19

Initiation: 2nd step via hydrogen permeation at nascent surface

* 10-20m in depth
[11] Kohara et al., 2006
[12] Otsuka et al., 2005

Lubricant (or water) chemisorption at nascent surface [11,12]

Hydrogen poisons: sulfur (MnS, additives)[3], (poly)urea
Water ingress[11]: thermal-oxidation, contamination
Electrical potential/current
Acid: H30++M+e- MHads + H20

Alkaline

: H20+M+e-

U1
Ur

Fresh surface

eH

e-

Tribofilm

H+

Crack tip
tensile
+
H+ H

Oxides

traction

H
H

MHabs MHads

OD

Oil (+H2O)
U2

MHads +

OH-

Oxides

e- eNascent surface

H H
H H Inclusions

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

Formation mechanisms

3.2 WEC surface affected initiation

12/19

Initiation: probable conjecture combination

Both conjectures are often supported by a similar driver:
High sliding surface energy (SRR, PV) + Mixed lubrication

* 10-20m in depth

Shallow hydrogen permeation* can first ease crack opening:

WEC reproducibility lowered in case of tribofilm formation on the ACBB IR
Connections to the surface quasi-punctual
Nevertheless, WEC propagation > 500 m deep

OD

U1

Raceway

SRR - PV

H
U2

H
WEC

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

Formation mechanisms

3.3 WEC tribochemical propagation

13/19

Propagation by local hydrogen embrittlement

1. Deep propagation: H is trapped at tensile crack tips and at inclusions[12]
Quasi-regardless the contact stresses
Hoop stress vs. compressive residual stress[5]
2. White etching microstructure: crack rubbing + Hydrogen Enhanced Localized Plasticity

OD

OD
U1

U1

H
U2

H
H

U2

H
H
H

hoop

compressive

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

Outline

Influent Drivers

1. Context

2. WEC reproduction on bearing test rigs

3. Understanding WEC formation mechanisms

4. Multiple influent tribochemical and mechanical drivers

From macro to tribo scales
Multiple influence and interdependencies
5. Laboratory reproduction on a Twin-Disc machine

6. Conclusion

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

4.1 WEC multiple influent drivers: influence and interdependencies

Asperity

Contact

Bearings

System

1-10m

100-500m

mm-cm

cm-m

Roughness

Running-in

Hardness
Abrasive
particules
Rotation speed

Vibrations

False brinelling

Stand still

Fretting
Contact time
lapse ratios
Aggressive
additives
Detergent
concentration

Seal leakage

Environment
Condensation

Surface
treatment
H2O lubricant
contamination

Electrostatic
discharges

Electricity

Boundary
lubrication

Wear

Kinematics

Lightning

Shaft e- current
Friction charges
Electrostatic
Triboaccumulation
electricity
Environment
Condensation

H2O lubricant
contamination

Tribofilm

Additives

Oxydation film
Patchy
tribofilm
Chemical
barrier
Corrosion pits

High slippage

Surface
activation

Surface initiation

Electrical pits

Fresh surface
at raceway

Local melt
by spark

AND/OR

Discontinuity
crack lubricant
penetration

Initiation: Lubricant + Nascent surface

Lubricant shear
Lubricant
Chemical
decomposition
stability
Voltage

Hygroscopy

Local epotential
H2O
decompostion

AND

Material
properties - stress

Subsurface propagation

Lubricant
molecules

Sulfur

Slow speed
Vibrations

Spin

Contact angle

Moderate
contact stress
Position vs.
load zone

Low loads
Bearing type
Misalignment
Clearance

Fretting
Local melt
by spark
Defects

Electrostatic
discharges
Machining

Inclusions

Orientation

Wind gust
Start-stop
Torque reversal
Low power
Gearbox/shaft
Shaft
displacement
Electricity
Manufacturer

Mechanical side

Propagation: Local hydrogen embrittlement

Hydrogen
chemisorption

Temperature

Grease/oil

Transient

Compressive
stress free
Defects
Dislocations
Carbides
Austenite
Chrome

Additives

Cage design

Large ellipse

Temperature
Thin film
Mechanical
stress (PV)

Roughness

Mixt
lubrication
High friction

Tribofilm

Tribochemical side
Impact loading

Viscosity

Vanadium

Moderate
contact stress
residual not
compressive
Grain flow
Grain size
Grain joints
Inclusions

Heat treatment
Hoop stress
Low loads

Mounting
Structural
stress

Forging or
machining
Manufacturer
Heat treatment
Cleanliness

Supplier

Surface
treatment
Heat treatment

Steel grade

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

4.1 WEC multiple influent drivers: influence and interdependencies

Roughness

Running-in

Hardness
Abrasive
particules
Rotation speed

Vibrations

False brinelling

Stand still

Fretting

Boundary
lubrication

Asperity

Contact

Bearings

System

1-10m

100-500m

mm-cm

cm-m

Wear

Viscosity
Cage design

Tribofilm

Additives

High friction

Tribofilm

Large ellipse

Environment
Condensation

Local melt
by spark

Tribo-electricity

Electrostaticat raceway
accumulation

Impact loading
Kinematics

Lightning

Environment

Condensation

H2O lubricant
contamination

Voltage

Hygroscopy

Discontinuity
Local
e lubricant
AND/OR
Voltage crack
penetration
potential

Propagation: Local hydrogen embrittlement

H2O
H2O lubricant
Hygroscopy
decompostion
Material
Hydrogen
contamination
AND
properties - stress
chemisorption

Thin film
Lubricant shear
Mechanical
Condensation
Lubricant
Chemical
stress (PV)
decomposition
stability

Shaft e- current
Friction charges
Electrostatic
Triboaccumulation
electricity
Environment

Chemical
stability

High slippage

Lubricant
decomposition

Initiation: Lubricant + Nascent surface

Tribochemical side
Temperature

Lubricant shear

Surface initiation

Electrostatic
discharges

Electricity

Transient

lapse ratios
Thin film
Oxydation film
Impact loading
Aggressive
Patchy
additives
Mechanical stress
tribofilm
Detergent
Kinematics
Surface
Chemical
(PV)
concentration
activation
barrier
Surface
Corrosion pits
Lightning
treatment
Electrical pitsShaft e- current
H2O lubricant
contamination
Fresh surface
Friction charges

Additives
Local e
potential

H2O
decompostion

Lubricant
Subsurface
propagation
molecules

Compressive
stress free

Sulfur
Defects
Dislocations
Carbides
Austenite
Chrome

Additives

Lubricant
molecules

Sulfur

Vanadium

Slow speed
Vibrations

Grease/oil

Temperature
Contact time

Seal leakage

Roughness

Mixt
lubrication

Temperature

Spin

Contact angle

Moderate
contact stress
Position vs.
load zone

Low loads
Bearing type
Misalignment
Clearance

Fretting
Local melt
by spark
Defects

Electrostatic
discharges
Machining

Inclusions

Orientation

Moderate
contact stress
residual not
compressive

Heat treatment

Wind gust
Start-stop
Torque reversal
Low power
Gearbox/shaft
Shaft
displacement
Electricity
Manufacturer

Hydrogen
chemisoprtion
Mechanical
side

Grain flow
Grain size
Grain joints
Inclusions

Hoop stress
Low loads

Mounting
Structural
stress

Forging or
machining
Manufacturer
Heat treatment
Cleanliness

Supplier

Surface
treatment
Heat treatment

Steel grade

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

4.1 WEC multiple influent drivers: influence and interdependencies

Asperity

Contact

Bearings

System

1-10m

100-500m

mm-cm

cm-m

Roughness

Running-in

Hardness
Abrasive
particules
Rotation speed

Vibrations

False brinelling

Stand still

Fretting
Contact time
lapse ratios
Aggressive
additives
Detergent
concentration

Seal leakage

Environment
Condensation
Electricity

Surface
treatment
H2O lubricant
contamination

Electrostatic
discharges

Boundary
lubrication

Wear

Viscosity
Cage design

Tribofilm

Additives

High friction

Tribofilm

Roughness

Mixt
lubrication

Transient

High slippage

Surface
activation

Surface initiation

Electrical pits

Fresh surface
at raceway

Local melt
by spark
Numerous

AND/OR

Discontinuity
crack lubricant
penetration

Slow speed
Vibrations

Grease/oil

Large ellipse

Oxydation film
Patchy
tribofilm
Chemical
barrier
Corrosion pits

Temperature

Spin

Contact angle

Moderate
contact stress
Position vs.
load zone

Low loads

Fretting
Local melt
by spark
Defects

Bearing type
Misalignment
Clearance
Electrostatic
discharges
Machining

Orientation
Inclusionsto another,
macroscopic drivers can differ from one application
Initiation: Lubricant + Nascent
with numerous interdependencies
but surface
similar tribological phenomena
Mechanical side
Tribochemical side

Wind gust
Start-stop
Torque reversal
Low power
Gearbox/shaft
Shaft
displacement
Electricity
Manufacturer

Propagation: Local hydrogen embrittlement

Temperature
Impact loading
Kinematics

Thin film
Mechanical
stress (PV)

Lightning

Shaft e- current
Friction charges
Electrostatic
Triboaccumulation
electricity
Environment
Condensation

H2O lubricant
contamination

Lubricant shear
Lubricant
Chemical
decomposition
stability
Voltage

Hygroscopy

Local epotential
H2O
decompostion

Hydrogen
chemisorption

AND

Material
properties - stress

Subsurface propagation

Compressive
stress free
Defects
Dislocations
Carbides
Austenite
Chrome

Additives

Lubricant
molecules

Sulfur

Vanadium

Moderate
contact stress
residual not
compressive
Grain flow
Grain size
Grain joints
Inclusions

Heat treatment
Hoop stress
Low loads

Mounting
Structural
stress

Forging or
machining
Manufacturer
Heat treatment
Cleanliness

Supplier

Surface
treatment
Heat treatment

Steel grade

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

4.1 WEC multiple influent drivers: WEC reproduction

Asperity

Contact

Bearings

System

1-10m

100-500m

mm-cm

cm-m

Roughness

Running-in

Hardness
Abrasive
particules
Rotation speed

Vibrations

False brinelling

Stand still

Fretting
Contact time
lapse ratios
Aggressive
additives
Detergent
concentration

Seal leakage

Environment
Condensation

Surface
treatment
H2O lubricant
contamination

Electrostatic
discharges

Electricity

Boundary
lubrication

Wear

THRUST
BEARING

BEARING

High slippage

Fresh surface
at raceway

AND/OR

Discontinuity
crack lubricant
penetration

Initiation: Lubricant + Nascent surface

Kinematics

Thin film
Mechanical
stress (PV)

Lightning

Shaft e- current
Friction charges
Electrostatic
Triboaccumulation
electricity
Environment
Condensation

H2O lubricant
contamination

Lubricant shear
Lubricant
Chemical
decomposition
stability
Voltage

Hygroscopy

Local epotential
H2O
decompostion

Hydrogen
chemisorption

AND

Material
properties - stress

Subsurface propagation

Compressive
stress free
Defects
Dislocations
Carbides
Austenite
Chrome

Additives

Lubricant
molecules

Sulfur

Slow speed
Vibrations

Spin

Contact angle

Moderate
contact stress
Position vs.
load zone

Low loads
Bearing type
Misalignment
Clearance

Fretting
Local melt
by spark
Defects

Electrostatic
discharges
Machining

Inclusions

Orientation

Wind gust
Start-stop
Torque reversal
Low power
Gearbox/shaft
Shaft
displacement
Electricity
Manufacturer

Mechanical side

Propagation: Local hydrogen embrittlement

Temperature
Impact loading

Temperature

Grease/oil

Transient

Surface initiation

Tribochemical side

Tribofilm

Additives
Large ellipse

Surface
activation

Local melt
by spark

Cage design

RADIAL

COMMON

Electrical pits

Roughness

Mixt
lubrication
High friction

Tribofilm

Oxydation film
Patchy
tribofilm
Chemical
barrier
Corrosion pits

Viscosity

Vanadium

Moderate
contact stress
residual not
compressive
Grain flow
Grain size
Grain joints
Inclusions

Heat treatment
Hoop stress
Low loads

Mounting
Structural
stress

Forging or
machining
Manufacturer
Heat treatment
Cleanliness

Supplier

Surface
treatment
Heat treatment

Steel grade

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

4.1 WEC multiple influent drivers: wind turbine bearings

Asperity

Contact

Bearings

System

1-10m

100-500m

mm-cm

cm-m

Roughness

Running-in

Hardness
Abrasive
particules
Rotation speed

Vibrations

False brinelling

Stand still

Fretting
Contact time
lapse ratios
Aggressive
additives
Detergent
concentration

Seal leakage

Environment
Condensation

Surface
treatment
H2O lubricant
contamination

Electrostatic
discharges

Electricity

Boundary
lubrication

Wear

Kinematics

Lightning

Shaft e- current
Friction charges
Electrostatic
Triboaccumulation
electricity
Environment
Condensation

H2O lubricant
contamination

Tribofilm

Additives

WIND TURBINE
Oxydation film
Patchy
tribofilm
Chemical
barrier
Corrosion pits

High slippage

Surface
activation

Surface initiation

Electrical pits

Fresh surface
at raceway

Local melt
by spark

AND/OR

Discontinuity
crack lubricant
penetration

Initiation: Lubricant + Nascent surface

Lubricant shear
Lubricant
Chemical
decomposition
stability
Voltage

Hygroscopy

Local epotential
H2O
decompostion

AND

Material
properties - stress

Subsurface propagation

Lubricant
molecules

Sulfur

Slow speed
Vibrations

Spin

Contact angle

Moderate
contact stress
Position vs.
load zone

Low loads
Bearing type
Misalignment
Clearance

Fretting
Local melt
by spark
Defects

Electrostatic
discharges
Machining

Inclusions

Orientation

Wind gust
Start-stop
Torque reversal
Low power
Gearbox/shaft
Shaft
displacement
Electricity
Manufacturer

Mechanical side

Propagation: Local hydrogen embrittlement

Hydrogen
chemisorption

Temperature

Grease/oil

Transient

Compressive
stress free
Defects
Dislocations
Carbides
Austenite
Chrome

Additives

Cage design

Large ellipse

Temperature
Thin film
Mechanical
stress (PV)

Roughness

Mixt
lubrication
High friction

Tribofilm

Tribochemical side
Impact loading

Viscosity

Vanadium

Moderate
contact stress
residual not
compressive
Grain flow
Grain size
Grain joints
Inclusions

Heat treatment
Hoop stress
Low loads

Mounting
Structural
stress

Forging or
machining
Manufacturer
Heat treatment
Cleanliness

Supplier

Surface
treatment
Heat treatment

Steel grade

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

Outline

Twin-Disc Tests

1. Context

2. WEC reproduction on bearing test rigs

3. Understanding WEC formation mechanisms

4. Multiple influent tribochemical and mechanical drivers

5. Laboratory reproduction on a Twin-Disc machine

Initiation: transposition of contact kinematics
Propagation: non-sufficient tribochemical and tribomechanical drivers

6. Conclusion

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

5.1 Laboratory twin-discs test rig: initiation drivers

Twin-Disc Tests

WEC reproduction without H-charging at low contact stresses and high slippage

16/19

Effective contact parameter control for a better repeatability for moderate cost

Better mechanisms understanding and efficient solution testing

OD

Follower Raceway

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

5.2 Laboratory twin-discs test rig: : tribomechanical drivers

Asperity

Contact

Bearings

System

1-10m

100-500m

mm-cm

cm-m

Roughness

Vibrations

False brinelling

Stand still

Fretting

Twin-Disc machine

Running-in

Hardness
Abrasive
particules
Rotation speed

Contact time
lapse ratios
Aggressive
additives
Detergent
concentration

Seal leakage

Environment
Condensation

Surface
treatment
H2O lubricant
contamination

Electrostatic
discharges

Electricity

Boundary
lubrication

SRR + mixed
lubrication

Wear

Kinematics

Lightning

Shaft e- current
Friction charges
Electrostatic
Triboaccumulation
electricity
Environment
Condensation

11/12

H2O lubricant
contamination
Additives

Cage design

Tribofilm

Additives
Large ellipse
Transient

Oxydation film
Patchy
tribofilm
Chemical
barrier
Corrosion pits

H2O lubricant
contamination
High slippage

Surface
activation

Inclusions
Surface initiation

Electrical pits

Fresh surface
at raceway

Local melt
by spark

AND/OR

Discontinuity
crack lubricant
penetration

Initiation: Lubricant + Nascent surface

Lubricant shear
Lubricant
Chemical
decomposition
stability
Voltage

Hygroscopy
Lubricant
molecules

Local epotential
H2O
decompostion
Sulfur

AND

Material
properties - stress

Subsurface propagation
Electricity

Compressive
stress free
Defects
Dislocations
Carbides

Formulations
In house additives

Slow speed
Vibrations

Spin

Contact angle

Moderate
contact stress
Position vs.
load zone

Low loads
Bearing type
Misalignment
Clearance

Fretting
Local melt
by spark
Defects

Electrostatic
discharges
Machining

Inclusions

Orientation

Wind gust
Start-stop
Torque reversal
Low power
Gearbox/shaft
Shaft
displacement
Electricity
Manufacturer

Mechanical side

Propagation: Local hydrogen embrittlement

Hydrogen
chemisorption

Temperature

Grease/oil

Hoop stress

Temperature
Thin film
Mechanical
stress (PV)

Roughness

Mixed
lubrication
High friction

Tribofilm

Tribochemical side
Impact loading

Viscosity

Austenite
Chrome
Vanadium

Moderate
contact stress
residual not
compressive
Grain flow
Grain size
Grain joints
Inclusions

Heat treatment
Hoop stress
Low loads

Mounting
Structural
stress

Forging or
machining
Manufacturer
Heat treatment
Cleanliness

Supplier

Surface
treatment
Heat treatment

Steel grade

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

5.2 Laboratory twin-discs test rig: : tribomechanical drivers

Asperity

Contact

Bearings

System

1-10m

100-500m

mm-cm

cm-m

Roughness

Vibrations

False brinelling

Stand still

Fretting

Twin-Disc machine

Running-in

Hardness
Abrasive
particules
Rotation speed

Contact time
lapse ratios
Aggressive
additives
Detergent
concentration

Seal leakage

Environment
Condensation

Surface
treatment
H2O lubricant
contamination

Electrostatic
discharges

Electricity

Boundary
lubrication

SRR + mixed
lubrication

Wear

Kinematics

Lightning

Shaft e- current
Friction charges
Electrostatic
Triboaccumulation
electricity
Environment
Condensation

11/12

H2O lubricant
contamination
Additives

Tribofilm

Additives

Transient
Oxydation film
Patchy
tribofilm
Chemical
barrier
Corrosion pits

H2O lubricant
contamination
High slippage

Surface
activation

Inclusions
Surface initiation

Electrical pits

Fresh surface
at raceway

Local melt
by spark

AND/OR

Discontinuity
crack lubricant
penetration

Initiation: Lubricant + Nascent surface

Lubricant shear
Lubricant
Chemical
decomposition
stability
Voltage

Hygroscopy
Lubricant
molecules

Local epotential
H2O
decompostion
Sulfur

AND

Material
properties - stress

Subsurface propagation
Electricity

Compressive
stress free
Defects
Dislocations
Carbides

Formulations
In house additives

Slow speed
Vibrations

Spin

Contact angle

Moderate
contact stress
Position vs.
load zone

Low loads
Bearing type
Misalignment
Clearance

Fretting
Local melt
by spark
Defects

Electrostatic
discharges
Machining

Inclusions

Orientation

Wind gust
Start-stop
Torque reversal
Low power
Gearbox/shaft
Shaft
displacement
Electricity
Manufacturer

Mechanical side

Propagation: Local hydrogen embrittlement

Hydrogen
chemisorption

Temperature

Grease/oil

Large ellipse

Temperature
Thin film
Mechanical
stress (PV)

Cage design

Hoop stress

OD

Roughness

Mixed
lubrication
High friction

Tribofilm

Tribochemical side
Impact loading

Viscosity

Austenite
Chrome
Vanadium

Moderate
contact stress
residual not
compressive
Grain flow
Grain size

500 m

Grain joints
Inclusions

Heat treatment
Hoop stress
Low loads

Mounting
Structural
stress

Forging or
machining
Manufacturer
Heat treatment
Cleanliness

Supplier

Surface
treatment
Heat treatment

Steel grade

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

5.2 Laboratory twin-discs test rig: : tribomechanical drivers

Roughness

Vibrations

False brinelling

Stand still

Fretting

Twin-Disc machine

Running-in

Contact time
lapse ratios
Aggressive
additives
Detergent
concentration

Environment
Condensation

Surface
treatment
H2O lubricant
contamination

Electrostatic
discharges

Electricity

Contact

Bearings

System

1-10m

100-500m

mm-cm

cm-m

Viscosity
Drivers that once triggered WEC do not seem to be self-sulficient for propagation
Roughness
Mixed
SubtleBoundary
and instable equilibrium between
tribochemical and tribomechanical
drivers
SRR + mixed
lubrication
Cage design
lubrication
lubrication
Wear
High friction

Hardness
Abrasive
particules
Rotation speed

Seal leakage

Asperity

Tribofilm

Tribofilm

Hoop stress

Transient
Oxydation film
Patchy
tribofilm
Chemical
barrier
Corrosion pits

High slippage

Surface
activation

Inclusions
Surface initiation

Electrical pits

Fresh surface
at raceway

Local melt
by spark

AND/OR

Discontinuity
crack lubricant
penetration

Initiation: Lubricant + Nascent surface

Tribochemical side

Kinematics

Thin film
Mechanical
stress (PV)

Lightning

Shaft e- current
Friction charges
Electrostatic
Triboaccumulation
electricity
Environment
Condensation

11/12

H2O lubricant
contamination
Additives

Lubricant shear
Lubricant
Chemical
decomposition
stability
Voltage

Hygroscopy
Lubricant
molecules

Local epotential
H2O
decompostion
Sulfur

Hydrogen
chemisorption

AND

Material
properties - stress

Subsurface propagation
Electricity

Compressive
stress free
Defects
Dislocations
Carbides

Formulations
In house additives

Vibrations

Grease/oil

Spin

Contact angle

Moderate
contact stress
Position vs.
load zone

Low loads
Bearing type
Misalignment
Clearance

Fretting
Local melt
by spark
Defects

Electrostatic
discharges
Machining

Inclusions

Orientation

Wind gust
Start-stop
Torque reversal
Low power
Gearbox/shaft
Shaft
displacement
Electricity
Manufacturer

Mechanical side

Propagation: Local hydrogen embrittlement

Temperature
Impact loading

Slow speed

Additives
Large ellipse

H2O lubricant
contamination

Temperature

Austenite
Chrome
Vanadium

Moderate
contact stress
residual not
compressive
Grain flow
Grain size
Grain joints
Inclusions

Heat treatment
Hoop stress
Low loads

Mounting
Structural
stress

Forging or
machining
Manufacturer
Heat treatment
Cleanliness

Supplier

Surface
treatment
Heat treatment

Steel grade

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

Conclusion

Summary

12/12

WEC understanding

WEC= surface affected tribochemical RCF:

Triggered by kinematics & lubricant additives

Initiation through lubricant decomposition at

nascent surface (2 possible mechanisms)

Propagation by local hydrogen embrittlement

Different local drivers maybe due to different

overall influent but non self-sufficient drivers

Unstable tribological equilibrium required

Drivers acting on initiation and propagation

Thank you for your attention!

Questions?

NREL Wind Turbine Tribology

Oct. 30th 2014, A. Ruellan et al.

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