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Fatigue strength improvement in CuAl8Fe3 bronze via diamond burnishing

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Abstract

The purpose of this study was to increase the fatigue strength of single-phase CuAl8Fe3 aluminum bronze via surface cold work. CuAl8Fe3 bronze possesses a unique combination of mechanical and chemical properties: good strength, excellent electro-chemical and general corrosion resistance, high ductility and wear resistance. However, due to its low aluminum content (below 8.5%), this bronze cannot be heat treated. Thus, the fatigue strength increase was achieved via diamond burnishing (DB). The quantification of the fatigue behavior of this bronze was achieved through rotating bending fatigue tests. The assessment of the fatigue strength improvement (FSI) due to DB was made on the basis of the S–N curve obtained from fatigue tests of samples processed by fine turning. FSI due to single-pass DB fluctuates between 12 and 13%, with the maximum value achieved at the beginning of the megacycle fatigue field. The increase in the number of passes leads to a significant increase in FSI of between 16.6 and 24.4%. Since a direct correlation exists between the surface integrity (SI) and fatigue behavior, the positive effect of DB on FSI is explained by the improved SI—appropriate surface texture, increased micro-hardness, useful compressive residual stresses and grain refinement in the microstructure of the surface and sub-surface layers.

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Abbreviations

\(a_{{\text{c}}}\) :

Depth of cutting

\(A_{5}\) :

Elongation

\(d\) :

Diameter

\(E\) :

Young’s modulus

\(f\) :

Feed rate

\(F_{{\text{b}}}\) :

Burnishing force

\({\text{HV}}\) :

Vickers micro-hardness

\(n\) :

Number of passes

\(N_{i}\) :

Number of cycles to failure

\(r\) :

Diamond insert radius

\(R\) :

Asymmetry coefficient

\(R_{0,2}\) :

Yield limit

\(R_{{\text{a}}}\) :

Arithmetic mean deviation

\(R_{m}\) :

Ultimate stress

\(s_{i}\) :

X-ray elastic constant

\(S - N\) :

Stress–Number of cycles

\(S_{{\text{a}}}\) :

Arithmetic mean deviation

\(S_{{{\text{ku}}}}\) :

Kurtosis

\(S_{{\text{p}}}\) :

Maximum peak height

\(S_{q}\) :

Root-mean-square deviation

\(S_{{\text{t}}}\) :

Total height

\(S_{z}\) :

Ten-point height

\(v\) :

Burnishing velocity

\(v_{{\text{c}}}\) :

Cutting velocity

\(\sigma_{i}^{j}\) :

Residual stress

DB:

Diamond burnishing

FSI:

Fatigue strength improvement

FSP:

Friction stir processing

HCF:

High-cycle fatigue

LCF:

Low-cycle fatigue

SEM:

Scanning electron microscopy

SE:

Surface engineering

SI:

Surface integrity

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Acknowledgements

This work was supported by: (1) the European Regional Development Fund within the OP, Science and Education for Smart Growth 2014-2020,” Project CoC “Smart Mechatronics, Eco- and Energy Saving Systems and Technologies,” No. BG05M2OP001-1.002-0023; (2) the project CZ.02.1.01/0.0/0.0/16_019/0000778 “Center for advanced applied science” within the Operational Program Research, Development and Education supervised by the Ministry of Education, Youth and Sports of the Czech Republic.

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Authors and Affiliations

  1. Technical University of Gabrovo, 5300, Gabrovo, Bulgaria

    G. V. Duncheva, J. T. Maximov, A. P. Anchev & V. P. Dunchev

  2. Technical University of Varna, Varna, Bulgaria

    Ya. B. Argirov

  3. Czech Technical University in Prague, Prague, Czech Republic

    N. Ganev & J. Capek

Authors
  1. G. V. Duncheva
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  2. J. T. Maximov
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  3. A. P. Anchev
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  4. V. P. Dunchev
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  5. Ya. B. Argirov
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  6. N. Ganev
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  7. J. Capek
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Correspondence to G. V. Duncheva.

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Technical Editor: Izabel Fernanda Machado.

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Duncheva, G.V., Maximov, J.T., Anchev, A.P. et al. Fatigue strength improvement in CuAl8Fe3 bronze via diamond burnishing. J Braz. Soc. Mech. Sci. Eng. 43, 569 (2021). https://doi.org/10.1007/s40430-021-03296-8

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  • DOI: https://doi.org/10.1007/s40430-021-03296-8

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