Research on Damage Mechanism of Ceramic Balls in Hybrid Rolling Friction Pairs

In hybrid rolling bearings operating under extreme high-temperature and high-load conditions, steel rolling elements are prone to early failure, which has accelerated the widespread adoption of ceramic materials. To address the limitations of conventional studies, which have focused mainly on macroscopic wear parameters while neglecting subsurface failure mechanisms and the relationship among sintering process, microstructure, and fatigue performance, this work systematically compares the tribological behavior of Si3N4 ceramic balls fabricated by high-pressure electric resistance hot-pressing (REHP) and B4C ceramic balls prepared by conventional hot pressing (HP) against 52100 steel counterparts. The central innovation of this study lies in clarifying, based on Hertzian contact theory and Lundberg-Palmgren life theory, that subsurface orthogonal shear stress, rather than surface compressive stress, is the fundamental driving force for contact fatigue failure of ceramic balls. In addition, two distinct damage evolution modes are revealed: B4C exhibits early-stage brittle fracture and large-scale spalling, whereas REHP-Si3N4 is characterized by microcrack initiation and slow crack propagation. Moreover, the intrinsic mechanism by which the REHP process significantly enhances the contact fatigue life of ceramics is elucidated; namely, it refines grain size, eliminates residual porosity, and increases densification. The results show that, under the same high-load conditions, the mass loss of REHP-Si3N4 ceramic balls is only 35.7% of that of HP-B4C, while the service life is extended by 20%. This work provides a key theoretical basis for ceramic material selection and sintering process optimization in high-performance hybrid bearings.