The effect of mean stress on the endurance limit of thin hard coatings has been studied by utilizing bending fatigue tests on SCM440 and ASP30, and axial loading fatigue tests on SKD11 and SKD61. The fatigue tests have been made on the specimens VC-coated by the thermo-reactive deposition and diffusion method, namely the molten salt bath immersion method, and the quenched-and-tempered specimens for reference.
The experimental results indicated that the endurance limit σ
w was predicted by treating the mean stress σ
m and the substrate residual stress σ
r in equivalence. The endurance limit was not influenced by the existence of a coating layer, even when the coating layer was cracked by high compressive stress under the first cyclic loading. This can be explained by the fact that the cracks, formed on the coating layer by compressive stress, do not play the role of trigger in the fracture of substrate because they have an obtuse angle (>120°).
The equations, obtained over the Vickers hardness of substate Hv 300, are as follows:
At σ
m+σ
r≥0,
σ
w={(Hv/10)+20}×9.8-(1.04Hv/1000)×(σ
m+σ
r)
Hv: Substrate Vickers hardness (kgf/mm
2), σ
w, σ
m, σ
r: (MPa)
However, in the case of steels containing a large inclusion,
σ
w=1.56×(Hv+120)/√
area1/6-(1.04Hv/1000)×(σ
m+σ
r)
area: Projected inclusion area (μm
2)
At σ
m+σ
r<0, irrespective of the existence of inclusion,
σ
w={(Hv/10)+20}×9.8×{1-(σ
m+σ
r)/σ
T}
σ
T: True strength of fracture (MPa)
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