Papers by Author: Takashi Honda

Abstract: In order to obtain experimental data to investigate the mechanism of crack initiation and propagation, an innovative rolling contact fatigue (RCF) machine was developed. Compared to the conventional thrust type RCF machine the new device enables more efficient RCF testing and observation of subsurface cracks. Experimental data and information on inclusions and micro-cracks were obtained through observation by a laser confocal microscope and comparison with stress analysis. The depth of detected crack initiation is strongly correlated with the stress distribution.

Abstract: An innovative type of one-point rolling contact fatigue (RCF) machine was developed in order to investigate crack initiation and propagation in metals. The microstructural changes and propagation of subsurface cracks during rolling contact in specimens tested by using the new device were studied by laser confocal microscope and X-ray diffraction. It was shown that this new method presents several important advantages compared to the conventional thrust type RCF machines.

Abstract: Fatigue failure of steel occurs when cracks form in a component and continue to grow to a size large enough to cause fracture. In order to understand the strength of a steel component, it is important to locate these cracks. We developed a scanning Hall probe microscope (SHPM), equipped with GaAs film sensors to observe fatigue cracks at room temperature in air while they were growing. In our previous works [1,2], the correlation between crack growth and magnetic field in high carbon tool steels (JIS SKS93 and JIS SUJ2) were determined. We also reported the sensitivity of the SHPM equipped with a three-dimensional line-probe that was developed to decrease the sensor gaps. By using the line-probe sensor we succeeded to measure the magnetic flux density distributions in very close proximity to the specimen’s surface. However, in order to further understand the relation between magnetic flux density and crack growth, other materials, microstructures and fatigue test conditions should be evaluated. In the present work, we focus on the effect of stress ratios on the changes of the magnetic flux density in annealed carbon tool steel.

Abstract: The influence of gas nitriding of commercial pure titanium and Ti-6Al-4V (Ti64) alloy by using a Q-sw laser on the wear loss during rolling contact fatigue is investigated. Despite very good biocompatibility, high strength to weight ratio and corrosion resistance, the tribological properties of titanium alloys are inferior to those of other metal alloys, such as steel. Fretting and wear related aspects become important issues when titanium alloys are used in rolling contact applications. Titanium bearings are employed in applications requiring high strength, light weight, and minimum maintenance (for example, aerospace and defense industries). In this work, a Q-sw laser was used to coat pure commercial titanium and Ti-6Al-4V bearings with TiN in a closed chamber in nitrogen atmosphere. The samples were tested under water by using a thrust-type rolling contact fatigue machine. The microstructure, morphology and crystallographic texture of the layers were observed by laser confocal microscope, scanning electron microscope and electron backscatter diffraction (EBSD). By optimizing the laser processing parameters, such as laser scanning speed, power and beam diameter, thin TiN coats of 1 to 3 mm were produced. The wear loss of the coated samples was at least ten times lower than that of the uncoated bearings.

Abstract: Cyclic stresses around welding joint-part affect the strength of mechanical components. In order to understand the fatigue phenomena caused by the cyclic stresses, non-destructive methods that can be related to number of stress cycles are necessary. In the present work, we used a newly developed scanning Hall probe microscope (SHPM) equipped with a GaAs film sensor and observed three dimensional magnetic fields of the specimen before and after four point fatigue testing at room temperature in air. Low carbon steel plates (JIS, SS400) were used in the experiments. It was found that the intensity of the magnet field in a direction perpendicular to the specimen surface was strongly affected by the fatigue testing. This result means that we can evaluate the fatigue in welding-joint area using quantitative magnetic field measurements. Furthermore, it was discovered that the key factor to evaluate the fatigue is the range between “S” and “N” (“peak-to-bottom” values) of the magnetic fields.