Rolling Contact Fatigue Behavior of Thermal-Sprayed Coating: A Review

Abstract Rolling contact fatigue (RCF) of sprayed coating is complicated process relating to materials, structures, loading conditions, etc. Herein, the research works over the past decades in RCF of sprayed coatings are summarized here to provide a guidance to further explore the new research interests. Firstly, comprehensive summaries including the common RCF-resisted coating materials, the regular RCF setups, typical failure modes of sprayed coatings, and statistical characterization methods for RCF lifetime are illustrated. Secondly, the influence of surface integrity on RCF behavior of sprayed coating is discussed. The according mechanisms are also discussed by fracture analysis, numerical calculation, and finite element method (FEM). Thirdly, the influence of working condition on RCF behavior of sprayed coating is discussed. The shear stress is recognized as the major contribution of the RCF fracture, and the sliding during rolling contact will deteriorate the lifetime of sprayed coating. Additionally, some new techniques and methodologies have been reported in the investigations of RCF behaviors of sprayed coatings. Nondestructive testing (NDT) and signal processing methods are critical in the detection of micro-fractures within the sprayed coatings. Finally, we have proposed some suggests in future investigation of RCF of sprayed coating based on the previous research achievements.