Rolling Contact Fatigue in Bearing Systems

Rolling contact fatigue (RCF) denotes the progressive damage and eventual failure of bearing surfaces subjected to repeated rolling loads. Under high Hertzian contact stresses, subsurface microstructural alterations emerge, including dark etching regions (DERs), low angle bands (LABs) and high angle bands (HABs), white etching bands (WEBs) and, ultimately, subsurface cracks. These features arise through cyclic plasticity, dislocation activity and carbon redistribution within martensitic or bainitic bearing steels. The sequence often begins with martensite decay forming DERs, which evolve into fine ferrite bands and textured grains delineated by LABs and HABs. Continued cycling promotes the formation of WEBs, ferrite-rich layers that signal severe strain accumulation. In advanced stages, white etching cracks (WECs) nucleate at inclusions or band intersections and propagate to the surface, causing flaking or spalling. Understanding these processes is vital for predicting service life of bearings in automotive, aerospace and wind‐turbine applications. Recent advances in multi‐scale characterisation and modelling have clarified how contact pressure, lubrication chemistry and material microstructure govern fatigue initiation and progression, enabling more resilient bearing designs and maintenance strategies.

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Rolling Contact Fatigue in Bearing Systems publication trend

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Technical terms

Rolling contact fatigue (RCF): progressive material degradation under cyclic rolling loads leading to subsurface damage.

Dark etching region (DER): subsurface zone appearing dark after etching, indicative of martensite decay and carbon redistribution.

Low angle band (LAB): microstructural feature characterised by low‐angle grain boundaries formed during early cyclic plasticity.

High angle band (HAB): microstructural feature with high‐angle grain boundaries marking advanced plastic deformation stages.

White etching band (WEB): ferrite‐rich layer visible as bright bands under etching, resulting from accumulated plastic strain.

White etching crack (WEC): subsurface crack bordered by white‐etched matter, often leading to flaking or spalling failure.

References

1. Mechanistic study of dark etching regions in bearing steels due to rolling contact fatigue. Acta Materialia (2023).
2. Microstructural decay of matrix and precipitates during rolling contact fatigue in a martensitic dual-hardening bearing steel. Materials & Design (2024).
3. Evolution of White Etching Bands in 100Cr6 Bearing Steel under Rolling Contact-Fatigue. Metals (2019).