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By
Friedrich Karl Naumann, Ferdinand Spies
By
Phillip Green
By
W.B.F. Mackay
By
Friedrich Karl Naumann, Ferdinand Spies
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Book Chapter
Crankshaft with Torsion Fatigue Fractures in Inductively Surface-Hardened Crank Pin
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.usage.c9001230
EISBN: 978-1-62708-236-5
... Surface-hardened steel Fatigue fracture A crankshaft which was overloaded on a test stand suffered an incipient crack in the crank pin ( Fig. 1 ). The crack run generally parallel to the longitudinal axis and branched off at the entrance into the two fillets at the transition to the crank arm ( Fig...
Abstract
A crankshaft was overloaded on a test stand and suffered an incipient crack in the crank pin. The crack run generally parallel to the longitudinal axis and branched off at the entrance into the two fillets at the transition to the crank arm. It consisted of many small cracks, all of which propagated at an angle of approximately 45 deg to the longitudinal axis, and therefore were caused by torsion stresses. Neither macroscopic nor microscopic examination determined any material or processing faults. Experience has shown that torsion vibration fractures of this kind usually appear in comparatively short journal pins at high stresses. This crankshaft fracture was an example of the damage that is caused or promoted neither by material nor heat treatment mistakes nor by defects of design or machining, but solely by overstressing.
Image
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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Book Chapter
Valve Seat Fractures
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.mech.c0090947
EISBN: 978-1-62708-225-9
... Abstract Valve seats fractured during testing and during service. The seats were machined from grade 11L17 steel and were surface hardened by carburization. Investigation (visual inspection, hardness testing, 59x SEM images, and 2% nital etched 15x cross sections) supported the conclusion...
Abstract
Valve seats fractured during testing and during service. The seats were machined from grade 11L17 steel and were surface hardened by carburization. Investigation (visual inspection, hardness testing, 59x SEM images, and 2% nital etched 15x cross sections) supported the conclusion that the fracture occurred via brittle overload, which was predominantly intergranular. The amount of bending evidence and the directionality of the core overload fracture features suggest that the applied stresses were not purely axial, as would be anticipated in this application. The level of retained austenite in the hardened case layer likely contributed to the failure.
Book Chapter
Fatigue Fracture of a Cast Chromium-Molybdenum Steel Pinion
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.steel.c0047406
EISBN: 978-1-62708-232-7
... to 1045 steel. The pinion was annealed before flame or induction hardening of the teeth to a surface hardness of 363 HRB and a core hardness of 197 HRB. The broken pinion had a tooth which had failed by fatigue fracture through the tooth root because of the low strength from incomplete surface hardening...
Abstract
A cast countershaft pinion on a car puller for a blast furnace broke after one month of service; expected life was 12 months. The pinion was specified to be made of 1045 steel heat treated to a hardness of 245 HRB. The pinion steel was analyzed and was a satisfactory alternative to 1045 steel. The pinion was annealed before flame or induction hardening of the teeth to a surface hardness of 363 HRB and a core hardness of 197 HRB. The broken pinion had a tooth which had failed by fatigue fracture through the tooth root because of the low strength from incomplete surface hardening of the tooth surfaces. Contributing factors included uneven loading because of misalignment and stress concentrations in the tooth roots caused by tool marks. Greater strength was provided by oil quenching and tempering the replacement pinions to a hardness of 255 to 302 HRB. Machining of the tooth roots was revised to eliminate all tool marks. Surface hardening was applied to all tooth surfaces, including the root. Proper alignment of the pinion was ensured by carefully checking the meshing of the teeth at startup.
Book Chapter
Fracture of a Cast Stainless Steel Lever Because of a Cold Shut
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.aero.c0089563
EISBN: 978-1-62708-217-4
... Abstract A lever (machined from a casting made of AISI type 410 stainless steel, then surface hardened by nitriding) that was a component of the main fuel-control linkage of an aircraft engine fractured in flight after a service life of less than 50 h. Investigation (radiographic inspection...
Abstract
A lever (machined from a casting made of AISI type 410 stainless steel, then surface hardened by nitriding) that was a component of the main fuel-control linkage of an aircraft engine fractured in flight after a service life of less than 50 h. Investigation (radiographic inspection) supported the conclusions that the lever broke at a cold shut extending through approximately 95% of the cross section. The normally applied load constituted an overload of the remainder of the lever. Recommendations included adding magnetic-particle inspection to the inspection procedures for this cast lever.
Book Chapter
Fatigue Failure of a Carbon Steel Piston Shaft on an Extrusion Press Billet-Loading Tray
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 2
Publisher: ASM International
Published: 01 December 1993
DOI: 10.31399/asm.fach.v02.c9001287
EISBN: 978-1-62708-215-0
..., and mechanical (hardness and tensile properties) analyses of failed shaft specimens were conducted. The examinations showed that the shafts had failed by fatigue. It was recommended that a low-alloy steel (e.g., 3% Ni-Cr) in the hardened and tempered condition and subjected to shot-peening surface-hardening...
Abstract
A recurring piston shaft failure problem on the billet-loading tray of an extrusion press was investigated. Two shafts fractured within a period of 10 days. The shaft was machined from normalized EN3 (AISI C1022) steel stock without further treatment. Visual, microstructural, chemical, and mechanical (hardness and tensile properties) analyses of failed shaft specimens were conducted. The examinations showed that the shafts had failed by fatigue. It was recommended that a low-alloy steel (e.g., 3% Ni-Cr) in the hardened and tempered condition and subjected to shot-peening surface-hardening treatment be used. The provision of a stop to reduce bending stresses was also recommended.
Book Chapter
Excessive Wear of Plain Carbon Steel Sprockets in a Chemical Plant Producing Fibers
Available to PurchaseSeries: ASM Failure Analysis Case Histories
Volume: 1
Publisher: ASM International
Published: 01 December 1992
DOI: 10.31399/asm.fach.v01.c9001073
EISBN: 978-1-62708-214-3
... be improved by through hardening or induction surface hardening of the teeth. Catastrophic wear Chain drives Chemical processing industry Shafts (power) UNS G10200 UNS G10450 1020 1045 (Other, miscellaneous, or unspecified) wear Background Replacement sprockets ( Fig. 1 ) installed...
Abstract
Replacement sprockets installed on chain drive shafts for winding fibers exhibited excessive wear. Metallographic and chemical analyses conducted on the original and replacement sprockets showed that the material of the replacement sprocket was 1020 low-carbon steel, whereas the original (and specified) material was medium-carbon 1045 steel. The low-carbon steel also had lower hardness because of a lower pearlite fraction in the microstructure. It was recommended that replacement sprockets be made of normalized 1045 steel. It was further suggested that wear resistance could be improved by through hardening or induction surface hardening of the teeth.
Image
Change in surface roughness due to crack propagation. Fracture surface roug...
Available to PurchasePublished: 15 January 2021
-hardened region. The crack then propagated on a helical plane in torsion. Note the change in surface roughness as the crack propagates from the surface-hardened region at the top into the core and finally into the hardened case at the bottom of the photograph. The roughest region on the fracture surface
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Image
Change in surface roughness due to crack propagation. Fracture surface roug...
Available to PurchasePublished: 01 January 2002
hardened region. The crack then propagated on a helical plane in torsion. Note the change in surface roughness as the crack propagates from the surface hardened region at the top into the core and finally into the hardened case at the bottom of the photograph. The roughest region on the fracture surface
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Series: ASM Failure Analysis Case Histories
Publisher: ASM International
Published: 01 June 2019
DOI: 10.31399/asm.fach.modes.c9001502
EISBN: 978-1-62708-234-1
... bull gears that had spalling teeth was submitted for evaluation ( Fig. 1 ). Fig. 1 Spur gear tooth, SAE 4147H, quenched and tempered to 311 HB, machined completely, induction hardened with a tooth space inductor by traversing one tooth space at a time. (a) Surface spalling along one tooth flank...
Abstract
A portion of two large spur tooth bull gears made from 4147H Cr-Mo alloy steel that had spalling teeth was submitted for evaluation. The gears were taken from a final drive wheel reduction unit of a very large open-pit mining truck. The parts had met the material and initial heat treat hardening specifications. The mode of failure was tooth profile spalling. By definition, spalling originates at a case/core interface or at the juncture of a hardened/nonhardened area. The cause of this failure was either insufficient or no induction-hardened case along the active profile. The cause was activated by a nonfunctioning induction hardening coil that did not or was not allowed to harden the midprofile of several teeth.
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
...-hardened at the flat ends. While the core material with the full wall thickness had the quench structure of low carbon steel ( Fig. 2 ), the structure of the flattened area consisted of coarse acicular martensite with a small amount of pearlite (quench troostite) and ferrite ( Fig. 3 ). At the surface...
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.
Image
Countershaft pinion that fractured in fatigue at roots of teeth because of ...
Available to Purchase
in Fatigue Fracture of a Cast Chromium-Molybdenum Steel Pinion
> ASM Failure Analysis Case Histories: Steelmaking and Thermal Processing Equipment
Published: 01 June 2019
Fig. 1 Countershaft pinion that fractured in fatigue at roots of teeth because of incomplete hardening at tooth surfaces. (a) Schematic illustration of the pinion, which was sand cast from a chromium-molybdenum steel. Dimensions given in inches. (b) Macrograph of a nital-etched section through
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Image
Surface of a torsional-fatigue fracture in an induction-hardened 1041 (1541...
Available to PurchasePublished: 01 January 2002
Fig. 19 Surface of a torsional-fatigue fracture in an induction-hardened 1041 (1541) steel shaft. The shaft fractured after 450 hours of endurance testing. 1 1 4 ×
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Image
Fracture surface of a hardened steel connecting rod. Arrows indicate large ...
Available to PurchasePublished: 01 January 2002
Fig. 36 Fracture surface of a hardened steel connecting rod. Arrows indicate large inclusions. Fatigue cracking initiated from the middle inclusion.
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Image
Fracture surface of a hardened steel valve spring that failed in torsional ...
Available to PurchasePublished: 01 January 2002
Fig. 37 Fracture surface of a hardened steel valve spring that failed in torsional fatigue. Arrow indicates fracture origin at a subsurface nonmetallic inclusion.
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Image
Fracture surface of a carburized-and-hardened steel roller. As a result of ...
Available to PurchasePublished: 01 January 2002
Fig. 38 Fracture surface of a carburized-and-hardened steel roller. As a result of banded alloy segregation, circumferential fatigue fracture initiated at a subsurface origin near the case/core interface (arrow).
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Image
Chevrons on the fracture surface of an induction-hardened axle fabricated f...
Available to PurchasePublished: 01 January 2002
Fig. 6 Chevrons on the fracture surface of an induction-hardened axle fabricated from 1541 steel. The V-shaped chevrons point back to an initiation site marked by the arrow at the top of the figure. Component shows fatigue crack growth initiating at the arrow creating the circular-shaped
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Image
Fracture surface of a carburized and hardened steel roller. As a result of ...
Available to PurchasePublished: 01 January 2002
Fig. 6 Fracture surface of a carburized and hardened steel roller. As a result of banded alloy segregation, circumferential fatigue fracture initiated at a subsurface origin near the case-core interface (arrow).
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Image
Fracture surface of subsized impact coupon prepared from the hardened perim...
Available to Purchase
in Effect of Strain Rate on the Failure Mode of a Rear Axle
> Handbook of Case Histories in Failure Analysis
Published: 01 December 1992
Fig. 12 Fracture surface of subsized impact coupon prepared from the hardened perimeter of the axle, showing cleavage rupture with river patterns. 3400×.
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Image
Scanning electron micrograph of case-hardened fracture surface where local ...
Available to PurchasePublished: 01 December 1992
Fig. 8 Scanning electron micrograph of case-hardened fracture surface where local cleavage occurred. 2000×.
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