SAE 1065 steel wire ropes are prone to individual wire fracture due to the martensite structure with high carbon and high microhardness formed on the wire surface because of friction. A new low-carbon microalloyed steel wire composed of lath bainite with fine carbides dispersed in bainitic ferrite and lath martensite is developed in this paper. For the developed steel wire with a diameter of 1.0 mm, the tensile strength and low-cycle fatigue resistance are higher than those of commercial SAE 1065 wire. It is shown that the individual wire fracture caused by as-quenched martensite formation and severe plastic deformation can be avoided in the developed steel wire. Also, the design process and associated manufacturing process are discussed in detail.
PeterkaP., KresakJ., KropuchS., FedorkoG., MolnarV. and VojtkoM.: ‘Failure analysis of hoisting steel wire rope’, Eng. Fail. Anal., 2014, 45, 96–105.
2.
ArgatuvI. I., GomezX., TatoW. and UrcheguiM. A.: ‘Wear evolution in a stranded rope under cyclic bending: Implications to fatigue life estimation’, Wear, 2011, 271, 2857–2867.
3.
BerettaS. and BoniardiM.: ‘Fatigue strength and surface quality of eutectoid steel wires’, Int. J. Fatigue, 1999, 21, 329–335.
4.
CruzadoA., UrcheguiM. A. and GomezX.: ‘Finite element modeling and experimental validation of fretting wear scars in thin steel wires’, Wear, 2012, 289, 26–38.
5.
American Petroleum Institute, Specification for Wire Rope, API Specification 9A (Spec 9A), 26th edn, 2011.
6.
de SilvaA. R. T. and FongL. W.: ‘Effect of abrasive wear on the tensile strength of steel wire rope’, Eng. Fail. Anal., 2002, 9, 349–358.
7.
PrawotoY. and MazlanR. B.: ‘Wire ropes: Computational, mechanical, and metallurgical properties under tension loading’, Comput. Mater. Sci., 2012, 56, 174–178.
8.
ZhangD. K., ChenK., JiaX. F., WangD. G., WangS. Q., LuoY. and GeS. R.: ‘Bending fatigue behaviour of bearing ropes working around pulleys of different materials’, Eng. Fail. Anal., 2013, 33, 37–47.
9.
Kastratovic´G., Vidanovic´N., Bakic´V. and RašuoB.: ‘On finite element analysis of sling wire rope subjected to axial loading’, Ocean Eng., 2014, 88, 480–487.
10.
WangH. S., YangJ. R. and BhadeshiaH. K. D. H.: ‘Characterisation of severely deformed austenitic stainless steel wire’, Mater. Sci. Technol., 2005, 21, 1323–1328.
11.
YilmazM.: ‘Failures during the production and usage of steel wires’, J. Mater. Process. Technol., 2006, 171, 232–239.
12.
MoradiS., RanjbarK. and MakvandiH.: ‘Failures analysis of a drilling wire rope’, J. Anal. Prev., 2012, 12, 558–566.
13.
LiuC., ZhaoZ., LiuY. and BholeS. D.: ‘Friction layers produced in two steels during laboratory friction testing’, Mater. Sci. Technol., 2006, 22, 110–114.
14.
AkiyamaM., TaniyamaA., NeishiY. and HamadaT.: ‘Dimensional change in high carbon steel wire owing to heavy reduction by tandem cold drawing’, Mater. Sci. Technol., 2004, 20, 903–908.
15.
ZhaoT. Z., ZhangG. L., SongH. W., ChengM. and ZhangS. H.: ‘Influences of simple strain path changes on mechanical behaviours of pearlitic steel wire’, Mater. Sci. Technol., 2015, 31, 310–316.
16.
WuH., LiuC., ZhaoZ. B., ZhaoY., ZhuS. Z., LiuY. X. and BholeS. D.: ‘Design of air-cooled bainitic microalloyed steel for a heavy truck front axle beam’, Mater. Des., 2006, 27, 651–656.
17.
IzumidaH., ShimizuK., TakamuraS., ShimodaY., MomozawaO. and MuraiT.: ‘Development of high-strength steel wire with superior weldability’, SEI Tech. Rev., 2012, 75, 141–145.
18.
LiuC., ZhaoZ. B. and BholeS. D.: ‘Lathlike upper bainite in a silicon steel’, Mater. Sci. Eng. A, 2006, 434, 289–293.
19.
ZhaoZ. B., NorthwoodD. O., LiuC. and LiuY. X.: ‘A new method for improving the resistance of high strength steel wires to room temperature creep and low cycle fatigue’, J. Mater. Process. Technol., 1999, 80–90, 569–573.
20.
WangD. G., ZhangD. K. and GeS. R.: ‘Effect of displacement amplitude on fretting fatigue behavior of hoisting rope wires in low cycle fatigue’, Tribol. Int., 2012, 52, 178–189.
21.
SankaranS., GouthamaS. Snagal and PadmanabhanK. A.: ‘Transmission electron microscopy studies of thermomechanically control processed multiphase medium-carbon microalloyed steel: Forged, rolled, and low-cycle fatigued microstructures’, Metall. Mater. Trans. A, 2006, 37, 3259–3273.
22.
DuJ., LiuZ. Q. and LvS. Y.: ‘Deformation-phase transformation coupling mechanism of white layer formation in high speed machining of FGH95 Ni-based superalloy’, Appl. Surf. Sci., 2014, 292, 197–203.
23.
XuY. H., FangL. and CenQ. H.: ‘Nano structure and transformation mechanism of white layer for AISI1045 steel during impact wear’, Wear, 2005, 258, 537–544.
24.
RameshA., MelkoteS. N., AllardL. F., RiesterL. and WatkinsT. R.: ‘Analysis of white layers formed in hard turning of AISI52100 steel’, Mater. Sci. Eng. A, 2005, 390, 88–97.
25.
HosseiniS. B., KlementU., YaoY. and RyttbergK.: ‘Formation mechanisms of white layers induced by hard turning of AISI 52100 steel’, Acta Mater., 2015, 89, 258–267.
26.
BhadeshiaH. K. D. H. and Solano-AlvarezW.: ‘Elimination of white etching matter in bearing steels’, Mater. Sci. Technol., 2015, 31, 1011–1015.
27.
TakahashiJ., KobayashiY., UedaM., MiyazakiT. and KawakamiK.: ‘Nanoscale characterization of rolling contact wear surface of pearlitic steel’, Mater. Sci. Technol., 2013, 29, 1212–1218.
