The material response to rolling contact loading has been analyzed using quantitative X-ray diffraction methods. This has led to the discovery of preferred crystalline orientation in very narrow subsurface regions of endurance-tested 6309 deep groove ball bearing inner rings. The high hydrostatic pressure field, derived from the load-induced three-dimensional stress field in each Hertzian contact load cycle, allows substantial microplastic deformation to be accommodated in the subsurface layers. This microplastic deformation is accompanied by transformation of retained austenite, decay of martensite and the development of texture and residual stresses, one of which is a subsurface tensile stress in a direction normal to the surface. Both the preferred orientation and the tensile residual stress allow for crack propagation parallel to the rolling contact surface. Based on these findings, an outline of a qualitative model for rolling contact fatigue is presented.

Deep-groove ball bearings have been endurance tested at high stress levels. The purpose of the work was to study the simultaneous generation of residual stresses and occurrence of structural changes owing to cyclic rolling contact fatigue. During the investigation the decomposition of both retained austenite and parent martensite were followed. The residual stresses and the austenite decomposition were measured by an X-ray diffraction technique, using signal averaging. Optical and transmission electron microscopy were used to observe the transformed regions resulting from the martensite decay. Depth profiles of residual stress and of successive structural changes were constructed. The observations are discussed in terms of a qualitative modelfor residual-stress generation under cyclic rolling contact.MT/630

Metal softening, induced during the so-called third stage of material response to rolling contact loading, increases the probability of spalling fatigue failure. Metal softening in the most heavily loaded subsurface region leads to micro-plastic deformation noticeable from the occurrence of microstructural change. The probability of crack initiation increases with the growth of the plastically deformed subsurface region. Subsequent crack growth in that region is stimulated by the induced residual stress and texture. Fatigue failure in modern clean bearing steel develops only when the material has reached the third stage. The threshold to the third stage can be determined, and thus fatigue life can be assessed from observations of microstructural change. Examples are discussed of observed reduction of the ferrite {211} diffraction-line width in relation to observed endurance.

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