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<p>Heavy-duty gears in shield tunneling machines suffer severe wear and fatigue under extreme conditions, underscoring the need for durable surface coatings. In this study, a modified Fe-based amorphous composite coating reinforced with Ni60-BN-Ti (NBT) was fabricated via supersonic, and damage evolution was investigated. XRD and SEM analyses revealed that the coating mainly consisted of an amorphous matrix with minor crystalline phases, while reinforcements were uniformly dispersed. At 10&#xa0;wt.% NBT, the coating exhibited peak hardness of 675.6&#xa0;HV<sub>0.3</sub>; excessive addition led to agglomeration and slightly reduced hardness. Morphological analysis was performed on the coating fracture surface. To clarify the failure mechanisms, a finite element cohesive zone model was developed to simulate crack initiation and propagation. Results showed that cracks originated from stress concentration, extended through the thickness, and induced interfacial failure. Interfacial cracks, dominated by shear stress, propagated from the edges toward the center, eventually causing delamination. The simulations elucidated the mechanism by which reinforcements retard crack growth and strengthen interfacial bonding. By combining experimental characterization with numerical modeling, this study confirms the effectiveness of NBT reinforcement in improving mechanical performance and interfacial reliability, and provides theoretical guidance for coating design and life prediction in heavy-duty gear systems.</p>

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Preparation and Crack Damage Study of Modified Iron-Based Amorphous Coatings for Shield Machine Heavy-Load Gears

  • 期刊论文

  • 发表日期：

    2026年4月16日

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  • Xinsheng Wang,
  • Lingang Wang,
  • Daohuan Qi,
  • Keming Pi,
  • Zhiguo Xing,
  • Yudong Zhong

摘要

Heavy-duty gears in shield tunneling machines suffer severe wear and fatigue under extreme conditions, underscoring the need for durable surface coatings. In this study, a modified Fe-based amorphous composite coating reinforced with Ni60-BN-Ti (NBT) was fabricated via supersonic, and damage evolution was investigated. XRD and SEM analyses revealed that the coating mainly consisted of an amorphous matrix with minor crystalline phases, while reinforcements were uniformly dispersed. At 10 wt.% NBT, the coating exhibited peak hardness of 675.6 HV0.3; excessive addition led to agglomeration and slightly reduced hardness. Morphological analysis was performed on the coating fracture surface. To clarify the failure mechanisms, a finite element cohesive zone model was developed to simulate crack initiation and propagation. Results showed that cracks originated from stress concentration, extended through the thickness, and induced interfacial failure. Interfacial cracks, dominated by shear stress, propagated from the edges toward the center, eventually causing delamination. The simulations elucidated the mechanism by which reinforcements retard crack growth and strengthen interfacial bonding. By combining experimental characterization with numerical modeling, this study confirms the effectiveness of NBT reinforcement in improving mechanical performance and interfacial reliability, and provides theoretical guidance for coating design and life prediction in heavy-duty gear systems.