Prediction of the crack extension under fretting wear loading conditions

Fretting is associated with small amplitude oscillatory movements between two surfaces in contact. One possible consequence of fretting is the formation and subsequent growth of cracks at the edges of the contact. This paper presents an experimental investigation of the cracking behaviour under fretting loading of two different aluminium alloys: 2024-T351 and 7075-T651. Systematic and controlled experiments with a cylinder-flat contact under partial slip fretting conditions were carried out. A model which combines both crack nucleation and propagation processes is used to predict the crack extension throughout the life of the component. The direction of crack propagation experimentally observed was taken into account by the model. Furthermore, an analytical prediction of crack nucleation based on the process volume approach is made. The predictions of both crack extension and nucleation are compared with the experimental results, and show good agreement.