A High-Temperature Sliding Contact Fatigue Life Prediction Model Based on Surface Integrity

Abstract

The fatigue failure of mechanical components under high-temperature sliding contact conditions is a key bottleneck issue in major equipment fields such as aero-engines and advanced gas turbines. Traditional life prediction models often treat the material as a homogeneous body and fail to fully account for the decisive influence of the surface integrity state, which is shaped jointly by the manufacturing and service processes, on the fatigue behavior, thereby leading to significant dispersion in the prediction results. To address this problem, this paper aims to construct a physics-mechanism-driven life prediction model that integrates multi-dimensional characterization parameters of surface integrity. The study systematically presents the characterization methods of surface topography, residual stress, and microstructure, as well as their evolution laws under high-temperature sliding contact. It deeply reveals the multi-mode damage competition mechanism under thermo-mechanical coupling and creep-fatigue interaction. Based on the multi-scale damage coupling theory, this work establishes a theoretical framework that quantitatively integrates key surface integrity parameters into the damage evolution equation and develops a numerical solution algorithm coupling finite element and damage mechanics. This model achieves a full-process physical simulation from the initial surface integrity state to final failure, providing a more accurate theoretical tool for the anti-fatigue design and reliability assessment of high-temperature sliding contact components.