Studies on Upper Limit of Surface Durability of Phosphor Bronze

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Using two kinds of rolling contact fatigue testing machines with high performance, the authors investigated the upper limit of surface durability of a forged phosphor-bronze with a Brinell hardness of 150HB. After many investigations, a new higher pitting limit of 1120 MPa (114 kgf/mm^2=0.76 HB) was obtained in the case of pure rolling conditions. when sliding was introduced, the pitting limit decreased by about 20%. The limit stress which can prevent the progressive plastic deformation was nearly equal to the new pitting limit. The flow of metal in the bronze rollers rotated at and near the new pitting limit was examined and compared with that obtained in the case of steel/steel combinations. The upper limit of work-hardening which can be attained in the bronze rollers before occurrence of pitting cracks was estimated using rollers with a few artificial protrusions. The scoring limit in bronze/steel combinations was investigated using a step load method and compared with that obtained in the case of steel/steel combinations. The bronze layer which adhered on steel roller surface after occurrence of scoring was analyzed using an X-ray micro-analyzer, and the effects of hardness of the mating steel-rollers were discussed.
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