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Friedrich Karl Naumann, Ferdinand Spies
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C. Kendall Clarke, Don Halimunanda
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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001595
EISBN: 978-1-62708-235-8
... Abstract Hardenability evaluation is typically applied to heat treatment process control, but can also augment standard metallurgical failure analysis techniques for steel components. A comprehensive understanding of steel hardenability is an essential complement to the skills...
Abstract
Hardenability evaluation is typically applied to heat treatment process control, but can also augment standard metallurgical failure analysis techniques for steel components. A comprehensive understanding of steel hardenability is an essential complement to the skills of the metallurgical failure analyst. The empirical information supplied by hardenability analysis can provide additional processing and service insight to the investigator. The intent of this paper is to describe some applications of steel thermal response concepts in failure analysis, and several case studies are included to illustrate these applications.
Book Chapter
Investigation of a Case Hardened Sleeve
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001214
EISBN: 978-1-62708-235-8
... Abstract A case-hardened sleeve made of C 15 (Material No. 1.0401) was flattened at two opposing sides and had cracked open at these places, the crack initiating at a face plane. The wall of the sleeve was 9 mm thick, but the flat ends were machined down to 5.5 mm from the outside. The customer...
Abstract
A case-hardened sleeve made of C 15 (Material No. 1.0401) was flattened at two opposing sides and had cracked open at these places, the crack initiating at a face plane. The wall of the sleeve was 9 mm thick, but the flat ends were machined down to 5.5 mm from the outside. The customer had specified a 2 mm case depth and a hardness of at least HRC 55 at a depth of 1.5 mm. An etched cross section of the cracked end showed that the case layer had a depth of 2.3 mm, so that the sleeve was almost through-hardened at the flat ends. While the core material with the full wall thickness had the quench structure of low-carbon steel, the structure of the flattened area consisted of coarse acicular martensite with a small amount of pearlite (quench troostite) and ferrite. Therefore the sleeve was overheated and probably quenched directly from case. To prevent damage, it would have been necessary to have a lower case depth, carburize less deeply, and prevent overheating that causes brittleness and leads also to increased case depth, or else use a fine-grained steel of lower hardenability.
Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.process.c9001212
EISBN: 978-1-62708-235-8
... Abstract Operation handles produced from C45 steel showed many fine cracks at the flame hardened noses. The cracks ran from the corners of indentations caused by the tool during alignment. Metallographic investigation showed the nose was overheated during flame hardening. It was concluded...
Abstract
Operation handles produced from C45 steel showed many fine cracks at the flame hardened noses. The cracks ran from the corners of indentations caused by the tool during alignment. Metallographic investigation showed the nose was overheated during flame hardening. It was concluded that the numerous hardening cracks were caused by abrupt quenching from over-heating temperature and by local stress concentrations due to indentations of the tool caused during alignment.
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in X-Ray Diffraction Residual Stress Measurement in Failure Analysis
> Failure Analysis and Prevention
Published: 01 January 2002
Fig. 17 S-N curves for as-hardened (gear A) and as-hardened plus double shot peened (gear B) gears. Source: Ref 41
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Effect of hardening by plastic deformation. (a) Case-hardened surface. (b) ...
Available to PurchasePublished: 01 January 2002
Fig. 92 Effect of hardening by plastic deformation. (a) Case-hardened surface. (b) Non-case-hardened surface. Both 243×. Source: Ref 30
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Illustration of (a) isotropic hardening, (b) kinematic hardening, (c) mixed...
Available to PurchasePublished: 30 August 2021
Fig. 21 Illustration of (a) isotropic hardening, (b) kinematic hardening, (c) mixed hardening, and (d) resulting stress-strain curves under reverse yielding. Adapted from Ref 71
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Comparison of carbon profiles of case-hardened and through-hardened bearing...
Available to PurchasePublished: 15 January 2021
Book Chapter
Failure Analysis of Induction Hardened Automotive Axles
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 3
Publisher: ASM International
Published: 01 December 2019
DOI: 10.31399/asm.fach.v03.c9001762
EISBN: 978-1-62708-241-9
... Abstract Rollover accidents in light trucks and cars involving an axle failure frequently raise the question of whether the axle broke causing the rollover or did the axle break as a result of the rollover. Axles in these vehicles are induction hardened medium carbon steel. Bearings ride...
Abstract
Rollover accidents in light trucks and cars involving an axle failure frequently raise the question of whether the axle broke causing the rollover or did the axle break as a result of the rollover. Axles in these vehicles are induction hardened medium carbon steel. Bearings ride directly on the axles. This article provides a fractography/fracture mechanic approach to making the determination of when the axle failed. Full scale tests on axle assemblies and suspensions provided data for fracture toughness in the induction hardened outer case on the axle. These tests also demonstrated that roller bearing indentions on the axle journal, cross pin indentation on the end of the axle, and axle bending can be accounted for by spring energy release following axle failure. Pre-existing cracks in the induction hardened axle are small and are often difficult to see without a microscope. The pre-existing crack morphology was intergranular fracture in the axles studied. An estimate of the force required to cause the axle fracture can be made using the measured crack size, fracture toughness determined from these tests, and linear elastic fracture mechanics. The axle can be reliably said to have failed prior to rollover if the estimated force for failure is equal to or less than forces imposed on the axle during events leading to the rollover.
Book Chapter
Poor Alloy Selection as a Cause of Failure
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c0047387
EISBN: 978-1-62708-225-9
... Abstract Induction-hardened teeth on a sprocket cast of low-alloy steel wore at an unacceptably high rate. A surface hardness of 50 to 51 HRC was determined; 55 HRC minimum had been specified. Analysis revealed that the alloy content of the steel was adequate for the desired hardenability...
Abstract
Induction-hardened teeth on a sprocket cast of low-alloy steel wore at an unacceptably high rate. A surface hardness of 50 to 51 HRC was determined; 55 HRC minimum had been specified. Analysis revealed that the alloy content of the steel was adequate for the desired hardenability but that the specified carbon content (0.29%) was too low. The low specified carbon content resulted in unacceptably low hardness. Because hardness largely controls wear rate, an early failure occurred. The specification for this part was changed so that a higher carbon content (0.45% C) was required.
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Two hardened-and-tempered 1070 steel hold-down clamps. The clamp at top was...
Available to PurchasePublished: 01 January 2002
Fig. 9 Two hardened-and-tempered 1070 steel hold-down clamps. The clamp at top was acceptable. The clamp at bottom was slack quenched because of faulty loading practice (stacking), and it failed by distortion (flattening) because of the resultant mixed microstructure.
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Induction-hardened 1151 steel rotor shaft in which a spline fractured becau...
Available to PurchasePublished: 01 January 2002
Fig. 27 Induction-hardened 1151 steel rotor shaft in which a spline fractured because of a seam. Top left: Configuration and dimensions (given in inches). Section A-A: Micrographs of section through broken spline, showing shape of fracture (arrow A), root of seam (arrow B), and decarburized
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Die failure caused by severe wear. (a) Die made from air-hardening tool ste...
Available to PurchasePublished: 01 January 2002
Fig. 43 Die failure caused by severe wear. (a) Die made from air-hardening tool steel that exhibited a crazed and eroded condition. Areas A and B are shown in (b) and (c), respectively. Both 10×. (d) Microstructural examination of area B revealing a layer of as-quenched martensite
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This die of manganese oil-hardening steel cracked (highlighted by magnetic ...
Available to PurchasePublished: 01 January 2002
Fig. 1 This die of manganese oil-hardening steel cracked (highlighted by magnetic powder) at the sharp change of section in quenching. A fillet or even an undercut could have eliminated the failure. Differential hardening which leaves the fillet soft can also help as can the use of an air
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Faint cracks in 102 by 95 mm (4 by 3.75 in.) die of manganese oil-hardening...
Available to PurchasePublished: 01 January 2002
Fig. 3 Faint cracks in 102 by 95 mm (4 by 3.75 in.) die of manganese oil-hardening steel are exaggerated by magnetic powder. During quenching, excessive stresses were set up between the body and the small protruding section and caused failure. Poor machining of the 13 mm (0.5 in.) radius
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A properly heat treated tool of manganese oil-hardening steel has a martens...
Available to PurchasePublished: 01 January 2002
Fig. 4 A properly heat treated tool of manganese oil-hardening steel has a martensitic structure (left) containing fine tempered martensite and carbides. An overheated tool material has an acicular martensitic structure (right) that cracks easily (see Fig. 5 ). Etchant, Nital; 700X.
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Quenching from too high a temperature cracked this manganese oil-hardening ...
Available to PurchasePublished: 01 January 2002
Fig. 5 Quenching from too high a temperature cracked this manganese oil-hardening steel die ( Fig. 4 pictures its microstructure). Some of the cracks which are exaggerated by magnetic powder probably are secondary and developed because the structure is particularly sensitive to grinding.
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Subsurface fatigue origins (at arrows) in an induction-hardened 8.25 cm (3....
Available to PurchasePublished: 01 January 2002
Fig. 4 Subsurface fatigue origins (at arrows) in an induction-hardened 8.25 cm (3.25 in.) high-manganese medium-carbon steel axle laboratory tested in rotating bending. Note absence of beach marks. Source: Ref 11
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Unetched metallographic cross section through hardened steel roller test sp...
Available to PurchasePublished: 01 January 2002
Fig. 8 Unetched metallographic cross section through hardened steel roller test specimen with sliding plus rolling contact (sliding to left and rolling to right). Fatigue cracks initiate at surface. Source: Ref 11
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Large circular spall on forged, hardened alloy steel mill roll. Faint white...
Available to PurchasePublished: 01 January 2002
Fig. 10 Large circular spall on forged, hardened alloy steel mill roll. Faint white arrow marks location of subsurface fatigue origin. Beach marks are evident within the fatigue propagation zone, which is surrounded by fast brittle fracture. Source: Ref 4
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Oblique view of a 102 mm (4 in.) diameter hardened-steel machine rod that f...
Available to PurchasePublished: 01 January 2002
Fig. 19 Oblique view of a 102 mm (4 in.) diameter hardened-steel machine rod that failed by fatigue fracture. Curved beach marks identify two distinct fracture origins, separated by a step of overload fracture (light gray). Older parts of fatigue fracture are decorated by corrosion product
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