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Wind Turbine
Gearbox Failures
Robert Errichello
GEARTECH
Crack Propagation
Beach Marks
Fracture
Ductile / Brittle
Classic bending fatigue with crack initiation at critical point of maximum bending stress. Curved trajectory of crack
growth is typical as shown by adjacent fracture. Failure was caused by incomplete flame hardening.
Copyright 2000 by GEARTECH, Townsend, MT 59644 All rights are reserved.
Beach marks
Crack origins
Bending fatigue cracks initiated in root fillets at left ends of teeth due to incomplete hardening on tooth ends.
Copyright 2000 by GEARTECH, Townsend, MT 59644 All rights are reserved.
FRACTURE
ORIGIN
RATCHET
MARK
BEACH MARK
FRETTING
CORROSION
F
D
E
MnS inclusions
A
B
10
F
D
E
MnS inclusions
A
B
11
Close-up of Origin
F
D
E
MnS inclusions
A
B
12
F
D
E
MnS inclusions
A
B
13
F
D
E
MnS inclusions
A
B
14
F
D
E
MnS inclusions
A
B
15
F
D
E
MnS inclusions
A
B
16
F
D
E
MnS inclusions
A
B
F
D
E
MnS inclusions
A
B
17
F
D
E
MnS inclusions
A
B
18
19
Conclusions
1.
F 2.
3.
4.
5.
6.
A
B
20
21
HERTZIAN FATIGUE
22
MICROPITTING
SUBCASE FATIGUE
Hertzian Fatigue/Macropitting
Micropitting
Macropitting
Macropitting on a wind turbine pinion caused by misalignment due to excessive bearing clearance. Micropitting
surrounding macropits is secondary failure. Note similar damage on each tooth including wear step at end of contact.
Copyright 2000 by GEARTECH, Townsend, MT 59644 All rights are reserved.
23
24
25
MICROPITTING
Hertzian Fatigue/Micropitting
Micropitted gear teeth appear dull, etched, or stained with patches of gray. It attacks high points on gear tooth
surfaces such as crests of undulations, peaks of cutter scallops, and ridges of grinding lay.
Copyright 2000 by GEARTECH, Townsend, MT 59644. All rights are reserved.
26
27
28
SUBCASE FATIGUE
Subcase fatigue may be caused by inadequate case depth, inclusions near case/core boundary, or grind temper. In
the helical gear shown, it was caused by grind temper. Fine, longitudinal cracks and sharp edged craters are typical.
Copyright 2000 by GEARTECH, Townsend, MT 59644. All rights are reserved.
29
30
31
WEAR
32
Wear/Adhesion
Scuffing
Adhesion is due to microwelding and tearing of asperities. Typically, mild adhesion occurs during running-in and
subsides after it removes local asperities. The photo shows some local scuffs (severe adhesion).
Copyright 2000 by GEARTECH, Townsend, MT 59644. All rights are reserved.
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35
FRETTING
CORROSION
Wear/Fretting Corrosion
Fretting corrosion on teeth of a wind turbine pinion. It occurred because the turbine was parked for three months and
the drive train vibrated when wind buffeted the rotor.
Copyright 2000 by GEARTECH, Townsend, MT 59644. All rights are reserved.
36
37
SCUFFING
Scuffing on teeth of a wind turbine pinion. It occurred because the oil supply was interrupted.
Copyright 2000 by GEARTECH, Townsend, MT 59644. All rights are reserved.
38
39
hmin
= (12 + 22)1/2
= hmin /
<1
12
>2
Lube Regime
Boundary
Mixed Film
Full EHD
40
41
42
GRINDING CRACKS
Cracking/Grinding Cracks
Grinding cracks occur on ground flanks usually perpendicular to the grind direction. They are relatively shallow and
parallel or in a crazed pattern. Nital etch may show grind temper as in the above photo.
Copyright 2000 by GEARTECH, Townsend, MT 59644. All rights are reserved.
43
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CASE / CORE
SEPARATION
Cracking/Case-Core Separation
Chevron marks
Case-Core separation is brittle fracture that usually occurs because case depth is too deep. Chevron marks on the
fracture surface point to the crack origin.
Copyright 2000 by GEARTECH, Townsend, MT 59644. All rights are reserved.
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