During the operation of bearings under alternating stress, contact fatigue failure often occurs, primarily due to non-metallic inclusions in bearing steel (GCr15). Based on actual fatigue-failed bearings, this study used Aspex scanning electron microscopy to analyze the inclusion distribution in bearing steels produced by two processes: electroslag remelting and vacuum refining. FIB-TEM technology was employed to characterize the microstructural evolution characteristics at the fatigue failure source area. Finally, considering the depth, area, and matrix hardness of the inclusions, a fatigue life prediction model based on gigacycle rolling contact fatigue (GRCF) was proposed. The prediction results closely matched the fatigue data of actual failed bearings.
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