AGMA Gear Materials 3 Published bys AMERICAN GEAR MANUFACTURERS ASSOCIATION 1330 Massachusetts Avenue, NW. @ Washington, D. C. 20005FOREWORD ‘This AGMA Gear Materials Manual wes prepared by the Metallurgy and Materials ‘Committee to combine all of the AGMA Gear Materials Standards into one Manual This Manual cstablishes the material manufacture, quality, and inspection procedures for ferrous, non-ferrous, cast and wrought gear materials. ‘The Manual is divided into four parts es follows: Part — General Information Part Il — Ferrous Gear Materials Part IM Non-Ferrous Gear Materials Part IV — Gear Heat Treating ‘The first draft of AGMA 240.01 was prepared in October, 1966. It was approved by the AGMA membership as of March, 1972 INDEX Part 1 General Information 4 I Ferrous Gear Materials 4 1. Wrought Steels 4 2. Cast Stools 9 3. Cast Iron n 4. Ductile Iron 2 5. Malleable Iron 4 I Non-Ferrous Gear Materials 16 1. Wrought Non-Ferrous Gear Materials 16 2. Cast Non-Ferrous Gear Materials 20 IV Gear Heat Treating A 2 1. Flame Hardening eee 2, Induction Hardening 6 3. Carburizing 30 4. Nitriding 32 copy RIGHT 1972, 8¥ AMERICAN GEAR MANUFACTURERS ASSOCIATION3S AGMA GEAR MATERIALS MANUAL. AGMA Standards are subject to constant improvement, revision or withdrawal as dictated by experience. Any person who refers to AGMA technical publications should satisfy himself that he has the latest information available from the Association on the subject matter. Personnel of Metallurgy and Materials Committee ‘Technical Division January, 1972 Russell Hoffman, Chaimar, The Tool Steet Geat & Pinion Company, Cincinnati, Ohio PH. Acker, Industral Drives Division, Eaton Corporation, Cleveland, Ohio RV. Adait, Gleason Works, Rochester, New York L.E. Amold, The Tool Steel Gear & Pinion Company, Cincinnati, Ohio H.R. Bergmann, The Falk Cowporation, Milwaukee, Wisconsin E, I, Bergquist, Western Gear Corporetion, Lynwood, California RE. Erxleben, National Broach & Machine Division, Lear Sieger, Inc , Detroit, Michigan HB. Gayley, De Laval Turbine Inc., Trenton, New Jersey 'W H. Glover, The Buehler Corporation, Indianapolis, Indiana F.H. Greenwood, The Boeing Company, Seattle, Washington PH. Gustafson, Cone Drive Geats, Ex-Cell.O Corporation, Traverse City, Michigan RZ. Johnston, Wamer & Swasey Company, Cleveland, Ohio Warren Lieberman, Vertol Division, The Boeing Company, Philadelphia, Pennsylvania HE. Lindner, Fellows Corporation, Springfield, Vermont A.M. Melntosh, Roy C. Ingersoll Research Center, Borg-Wamer Corporation, Des Pleines, [inois .S. Merkert, Link-Belt Enclosed Drive Division, FMC Corporation, Philadelphia, Pennsylvania Gerhard Richter, Farrel Company, Division of USM Corporation, Ansonia, Connecticut, F.E. Seymour, Winsmith Division of UMC Industries Ine, Springville, New York W L, Shoulders, Reliance Blectric Company, Columbus, Indiana RW. Smith, Ford Motor Company, Livonia, Michigan W.A. Sperks, D. O James Gear Manufacturing Company, Ex-Cell-O Corporation, Chicsgo, Minois J,H. Turner, Dominion Engineering Works Limited, Lachine, Quebec, Canada R, A Wilde, Eaton Comporation Research Center, Southfield, Michigan RJ. Zak, Philadelphia Geat Corporation, King of Prussia, Pennsylvania Tables or other self-supporting sections may be quoted or extracted in their entirety. Credit lines should vead: “Extracted from AGMA Gear Materials Manual (AGMA 240.01), with the permission of the publisher, the American Gear Manufacturers Association, 1330 Massachusetts Avenue, N.W., Washington, Dc. 20005.”AGMA GEAR MATERIALS MANUAL Part I General Information 1, Scope 1.1 This manual establishes the material manufacture, quality, and inspection procedures for ferrous, non-ferrous, cast and wrought gear materials. 1.2 This manual is divided into four Parts as follows: Part I General Information Part Il Ferrous Gear Materials Part III Non-Ferrous Gear Materials Part IV Gear Heat Treating 2. Material Inspection 2.1 The inspector representing the gear manufacturer shall have free entry at all times, while work on the contract of the gear manufacturer is being performed, to all parts of the ‘manufacturers’ works which concern the manufacture of the material ordered. The producer shall afford the inspec- tors, without charge, ail reasonable facilities to satisty him ‘that the material is being furnished in accordance with the specification. Unless otherwise specified, all tests and inspections shall bo made at the producers’ works prior to shipment and shall be conducted 2s not to interfere unnecessarily with the operation of the works. 2.3 Material which shows nonconformance to specification ‘at any stage in the manufacture of the gear is subject to rejection by the gear manufacturer. 3. Quality 3.1 In addition to the specific quality requirements ofthis manual, all parts furnished shall be capable of being machined to finish dimensions, free of surface imperfec- tions or virgin surface on machined surfaces. Part Ferrous Gear Materials 1, Wrought Steels 1.1 Wrought steols includes forgings bar mill products and rolled rings. 1.2 Material Manufacture 1.2.1 Gear materials to this specification may be made by ‘the open hearth, electric are furnace or basic oxygen practice. Vacuum processed or melted steel may be used. 1.22 The product shall be free of piping, and other internal defects of macroscopic size 123 The product shall be fiee of surface defects or imperfections which will not be removed by finish machin- ing 1.24 The manufacturer's current standards on size, quality, ‘and tolerance shall apply.oo AGMA GEAR MATERIALS MANUAL 1.2.5 Forgings shall be produced to provide the optimum, properties in the tooth portion 125.1 When upset forgings are specified, the inclusion ‘low lines shall be essentially in the radial direction, 1.3 Heat Treating 1.3.1 After mechanical working the stzel shall be given 2 heat treatment as necessary to prevent flaking, ruptures or cracking, and to condition the part for subsequent mechani- cal property heat treating 1.3.2 When specified by the gear manufacturer the parts shall be heat treated to the hardness and tensile properties specified, 1.4 Chemical Analysis 144. The chemical analysis shal be as specified by the gear ‘manufacturer or as agreed upon by the gear manufacturer and steol producer 142 The AISI standard for product analysis shall apply 143 The chemical analysis shall be determined from a sample obtained during the pouring ofthe heat. 144 The gear manufacturer may perform a product analysis on chemistry. 145 In the event of disagreement on chemical analysis ASTM Method E30 for chemical snalysis shall be used as the rofereo method 1.8 Mechanical Properties, 15. Hardness 1.5.1.1 Gears rated according to AGMA practice are rated ‘on hardness. Therefore, the hardness test determines the rating of the gear. 1.5.1.2 Typical hardness ranges are found in Table 1 1.8.13 Hardness tests shall be made in accordance with ASTM Designation A370, “Standard Methods and Defini- tons for Mechanical Testing of Steel Products” 1.5.1 4 Hardness tests are to be made on the tooth portion of the part after final hest treating 15.1.5 The number of hardness tests per piece is based on the tooth portion diameter as follows: eee Number of ‘Tooth Portion ne ‘Tests To 8 in. inclusive 1 Over 8 in to 12 in. inclusive 2 Over 12 in 4 15.15.1 Hardness tests are to be made at the mid-face ‘width of the tooth portion diameter When two hardness tests are specified they shall be 180 deg apart. When four hardness tests are specified they shall be 90 deg apart 1.5.1.5 2 Closed die forgings may be hardness tested based con a sampling plan with the approval of the gear manufac- turer. 1.5.1.5.3 For gear rings the hardness test shall be made at the mid-wall thickness The number of tests per piece shall be as follows: Diameter of Ring amber of To 36 in > Over 36 in. to 60 in. inclusive 4 Over 60 in 3 1.15.4 When two hardness tests ate specified they shall be made 180 deg apart, one on one ring edge and the other ‘on the opposite ring edge 1.5.1.5.5 When four hardness tests are specified they shall bbe made 180 deg apart on each ring edge, 90 deg apart from ‘one edge to the other 1,5.1.5.6 When eight hardness tests are specified they shall bbe made 90 deg apart on each rim edge 1.5.16 The specified hardness range must be obteined to the finish machined dimensions for acceptance 1.5.2 Tensile Tests, AGMA 24001 — October, 1972AGMA GEAR MATERIALS MANUAL Table 1 Hardness Ranges for Class A-1 Carbon and Alloy Wrought ‘Steel Including Rolled Rings Brinell cis bsaccahiee Hares at Tene rio Annealed o ft Normalized and Tempered aaa Normalized and Tempered or : a Quenched and Yempered Ginsacied Normalized and Tempered or a Quenched and Tempered eaenaee Add Quenched and Tempered 245-285, Ale ‘Quenched and ‘Tempered 265-305 Alf Quenched and Tempered 285-325 Me uence and Tempers 310-350 a uence and Tempered 335-275 Ath uence and Temper 250-290 NOTES: (1) Other hardness ranges can be used as specified. (2) Class A-1 subject to hardness test only. (@)_ The 160-200 Bha range rates at 180 Bhn for AGMA gear rating purposes. 152.1 Tensile Tests 15.2.1 Tensile tests aro only roquired when specified and are not applicable to closed die forgings. 15.2.2 Typical tensile properties for selected hardness ranges for forgings and barstock are found in Table 2, and for rolled rings in Table 3 15.23 For intermediate hardness ranges the tensile prop- erties are 10 be established by interpolation 15.24 Tensile tests are to be performed in accordance with ASTM Designation A370, “Standard Methods and Definitions for Mechanical Testing of Stee! Products” 1525 Tensile test bars are to be obtained from a prolongation or test coupon with the same diameter as the tooth portion diameter. The test bar axis shall be at the same depth below the surface as the coot diameter of the teeth to be machined into the part, and shall be taken with the longitudinal axis of the bar in the axial direction of the partAGMA GEAR MATERIALS MANUAL @ ws (9 wiauans ppars oqgemoyp soy soustagor sv pasn 9q AoUr TO'SS7 VOY WO OF anita (@ “ayqisstustad st pais uadord apsua; weomioq uonejodionut sofue ssoupsEN TOYO 104 ( “ALON “Bunvon yoy Jo cum ye suorsuaWIP arp UO pasea st ZeYOUIEID Jo uoRNE MINUETKEU at, (Z) ‘sosodind unt 1008 VINOV +05 ug OST Ve Seve ofucs stoupiey sm (1) oor o00'0ET 000'Sst ose o00%0ET 000'sST “ suas pur pasiony | 2 pe peat tomer ose-ose ] —parduny pur auing | 2¢y oor o00'sET o00°091 ost 000°0ET oor o00'0E 4 9 ue Pe Ose coset ore-o0e poreduay, pus poyouond | cy ose 00'S TT o00'orI O'oe ‘00°001 O00'0ET ose ooo'cot | ono‘! : suet ue 7 he poate eee see-sec | venduns pur ominiony | cy oor 00'S 17 000°SEL OE 000°08 000°OTT Ose 000's8. 000°0TT -" - sso pu pound | pr OO 00°06, 00°01 eee re pesedual, pur Patfouang | Poy gros 00°06 000'S1I Ose 00°08, 000°S0L OOF 00°08, 000‘SOr Posaduto], pue poyouang) 10 Osh 00°08 000'SOr S9t-Ste pesaduray, pur pazqruoy | CV oros 00°08 000'SOr oe co0'Os: 000'S6 an ue per io aoe cooss | on0s6 ose-ore | Pau permmumd 0 | 5.4 Ose 000'ss 000'S6, oor osu | oovoz (| panduay prvemraaon | ow sooo | eadsz a ve gn REIN | acy oo 000°0r 000'SL ‘eatsnpoUy 8 OL vm ured ( Bury 2 wong 0 swaneot we e31y Jo amas OS | eum rH) enn sone "rR sequin | ET Pusan a PoTIoy pur sfutBro o1q paso sdaoxa [oars aufnoay, oqry pu woqaED z-y S89 10} sapsadong eoMTENDOHY. aL@E © AGMA 260.01 — October, 1972& AGMA GEAR MATERIALS MANUAL “aqssuniod st paxsy sonsodord oysuay usemjoq voneyodsayur saBuer ssoupIU rom 104 “ALON. “sosodind Sunes 3008 viNDY 20} uy OT 18 saver oftex ssouprey sry, (1) ose oz coo'cst | oon'sst | wur.gox | o6e-ose Porodutay, PEE Poyouand) ey ose ov coo'sor | oooser | mmusex | ove-o0e Poradutey, pu pousuaN — J-EV ose ov ooo'cot | ooo'oer ox | sze-see Paraduray pue pawound ogy oor or 000'06 ooo'orr «3oL | see-ste poradunoy, pue peqousn pey : ; : peteduray pe porpuang 20 ose oot oo0'oe ooo'sor | puso | sox-sez porndwa] poe peaqetsoy | EY : : ‘ . a a osaduio], pue pououand 10 ose ost 00's 000's6 purse, | ose-o1z Poladwny pur pezrpunoy SCV o oor ooe o00'or ooo'ss | “P.gex | o0c-a91 Poredway pur pazymmoy egy 7 10 poreaury “ug, “uns, vumartsd | cussed fury, eavio | zm | wavang | anions | tomes | cat NEUE sy uononpoy, wonriuopg PRIA osu, on qeuug PepusuTUoseY sSuny panloy AoyTy pue uoqaeD ¢-y ssu{5 205 sapradorg aTUENDOW ¢ 91qU],AGMA GEAR MATERIALS MANUAL 15.251 When agreed upon by the gear supplier and customer, a separately forged test coupon of agreed upon dimensions may be used. The test coupon must be heat ‘treated with the forging(s) it represents 1.5.2.6 For small forgings made from one heat of stel, an, {individual forging may be sectioned to obtain the test coupon. 15.2.7 For rolled ring forgings the tensile test coupons shall be obtained from a prolongation of the ring with the axis of the test coupon tangent to the mid-wall thickness. 1.5.28 Tensile test coupons ate to be removed from the part after final heat treatment, 1.5.29 When agreed upon the gear supplier and customer, 1 separately forged test coupon of agreed upon dimensions ‘may be used, The test coupon must be heat treated with ‘tho forging(s) it represents. 152.10 Should a tensile test bar fail to meot require. ments, one retest may be made without reheat treatment of the parts. The parts may be reheat treated three times without approval of the purchaser. 2. Cast Steels 2.1 Material Manufacture 24.1 Cast steels to this specification may be made by the ‘open hearth, electric are or induction process. 2.12 Cast steel castings shall be free of shrink, porosity, {gas holes and entrapped sand in the tooth portion. 21.3 Repair welding of cast stee! castings in other than the tooth portion may be performed by the casting supplier Repalt welds in the tooth portion may only be performed with the approval of the gear manufacturer 21.4 Castings shall be furnished free of send, scale, ‘extraneous appendages and hard areas resulting from ‘welding, arc-siring or gas torching 22 Heat Treating, 2.2.1 Cast steel castings shall be given a thermal treatment after removal from the mold and prior to heat treating for mechanical properties to refine the as-cast microstructure. 22.2 When specified by the gear manufacturer, the casting shall be heat treated to obtain the hardness or hardness and properties specified. ten: 2.3 Chemicsl Analysis 23.1 The chemical analysis shall be as specified by the gear ‘manufacturer or as agreed upon by the gear manufacturer and casting producer. 23.2 The chemical analysis shall be determined from a ‘simple obtained during the pouring of the heat 23.3 The gear manufacturer may perform a product analysis on chemistry 2.34 In the event of disagreement on chemical analysis, ‘ASTM E30 for chemical analysis shall be used as the referee method 24 Mechanical Propertios 241 Hardness. 24.1.1 Gears rated according to AGMA practice are rated on hardness. Therefore, the hardness test determines the rating of the gear 24.1.2 Typical hardness ranges are found in Table 4 2.4.13 Hardness tests shall be made in sccordance with ASTM Designation A370, “Standard Methods and Detini- tions for Mechanical Testing of Steel Products.” 24.1.4 Hardness tests are to be made on the rim edge at mid-rim thickness after final heat treating 24.15 The number of hardness tests per piece is based on. the diameter of the casting as follows: Outside Diameter Number of of Casting Hardness Tests To12in 1 Over 12 in, to 60 in 2 Over 60 in 4 24.15.1 When two hardness tests are specified, one shall ‘be made on the cope side over a riser and the other on the drag side, approximately 180 deg away between risers AGMA 240.01 ~ October, 1972AGMA GEAR MATERIALS MANUAL Table 4 Hardness Ranges for Class A-4 Carbon and Alloy Cast Steel Banell Recommended Class es taser Hardness Range Annealed or on Normalized and Tempered ot Normalized and Tempered or ae Quenched and Tempered ae ; Normalized and Tempered or ad Quenched and Tempered ee Aaa Quenched and Tempered 245285 Ade Quenched and Tempered 265-305 Aad Quenched and Tempered 285-325 Mag Quenched and Tempered 310-350 Aah Quenched and Tempered 335-375 NOTES: (1) Other hardness ranges can be used as specified (2) Class A cast steels subject to hardness test only. @ 24,1.5.2 When four hardness tests are specified, two tests shall be made on the cope side, one over a riser and the other approximately 180 deg away between risers, and two tests on the drag side 90 deg away from the tests on the cope side, 24.1.6 The specified hardness range must be obtained to the finish machined dimensions for acceptance 242 Tensile Tests 24.2.1 Tensile tests are only required when specified 2422 Typical tensile properties for selected hardness ranges are found in Table S "The 160-200 Bhan range rates et 180 Bhn for AGMA gear rating purposes. 2.4.23 For intermediate hardness ranges the tensile prop- erties are to be established by interpolation, 2424 Tensile tests are to be performed in accordance with ASTM Designation A370, “Standard Methods and Definitions for Mechanical Testing of Steel Products.”” 24.25 Tensile test coupons may be attached to the casting fr cast in separate molds from the same heat as the parts they represent and shall receive the same heat treatments as the parts The test coupon may be given an additional temper to match the hardness of the part 2425.1 The minimum cross-section of the cast coupon shall be 1 in, x 1-1/4 in -10-AGMA GEAR MATERIALS MANUAL Table $ Mechanical Properties for Class A-S Carbon and Alloy Cast Steel cms | Beoamentet | gtetnen | stent | steak | ints” | tam Range | psipmin | psi,min. | min %, min ‘ASat | Annealed or 160-200 | 70,000 | 35,000 180 300 ‘ASa2 | Normalized & Tempered | 160-200 | 80,000 | 45,000 230 35.0 At | ee ar mmere, | 210-250 | 95.000 | 60,000 20 400 Ase | Onched te Tenpeea | 225-265 | 100,000 | 70,000 150 350 AS | Quenched & Tempered | 245-285 | 110,000 | 80,000 130 310 As2 | Quenched & Tempered | 285-325 | 130,000 | 100,000 100 260 As¢ | Quenched & Tempered | 310-350 | 140,000 | 110,000 90 240 AS | Quenched & Tempered | 335-375 | 150,000 | 120,000 30 200 NOTES: (1) Class A-Sal is for carbon cast steel (@) Class A-$-22 is for alloy cast steel (3) For other hardness ranges interpolation between tensile properties listed is permissible. (4) The 160-200 Bhn hardness range rates at 180 Bhn for AGMA gear rating purposes, (5) Mechanical properties listed applicable to a maxiraum of 3 in. rim section, 2426 Should a tensile test bar fail to meet requirements, one retest may be made without reheat treatment of the parts and test coupons. The parts may be reheat treated throe times without approval of the purchaser 3, Cast Iron 3.1 Material Manufacture, 3.1.1 Cast irons for gears may be made by the electric arc furnace, coupols, or induction practice 3.12 Cast iron castings shall be free of shrink, porosity, gas holes, entrapped sand and difficult to machine arecs in the tooth portion 3.1.3 Repair welding in other than the tooth portion is permitted without prior approval. Repair welds in areas to be machined must have equivalent machinsbility as the casting Repair welds in the tooth portion may only be performed with the approval of the gear manufacturer 3.1.4 Castings shall be furnished free of sand, scale, extraneous appendages and hard areas 32 Heat Treating 3.2.1 Cast iron castings are to be furnished as-cast unless ‘othorwise specified 3.2.2 When stress relieving is deemed necessary to hold close dimensional tolerances, it is recommended that the AGMA 24001 — October, 1972 sieAGMA GEAR MATERIALS MANUAL castings be heated to 1000 to 1100 F holding at tempera- ture for 1 hour per inch of maximum section and furnace cooled to below 200 F 3.3. Chemical Analysis 33.1 Unless otherwise specified, the chemical analysis shall be at the discretion of the casting supplier as necessary to produce castings to this specification 3.4 Mechanical Properties 34,1 Cast iron gears are rated accordingly to AGMA practice based on hardness, Therefore, the hardness deter- ines the rating of the gear. 3.42 Minimum hardness requirements for the classes of cast iron are shown in Table 6, Table 6 Tensile Test and Minimum Hardness Requirements for Cast Iron AGMA, ‘Brinell Tensile Class Hardness, Strength Number Minimum si, min 20 155 20,000 30 185 30,000 35 205 35,000 40 20 40,000 50 250 50,000 60, 285 60,000 3.43 Hardness tests shall be made in accordance with ASTM Designation E10, “Standard Method of Test for ‘Brinell Hardness of Metallic Materials.” 344 Hardness tests are to be made on the mid-rim thickness or mid-face width of the tooth portion diameter. 3.45 At least one hardness test shall be made on each piece and sufficient hardness tests shall be made to verily ‘that the part meets the minimum hardness specified. 3.4.6 The specified minimum hardness mast be maintained to the finish machined dimensions for acceptance 38.1 Tensile Strength 12 35.1.1 Tensile tests are only required when specified 35.12 Tensile test requirements are shown in Table 6. 35.13 Tonsile tests are to be performed in accordance with ASTM Designation A48, “Standard Specificstion for Gray Iron Castings ” 3.13.1 Test coupons are to be cast in separate molds in accordance with the provisions of ASIM Designation AAS (Gee paragraph 3.5.1.4) 38.14 The size of cast test coupon is dependent upon the thickness of the tooth portion of the casting as follows: ‘Thickness | AsCast | Machined | ASTM A43. of Tooth | Diameter, | Diameter, | Test Bar, Section, in in. in. in. 025-050 | oss 050 A osi-100 | 1.20 0.750 B 101-2 inet. | 2.00 125 c Note: See ASTM A48 for tolerances on as cast and machined diameter. 3514.1 For thinner or thicker sections the test bar dimensions shall be by agreement between gear manufac turer and casting producer, 35.15 In the event a test bar fails to meet the tensile strength requirements, one additional test may be per- formed from the same ladle or tap of iron. Should the second bar fail, the castings from this ladle or tap of iron shall be subject to rejection. 4, Duetile fron 4.1 Material Manufacture, 4.11 Ductile iron castings may be made by the electric are furnace, coupola or induction practice. 4.1.2 Ductile iron castings shall be free of shrink, porosity, 428 holes and entrapped sand and difficult to machine aroas {n the tooth portion 41.3 Repair welding in other than the tooth portion is permitted without prior approval, Repair welds in areas tofy 3 AGMA GEAR MATERIALS MANUAL be machined must have equivalent machinability as the casting. Repair welding in the tooth portion may only be performed with the approval of the gear manufacturer, 4.14 Castings shall be furnished free of sand, scale, extraneous appendages and hard areas, 4.2 Heat Treating 42.1 Ductile icon castings shall be heat treated by anneal ing, normalizing and tempering or quenching and tempering or acast a8 required {0 meet the specified mechanical propeities 43 Chomical Analysis 43.1 Unless otherwise specified, the chemical analysis shall be at the discretion of the casting supplier as necessary to produce castings to this specification 44 Mechanical Properties 4.4.1 Typical mechanical properties a shown in Table 7. Other properties may be as agreed upon by the gear ‘manuiacturor and casting producer 442 Tensile Properties 442.1 Tensile test coupons shall be poured from the same ladle or heat and be given the same heat treatments as the castings they represent 4422 ‘The test coupon mold design shall be in accordance with ASTM Designation A536, “Standard Specification for Ductile Iron Castings ” The size of the Y-block mold if used shall be at the option of the producer unless specified by the gear manufactures 4423 Tensile tests are to be performed in accordance with ASTM Designation E8, “Standard Method of Tension Testing of Metallic Materials” The yield strength shall be determined by the 0.2 per cent offset method, 442.4 In the event a tensile test bar fails to meet requirements, a second test bar may be tested from the same test coupon mold or another mold cast from the same ladle or heat a5 the castings they represent, Should the second bar fail, the parts, including test coupons may be reheat treated and retested. Should the properties not be obtained, the parts are subject to rejection 443 Hardness. 443.1 Hardness tests are to be performed in accordance with ASTM Designation E10, “Standard Method of Test for Brinell Hardness of Metallic Materials.” ‘Table 7 Mechanical Properties for Class A-7 Ductile Iron eee | he ae AT 65—45—-12 As-Cast or Annealed ~ | 150-200, 65,000 45,000 12.0 ee ‘Ave | 120-90-02 | Quenched& Tempared | 270-330 | 120000 | 90,000 20 NOTE: Other tensile properties and hardnesses may be used by agreement between gear manufacturer and casting producer. “1B. AGMA 240 01 — October, 1972AGMA GEAR MATERIALS MANUAL 4432 Hardness tests are to be made on the mid-rim thickness or mid-face width of the tooth portion diameter. 4433 The number of hardness tests per pioce is based on the diameter of the casting as follows: Number of Hardness Tests Outside Diemeter of Casting To l2in Over 12 in. to 36 in. Over 36 in. to 60 in Over 60 in 4433.1 When two hardness tests are specified, one shall bbe made on the cope side over @ riser and the other on the drag side approximately 180 deg away between risers 443.32 When four hardness tests aro specified, two tests shall be made on the cope side, one over a riser and the other approximately 180 deg away between risers and two tests on the drag side 90 deg away from the tests on the cope side. 4433.3 When eight hardness tests are specified, they shal bbe made 90 dog apart on both cope and drag side 4434 For cylindrical pieces with length over diameter of ‘one or moro the number of hardness fests shall be as follows: Number of Hardness Tests Diameter of Tooth Portion Note: ‘The hardness tests shall be spaced uniformly sround ‘the circumference 443.5 When many small pieces are involved, all poured from the same ladle or heat, and heat treated in a single farnaco load, a sample testing plan may be used with the approval of the gear manufacturer oie S. Malleable Iron 5.1 Material Manufacture 5.11 Malleable iron castings may be made by the electric arc furnace, coupola, induction or air furnace practice or combinations thereof 5.12 Malleable iron castings to this specification are limited to pearlitic malleable irons. 5.13 Malleable iron castings shall be free of shrink, porosity, gus holes, entrapped sand and difficult to machine areas in the tooth portion, 5.14 Castings shell be furnished free of send, scale extraneous sppendages and hard areas. 5.2 Heat Treatment 5.21 The castings and the test bars they represent shall be heat treated in a manner to produce the requirements of this specification, or such other mechanical propertios 2s agreed upon $3 Microstructure $3.1 The microstructure of the castings must be free of primary graphite and primary cementite $4 Chemical Analysis 5.41 The chemical analysis shall be at the option of the casting producer as required to meet the requirements of this specification 5.8 Mechanical Properties 5.5.1 Typical mochanical properties are shown in Table 8. Other properties may be as agreed upon by gear manufac ‘turer and casting producer. 552 Tensile Properties, 55.21 The requirements of the tension test specimen, method of tension testing and number of tests and retests shall be in accordanco with ASTM Designation A220, “Standard Specification for Pearlitic Malleable tron Cast- ings.3 AGMA GEAR MATERIALS MANUAL Table 8 Mechanical Properties for Malleable Iron soma | Commerc Diet Ten Yi Hongaton Class Designetion Hardness oe on oe —_ pai, min si, min %,min Age 40010 160-210 60,000 40,000 100 Ash 43010 160-210 60,000 43,000 100 Ase 45007 165-220 65,000 45,000 70 Aged 43005 180-230 70,000 48,000 50 Ase 5000s 180-230 70,000 50,000 50 Ase 3007 195-240 75,000 53,000 40 Ags 60003 195-245 80,000 60,000 30 Ash 70003 205-265 85,000 70,000 30 Asi 80002 240-270 95,000 80,000 20 A83 90001 265-305 105,000 90,000 10 NOTE: Other tensile properties and hardnestes may be used by agreement between Gear Manufacturer and Casting Producer. 553 Hardness 55.3.1 When two hardness tests are specified, one shall 5.5.3.1 Hardness tests are to be performed in accordance with ASTM Designation £10, “Standard Method of Test for Brinell Hardness of Metallic Materials.” 5.53.2 Hardness tests are to be made on the mid-rim thickness or mid-face width of the tooth portion diameter 5.5.33 The number of hardness tests per piece is based on ‘the diameter of the casting as follows: Outside Diameter Number of of Casting Hardness Tests To 12in 1 Over 12 in. to 36 in. 2 Over 36 in, to 60 in. 4 Over 60 in 8 +15- ‘be made on the cope side over a riser and the other on the dag side approximately 180 deg away between risers 5.5.3.3.2 When four hardness tests are specified, two tests shall be made on the cope side, one over a riser and the other approximately 180 deg away betweon risers and two tests on the drag side 90 deg away from the tests on the cope side. 55.333 When eight hardness tests are specified, they shall ‘be made 90 deg apart on both cope and drag side. 5.5.3.4 For cylindrical pieces with length over diameter of fone or more, the number of hardness tests shall be as follows: AGMA 240.01 — October, 1972AGMA GEAR MATERIALS MANUAL Number of Hardness Tests Diameter of ‘Tooth Portion To 3 in incl To 6 in. incl 1 2 Over 6 in 4 Note: The hardness tests shall be spaced uniformly around the circumference 5.5.3.5 When many small pieces are involved, all poured from the seine ladle or heat, and heat treated in a single fumace load, a sample testing plan msy bo used with the approval of the gear manufacturer Part 11 Non-Ferrous Gear Materials 1. Wrought Non-Ferrous Materials 1A Wrought non-ferrous gear materials include forgings, bar mill products and rolled rings 1.2 Material Manufacture. 1.2.1 Nonferrous gear materials to this specification shall ‘be melted in a commercially recognized melting method for the composition involved 1.22 The product shall be free of piping and other internal defects of macroscopic size 123 The product shall be free of surface defects or imperfections which will not be removed by finish machin- ing. 1.24 The manufacturers current standards on size, toler- ance and quality shall apply 1.25 Forgings shall be produced to provide the optimum properties in the tooth portion, 1.2.5.1 When upset forgings are specified the flow lines shall be essentially in the radial direction 13 Heat Treating, 13.1 After mechanical working, the material shal be given the necessary thermal heat treatments to obtain the specified properties (see Table 2). 1.4 Chemical Analysis. -16- 1.4.4 The chemical analysis shal be in conformance to one of the materials shown in Teble 1 142 The chemical analysis shall be determined from a sample obtained during the pouring of the heat, 143 The gear manufacturer may perform a product analysis on chemistry. 1.44 In the event of disagreement on chemical analysis, ASTM Designation 54, “Standard Methods for Chemical Analysis of Special Brasses and Bronzes,” shall be used 2s the referee method 1.5 Mechanical Properties. 1.5.1 Hardness 15.1.1 The required hardness as shown in Table 2 is to be ‘obtained in the tooth portion of the part 1.5.1.2 Hardness tests are to be made in accordance with ASTM E-10, “Methods of Test for Brinell Hardness of Metallic Materials ” The load in kilograms foree as listed in Table 2 is to be used 1.8.1.3 Hardnoss tests are to bo made on the tooth portion of the part after final heat treatment, if required 15.14 The number of hardness tests to be made shall be specified by the gear manufacturer. 15.2 Tensile Tests2 Z g 3 = 4 3g & g = % g < 5 g | eu zo] em 05°90 Osst | oro | ovoe |spmury| ossoes] 8? (Ganding puw oneysing wooneg ussite Ag) om wane seu 0s0 sewozo | xousco | ssov | xwost | opoz ~ |ossos.) 9 wav “saw 9s reuse | vmmze | xwor | xmoct | sawor | otrss | semoT| oseoss! suai (Gandding puw aseusing voone yuouoite Ag) om weIV pet | wn | woos | raion | asomtun | von | uneumy | 2uz | seddog | sexy Feusjeyy 4099 soneg-uon 1YStO%y — sisAjoUY ORIN | 2IqeL AGMA 24001 — October, 1972 “7.AGMA GEAR MATERIALS MANUAL Table 2 Mechanical Properties — Wrought Non-Ferrous Gear Material Tensile Bhn Bhn rex Yield Strength Elongation in 2 in. Min, Min, ym | Simei | ON ‘asia soo | sano | Remus - ef ef ALBR WO Q) tees” | root | 3000 no 180 ALBR 6 90,000 45,000 100 180 MNBR WO @ MNBR 5 85,000 45,000 (1) 20.0 150, MNBR 6 93,000 50,000 (1) 70 190 MNBR 7 100,000 55,000 (1) 5.0 210 (1) The yield strength shall be determined by the extension under load method. The limiting extension under load shall ‘be calculated as follows: x = y/z + 0002 y = Specified yield strength z= Modulus of elasticity for the alloy. = Limiting extension inches/inch of gage length. The modulus of elasticity for manganese bronze shall be 15,000,000 psi unless otherwise approved or specified by the purchaser @) _Asagreed upon between producer and consumer 15.2.1 Tensile tests are only required when specified by the customer. 1.52.2 Tensile test requirements for wrought non-ferrous materials are found in Table 2. 15.23 ‘Tensile tests are to be performed in accordance ‘with ASTM Designation B8, “Standard Methods of Tension ‘Testing of Metallic Materials” 15.24 Tensile test bars are to be obtained from a full size prolongation of the same diameter as the tooth portion diameter. The test bar axis shall be at the same depth below the surface as the root diameter of the teeth to be ‘machined into the part, and shall be taken with the longitudinal axis of the bar in the axial direction of the part 15241 When agreed upon by the gear supplier and customer, @ separately forged test coupon of agreed upon dimensions may be used. When the forging(s) require heat treatment, the test coupon must be heat treated with the forging(s) it represents 15.2.5 For small forgings, all of which are made from one heat, an individual forging may be sectioned to obtain the test coupon 1.5.26 For rolled ring forgings, the tensile test coupons shall be obtained from 2 prolongation of the ring with the axis of the test coupon tangent to the mid-wall thickness. 15.27 Tensile test coupons are to be removed from the part after final heat treatment -18-2 3 g 3 s a z = 2 8 3 g “xour §z°0 SLTSCT oss-0'98] ¢ azNous. eeu $20 “xe $0 }o'680'98] + aZNOWE pee $70 oer oee-0'98| € IZNOUT eeu s7'9 | “xoM OZ OT-V0r] 006098] z aZNOUT eeu $70 SU SCT | sLorst'6| 006-088] T AZNOUT ‘Geonporg par rasmoejnueyy 1295) uBoAaq qaWeaxBy Aq) 12 AZNOWL japurewiny | “xe 79 ossz 9 e MANN opurewicy | “eu $70 eu ST xeu £9 c YaNN 7 fPomewea] sts0 | rxour sy | eu 0% vu st{ozo-09s] 1 YaNW (Geonpong pure romiseinueyy 1295 w9aMI0q aUIDAIBy AG) 09 WENN eu 50 ] seugse | ove] stroor | ssoe vamos] > ueT¥ nee S10 j ew so | osoe| siroor | eusz vam ges) € wav ew OL [stsco| otros vamos) 2 uaTV eu OT | ose] sess uu g'98) 1 UgTV (Gepaporg pue saimoepnuey_ 3095 uaoMOq juOWOR:By Ag) 00 ueTv = T sepureutay| * 109 eu ay | un or fonundun| MZ | peeT | sou mms | asouedueyy [= eamyy | exeIN my | seddog | ody, Tourney 1899 snoxie,-uoN 384 — sIsdqouy HeoHIDYD ¢ aIaEL, ”~ AGMA 240.01 — October, 1972 -19-AGMA GEAR MATERIALS MANUAL 15.28 Should a tensile test bar fail to meet requirements, ‘one retest may be made without reheat treatment of the parts. The parts may be reheat treated three times without approval of the purchaser 2. Cast Non-Bercous Materials 2.1 Materials Manufacture, 21 Non-fersous gear materials to this specification may bbe melted in any commercially recognized melting method for the composition involved. 2.1.2 Non-ferrous castings shall be free of shrink, porosity, gas holes, and entrapped sand in the tooth portion, 2.1.3 Repair welding in other than the tooth portion may be performed by the casting supplier. Repair welds in the tooth ares may only be porformed with the approval of the gear manufacturer. 2.1.4 Castings shall be furnished free of sand and extra- neous appendages 22 Heat Treating. 2.2.1 Non-forrous castings shall be heat treated as required to obtain the specified mechanicel properties (see Table 4) 23 Chemical Analysis. 2.3. The chemical analysis shall be in conformance with the type specified (see Table 3) or as agreed to by the gear manufacturer and casting producer 2.32 The chemical analysis shall be determined from a sample obtained during the pouring of the heat, 23.3 The gear manufacturer may perform a product analysis for chemistry. 2344 In the event of disagreement on chemical analysis, ASTM Designation E54, “Standard Methods for Chemical Analysis of Special Brasses and Bronzes,” shall be used as the referee method. 2.4 Mechanical Properties 241 Hardness 24.1.1 The requited hardness as shown in Table 4 is to be ‘obtained in the tooth portion of the part 24.1.2 Hardness tests are to be made in sccordance with ASIM E-10, “Method of Test for Brinell Hardness of Metallic Materials” The load in kilograms foreo as listed in Table 4 is to be used 2.4.1.3 Hardness tests ate to be made on the tooth portion of the part after final heat treatment, if required 24.1.4 The number of hardness tests to be made shall be specified by the gear manufacturer. 2.42 Tensile Properties 24.2.1 Tensile test requirements are shown in Table 4. 2.42.2 Tensile tests axe only required when specified. 242.3 Tensile tests when specified are to be made in accordance with ASTM E8, “Tension Testing of Metallic Matorials.” 2.4.2.4 Tensile test bars for sand castings may be atteched to the casting or cast separately. Tensile test bars for static chill castings may be cast separately with chill in the bottom of the test bar mold, Tensile test bars for ‘contrifugel castings may be cast in a separate centrifugal ‘mold for test bars or cast in 2 chill test bar mold. Note: A cast on or soparately cast test bar does not necessarily represent the properties obtained in the casting ‘Tho propertios in the casting are dependent upon the size and design of the casting and foundry practice 2425 Three test coupons shall be poured from each melt ‘of metal or per 1000 Ibs. of melt except where the individual casting weighs more than 1000 tbs 2426 Heat treated castings are to have the test coupons hheat treated in the same furnace loads as the castings they represent, a.“rosmysand £q ponosdde 31 posn 04 Ket (fy QOS 30,/8 0001) stexa peor zoMpO Te UU (4) “uo 9868 your 7 8 ur souoUt 10'9 ‘te “Y499 94 <0 J0 Beer JaPUR YOHHHBUO(® ue BuroNpord ssn oN Fe PoumsSEp Og TUS MABUaNS PIA (6) “poforduse worpuoo usm jo Sunes s04 (2) semonaed ou uodn puodap (gas Sy sosovy stouereyy ox (WoRIpS 389181 40) HOOP VIN WHIM souepiocoe uy iva “aasoysund om Aq patsfoads 10 panordde astauouno ssorun ‘sd Q00'000'ST 94 TeYS azuorg asaueSueLt 205 Astoryseyo Jo snAMpOU ayy, POW = 2 PistK poyroads = « “WBu9} a8e8 Jo yout/soyour WoIsuarxe parqwUTT = xX lau 2000 + 2/€ = x :swoy[oy se pozenorso aq sys proy z9pun uorsua}xo Bu UL “potas peo] zapun wosuarxe ox £q poutuorap og EUS WiFUELI PIoHA au, (1) 2 06 ost (©) 00097. 0000 @aweo | s nan T 5 réryiiwe9 |” azNoud 4 08 vor ©) o00're 000'sh @eommD | s NIALL AZNOUE = c |e ose (ooo | oogor | @reoms | oaHL T z I SZNONT g (deonporg pu seamioesmueyy 2806) weemiog 1woWIaarBy Ka) 09 aZNOua | & g Tc oct (Do00'09 | oog'ort wsosy |» ENN = ont ost (1) 000'se 00006 weg sy £ YaNW ~ zr oor (1) o00'sz 00's9 wegsy |Z MEN s (ee ost Moov | oov09 wosy | 1 MaNK a 7 Goonposg pur soinjoesnieyy 2809) w9eK0q wuautoasBy Aq) 0D WENA = g zor T os 000'09 oodiort EOL WOH usTY 7 sit { 09 000'0F 00°06 380 5y vy ¥aTY oot 09 00's 00°06 weywon | uaIV Ort ot oo0'0s 00's 370 5¥ e Mey Tet | ou 00'0r ooo'os wei | 7 ugIV on oe 00's o00's9 wosy | 2 aay our oor 00's¢ 000's9 30 5¥ 1 Maqy F (Geonpong pu soumaejnusy sap uaamaq weaWearSy Ag) 09 waT¥ FRY 000'E BY 095'1 ex 008 vom 4g ‘uu as 4 “uu “amu “uur ‘ucu ‘nduang anduons wortpu09 adh was yg uy uonoio(g PRIA aUsuay STUUDIER AvaN snoMDY-ON I3eD — sopradorg JEDHURIPO, a1qeL, AGMA 24001 — October, 1972 221.AGMA GEAR MATERIALS MANUAL 2.4.2.7 One test specimen shall be tested from each group Of throo test coupons cast. If this bar meots tho tonsle requirements, the lot shall be accepted. If the first bar should fail to meet requirements specified, the two remain- ing specimens shall be tested. The average properties of these two bars must meet specified requirements for acceptance of the lot Part IV Gear Heat Treating Section 1 Recommended Procedure for Flame Hardened Gears and Pinions 1. Purpose 11 The purpose of this recommended procedure is to provide information, means of specifying and inspection of flame hardened gears. 2. Scope 2. This recommended procedure covers the selection and ial, hardnesses obtainable, hardening pattems, and definition and inspection of depth of harden- ing 3. Materials 3.1 Carbon or alloy steels (cest and wrought) including the ‘martensitic stainless steels; ductile iron, cast iron, and malleable iron can be flame hardened, 32 Alloy steels of SO per cent or higher are prone to cracking on flame hardening. The higher the alloy content with high carbon, the greater the tendency for cracking 4, Prior Heat Treatment 41 Alloy steels which have been previously quenched and tempered to produce an essentially tempered martensitic structure free of spheroidal carbides can be flame hardened with the shortest heating time consistent with the specified Gepth of hardening and maximum surface hardness for the carbon content 4.2 Carbon steels will harden readily to meximum hardness with prior heat treatments of quenching and tempering, normalizing, or normalizing and tempering. Spheroidal carbides due to high tempering temperatures, or large patches of ferrite may reduce the hardness or cause spotty hardness 5. Surface Hardness 5.1 The surface hardness obtainable in steel is primarily 2 function of the carbon content of the steel 2s shown in Figure 1-1 52 Lower hardnesses may oocur as a result of prior heat treatment of the part, alloy content, depth of hardening, heating time, mass ofthe part, and quenching 6. Hardening Patterns 6.1 There are three basic methods of flame hardening gear teeth 1. Rotating the gear while the surface is heated by flame heads or burners positioned around the gear 2. Passing two integral flame heads with or without integral quench along both flanks of a single tooth 3. Passing @ flame head with or without integral quench through the space between two teeth to harden the adjacent flanks and intervening root area -22-ww he AGMA GEAR MATERIALS MANUAL Note: This last method is of recent development. Its applications and limitations cannot be defined at this time 611 Typical examples of the hardening patierns obtain able are shown in Figure 1-2. 62 The allowable durability and root strength rating for the different hardening pattems are to be obtained from appropriate AGMA rating practices 63 The hardening patterns shown are not possible for all sizes and pitches of gearing and sre dependent upon the capacity of the equipment. 64 The rotating method of flame hardening is limited to approximately 5 DP and finer. The maximum diameter and face width is dependent upon the available equipment Some specialized equipment can flame harden gears up to 44 in diameter by 12 in. face 64.1 Long slender parts can be flame hardened by having a ring type flame scan the part axially while the part is rotating 6$ Flank hardening, and flank and root hardening can be applied to almost any size piece with adequate supporting equipment, The minimum practical pitch is approximately 21/2 DP. 7. Depth of Hardening 7.1 The depth of hardening at the particular or several locations on the tooth profile is to be specified by the design engineer 7.2 The depth of hardening shall be determined at that dopth where the hardness below the surface is $ Re points below the surface hardness. 7.2.1 Total hardening depth to core hardness may be used when specified. 7.3 Bifective case depth hardness based on carbon content, is shown in Figure 1-1 Note: It may be desirable to reduce the tendency towards cracking to use a slow quench and therefore not obtain full surface hardness, The hardness at effective case depth must be adjusted accordingly 7.4 Recommended case depths are the same 2s for car- bourized gearing See AGMA rating practices. 7.5 Inspection of Case Depth, 75.1 The only positive way to check caso depth is by seetioning an actual part For the flank hardening method, and the flank and root hardening method, a segment of a gear can be flame hardened and sectioned 7.5.2 The case depth can be determined on a normal tooth section using a microhardness testing machine 8. Quenching 8.1 Various methods of quenching and quenching medium te employed depending upon the hardening process, specified surface hardness, and steel composition. Parts rotated in a flame are usually quenched by submerging after heating in an agitated liquid such as oil, water or water rnixtures, Scanning flame hardening techniques usually have an integral quench following behind the flame, The ‘quenchant may be compressed ai, water, or special water mixture. Oil cannot be used because of the danger of fie 9. Tempering 91 Tempering need only be performed when specified. ‘Tempering is sometimes necessary to prevent cracking of the teeth and may require that the parts be tempered immediately after hardening 9.2 When specified, tempering shall be for one hour ‘minimum per inch of section at the specified temperature. 10. Specifications 10.1 ‘The drawing, order or written specification should include the following information: a The chemical analysis range of the material or designation, The prior heat treatment The hardening pattern required. “2B. AGMA 240.01 — October, 1972AGMA GEAR MATERIALS MANUAL 4 HARDNESS ~ ROCKWELL ‘Cc! .20 30 40 50 60 70 CARBON CONTENT—PER CENT FIG. 1-1 RECOMMENDED MAXIMUM SURFACE HARDNESS AND EFFECTIVE CASE DEPTH HARDNESS VS. PER CENT CARBON CONTENT OF STEEL FOR FLAME HARDENING 4. The surface hardness required 11. Documentation . Those areas where the surface hardness is to be 111 The heat treater shail submit the following infor- reasured andthe frequency of inspection tation, £ The depth of hardening roquzed and the location(9) 11.14 The surface hardness range obtained and the nom- at which the depth is to be obtained ber of pieces inspected g. Whether destructive tests are to be used for deter- 11.1.2 The depth of hardening obtained at each location rining the degth of hardening and the frequency of specifiod when destructive tests are required, and. the such inspections number of pieces checked 1 The tempering temperature if required 11.1 3 The tempering temperature used 4. Magneti particle inspection if required 11.14 Results of magnetic particle inspection if specifieda AGMA GEAR MATERIALS MANUAL ROTATING FLAME HARDENING FLAME HEAD FLAME HEAD FEE —_ FROM THIS ‘TO THIS FLANK FLAME HARDENING FLAME HEAD FLAME HEAD FROM THIS TO THIS FLANK AND ROOT FLAME HARDENING FLAME HEAD FLAME HEAD FROM THIS TO THIS, FIG, 2-1: VARIATIONS IN HARDENING PATTERNS OBTAINABLE ON GEAR TEETH -25+ AGMA 240.01 — October, 1972AGMA GEAR MATERIALS MANUAL Section 2 Recommended Procedure for Induction Hardened Gears and Pinion 1. Purpose LA The purpose of this recommended procedure is to provide information, means of specifying and inspection of induction hardened gears. 2. Scope 21 This recommended procedure covers the selection and processing of materials, hardnesses obtainable, hardening patterns, and definition and inspection of depth of harden- ing 3. Materials 3.1 Carbon or alloy steels (cast and wrought) including the ‘martensitic stainless steels; ductile iron, cast iron, and ‘malleable iron, can be induction hardened 32 Alloy steels of SO per cont carbon or higher are prone to cracking on induction hardening. The higher the alloy content with high carbon, the greater the tendency for cracking, 4, Prior Heat Treatment 4,1. Alloy steels which have been previously quenched and tempered to produce an essentially tempered martensitic structure free of spheroidal carbides can be induction ‘hardened with the shortest heating time consistent with the specified depth of hardening and maximum surface hard- ness for the carbon content. 42 Carbon steels will harden readily to maximum hardness with prior heat treatments of quenching and tempering, normalizing, or normalizing and tempering Spheroidal carbides due to high tempering temperatures, or large patches of ferrite may reduce the hardness or cause spotty hardness 5 Surface Hardness 5.1 The surface hardness obtainable in stool is primarily a function of the carbon content of the steel as shown in Figure 2-1 5.2 Lower hardnesses may occur as a result of prior heat ‘treatment of the part, alloy content, depth of hardening, heating time, mass of the part, and quenching. 6, Hardening Patterns 6.1 There are three basic methods of induetion hardening ‘gear teeth, 4, Rotating the gear in an induction cof 2. Enveloping a single tooth in an inductor and hardening both flanks simultaneously. 3. Pessing an inductor through the space between two teeth hrardoning the adjacont flanks and intervening root area 6.1.1 ‘Typical examples of the hardening pattems obtain- able are shown in Figure 2-2 62 The allowable durability and root strength rating for the different hardening pattems are to be obtained from appropriate AGMA rating practices. 63 The hardening patterns shown are not possible for all sizes and pitches of geering and is dependent upon the KW capacity of the equipment 6A The induction coil method is limited to approximately 5 DP and finer The maximum diameter and face width is determined by the projected outside diameter arca and the KW capacity of the equipment. A general guide is 1 10 6 KW/squate inch of suxface, Long slender parts can be induction hardened with lower KW capacity equipment by having the coil scan the length of the part while the partis rotating in the col.3 2 w AGMA GEAR MATERIALS MANUAL 65 Flank hardening and flank and root hardening can be applied to almost any pitch and size with appropriate supporting equipment and KW capacity. For pitches of approximately 16 and finer these methods are not recom: mended 7. Depth of Hardening 71 The depth of hardening at the particular or several locations on the tooth profile is to be specified by the design engineer 72 The depth of hardening shall be determined at that depth where the hardness below the surface is S Re points, below the surface hardness. 72.4 Total hardening depth to core hardness may be used when specified 7.3 Effective case depth hardness based on carbon content, is shown in Figure 21 Note: It may be desirable to reduce the tendency towards, cracking to use 2 slow quench and therefore not obtain full, surface hardness, The hardness at effective case depth must, be adjusted accordingly 74 Recommended case depths are the same as for car burized gearing, See AGMA rating practices. 7 Inspection of Case Depth, 75.1 The only positive way to check case depth is by sectioning an actual par. For the flank hardening method, and the flank and root hardening method a segment of a sear can be induction hardened and sectioned 752 The case depth can be determined on a normal tooth section using a micro-hardness testing machine 8. Quenching 811 Various methods of quenching and quenching medium, fare employed depending upon the hardening process, specified surface hardness, and steel composition. Parts, heated in an induction cofl are usually quenched in an {integral quenching sing or in an agitated liquid of water, oll, Oo special water mixtures. When the pact is scanned while 27+ rotating in the coil a spray quench usually fellows behind the coil 8.1.1 Flank hardened teeth usually have an integral quench following behind the inductor, or are submerged in the quench during heating 9 Tempering 9.4 Tempering need only be performed when specified Tempering is sometimes necessary to prevent cracking of the teeth and may require that the parts be tempered immediately after hardening 9.2 When specified, tempering shall be for one hour minimum per inch of section at the specified temperature. 10. Specifications 10.1 The drawing, order or written specification should include the following information a. The chemical analysis range of the material or desig. nation b. The prior heat treatment, , The hardening pattern required. . The surface hardness required. , Those areas where the surface hardness is to bo measured and the frequency of inspection, £. The depth of hardening required and the location(s) at which the depth is to be obtained g, Whether destructive tests are to be used for determining the depth of hardening and the frequency of such inspections. fh, The tempering temperature if required. |. Magnetic particle inspection if required 11. Documentation 111 The heat treater shall submit the following infor- mation, AGMA 240.01 ~ October, 1972AGMA GEAR MATERIALS MANUAL 11.1.1 The surface hardness range obtained and the num- ‘11.1.3 The tempering temperature used. ber of pieces inspected 11.14 Results of magnetic particle inspection if specified. 11.12 The depth of hardening obtained at each location specified when destructive tests are required, and the umber of pieces checked a 3 HARDNESS - ROCKWELL ‘Cc! Fs $ + 3025 30 40 50 60 70 CARBON CONTENT- PER CENT FIG, 2-1 RECOMMENDED MAXIMUM SURFACE HARDNESS AND EFFECTIVE __ CASE DEPTH HARDNESS VS. PER CENT CARBON CONTENT OF STEEL FOR INDUCTION HARDENING3 we AGMA GEAR MATERIALS MANUAL SPIN INDUCTION HARDENING INDUCTION INDUCTION a Za — FROM THIS — To nin FLANK INDUCTION HARDENING Tal INDUCTOR | TO THIS FLANK AND ROOT HARDENING FROM THIS To THIS INDUCTOR, FROM THIS FIG. 2-2: VARIATIONS IN HARDENING PATTERNS OBTAINABLE ON GEAR TEETH +29. AGMA 240 01 — October, 1972AGMA GEAR MATERIALS MANUAL Section 3 Recommended Procedure for Carburized Industrial Gearing 1. Purpose 11 The purpose of this recommended procedure is to establish uniform prectices and procedures relating to the carburizing of carburized industrial gearing 2. Scope 2. This recommended procedure defines terms and recom mends specifications inchiding inspection techniques, pro- cedures, and suggests materials for carburized industrial searing, 3. Definition of Terms 3.1 Case Hardness 3.11 Case hardness is the surface hardness including the first 002 in. thickness of the working flank area at mid-working depth at mid-face width after carburizing, hardening, deep freezing (if used) and tempering 3.2 Core Hardness 321 Core hardness is the hardness obtained at the intersection of the root diameter and the centerline of the tooth at mid-face widih after all heat treatments are completed. 33 Case Depth 33.1 Case depth is the depth at which a hardness of 50 Re scale is obtained normal to the tooth surface at the mid-ooth height at mid-face width on a normal tooth section after completion of all of the heat treatments prior to any finishing operations 3.3.2 When stecls of high hardenability such as 4320, 18627, 4820, 9310 and 3310 are used for pitches of 12 and finer, the through hardening characteristics of the steel may prevent obtaining a hardness less than 50 Re scale across the tooth section. The case depth should then be deter- mined on a test bar. See paragraph 38. =30- 3.4 Case Carbon Content 3.4.1 The case carbon content is the carbon content of the outer 20 per cent of the case or the outer 005 in ‘whichever is less, 35 Decarburization 3541 Decarburization is a reduction in the surface carbon content of the outer 20 per cent or 005 in whichever is less, below the specified minimum carbon content when the specitied carbon content is present at greater depths below the surface 3.82 When all depths of the entire case is below the specified minimum carbon content the part has not been properly carburized. 3.6 Caso Microstructure 3.6.1 The case microstructure is the microstructure of the tooth portion at mid-working depth at mid-face width from the surface to the case depth (50 Rc) when viewed at a magnification of at least 400X. 3.7 Core Microstructure. 37.1 The core microstructure is the microstructure at the junction of the root diameter and the centerline of a tooth at mid-face width when viewed at a magnification of at least 400X. 38 Test Bar 381 A test bar is # piece of steel of the same analysis range as the patts it represents witich has been subjected to all heat treatments as the parts it represonts. Note: It is realized that it is impractical to quench a test bar in the same manner as parts which are press quenched. Suitable arrangements must be made for quenching the test bar so as to produce comparable results, 382 A test bar of 5/8 diameter by 2 in long shall be considered satisfactory for determining all metallurgical> Ww AGMA GEAR MATERIALS MANUAL properties of carburized gearing up to 2 DP. Core hardness and microstructure shall be determined at the center of the ar 38.21 For coarser pitches the test bar shall be as agreed upon It is recommended that the test bar diameter be equal to the inscribed diameter of the normal tooth thickness at mid-working depth at midface width 383 Where disagreement exists as to the properties obtained on the test bar and the parts, an actual part may be sectioned for checking conformance to specifications When it is impractical to obtain turnings or filings from the actual part for checking surface carbon content, the results of the test bar shall be acceptable 4. Metallurgical Inspection 4.1 Case Hardnoss, 41.1 Case hardness can be measured with standard Rock- well C or A scale, Rockwell superficial hardness, or ‘microhardness testers 41.1.1 When using Rockwell C or A scales on curved surfaces such as the round test bar, correction must be made for the curvature of the part. 412 Consideration must be given to the case depth relative to the depth of the impression made by the tester. ‘Low readings can be obtained when the indentor penetrates through or partially through the case 4.1.3 Microhardness tests are to be made on « mounted and polished cross-section at a depth of 002 below the surface 42 Core Hardness 42.1 Core hardness may be determined by any hardness tester giving due consideration to the size of the specimen 43 Case Depth, 4311 The case depth is to be determined on a mounted and polished specimen using 2 microhardness tester Hard- ross tests shall be made starting at .002 below the surface {o at least .010 beyond the depth at which 50 Re is obtained -31- 4.4 Case Carbon Content 44.1 Case carbon content is to be determined from the round test bar by taking tumings to a depth of 00S in. ‘The bar should be softened by heating to as high a tem- perature as possible below the lower critical temperature 44.1.1 The tumings must be free of sny extraneous carbonatious materials prior to analysis 45 Microstructure 45.1 The microstructure is to be determined on a normal section of the test bar or tooth, preferably mounted, which hhas been polished and etched following good metallurgical specimen preparation techniques. 5. Materials 5.1 The material selection is to be made by the desiga engineer 5.11 ‘The material is the primary factor in determining the core hardness 5.2 Approximate minimum core hardnesses which can be obtained from some typical carburizing grades of steel are as follows Grade Hardness Re min 1020 14 46201 20 3620H 25 9310H 32 3310H 35 9315H 37 52.1 The minimum core hardness may be increased for dismetral pitches greater than 12, and reduced for dia- -metral pitches less than 4, 6. Carburizing Procedure 641 The entire carburizing procedure must be performed and controlled in & manner to produce the results specified on the drawing specification or order AGMA 240.01 — October, 1972AGMA GEAR MATERIALS MANUAL 62 When the surface hardness is not obtained, and the surface carbon content is greater than the specified mini- mum carbon content, a deep freezing treatment may be applied to transform retained austenite. The parts must be subsequently temperéd at the specified tempering tempera ture 63 Parts which are cooled ptior to quenching must be ‘cooled in a manner to prevent decarburization and scaling, 64 Whon a surface carbon content range is specified, decarburization is not permitted, TAA The range on case depth should be 010 up to 2 case depth of 030 minimum; .020 to a case depth of 090 minimum, and 025 for deeper case depths Note: Recommended case depths are found in the appro- priate AGMA Standards for surface durability and strength Allowance should be made for tooth finishing operations 7.2 When additional control is requited the following ‘additional itoms may be specified in whole or part: 7, Specifications a. Tempering temporature range 71 The specification for carburized gearing shall include as > ees a minimum the following: a icoa emacs a. Material 2 Core microstructure ». Case depth range (see note) £, Deep freezing © Surface hardness — minimum & Areas to be free of carburizing Section 4 Recommended Procedure for Nitriding 1, Purpose LL The purpose of this recommended procedure is to provide information, means of specifying and inspection of nittided geating. 2. Scope 2.1 This recommended procedure covers the selection and processing of materials, hardnesses obtainable, and defini- tions and inspection of depth of hardening 3. Materials: 3.1 Steels containing chromium, vanadium, aluminum, and molybdenum, either singly or in combination, are required to form nitrides that are stable at nitriding temperatures. 32 Typical steels suitable for nitriding are 4140, 4150, 4340, the Nitrafoy steels and steels with chromium 232+ contents of 100 to 3.00 per cent. Higher chromium contents show a decreased case depth for the same nitriding time 4. Preliminary Processing, 4.1 Parts to be nitrided should be quenched and tempered ‘to produce an essentially tempered martensitic microstruc- ture fice of primary ferrite. Tempering above the nitriding temperature will reduce distortion or movement in nitrid- ing 4.1.1 Free ferrite in the microstructure produces a brittle case prone to spalling 42 Residual stresses in a part can be relieved during nitriding causing distortion of the part, Residual stresses ‘can be reduced by stross relieving at a temperature between the nitriding temperature and the temperature which will result in softening of the part below core hardness requirements. lime at stress relieving temperature should bbe one hour minimum per inch of section. @AGMA GEAR MATERIALS MANUAL 43 Nitriding over decarburized steel causes a brittle case may spall under load. Therefore, nitrided surfaces subject to stress should be free of decarburization. 44 Sharp comers or edges subjected to load should be removed to prevent possible chipping 45 Where it is desired to selectively nitride a part, the surfaces to be protected from nitriding can be plated with dense copper 0007 in, minimum thickness, tin plate .0003 to 0005 in. thick or by coating with propriatory paints for this purpose. 46 Nitrided parts will move in a consistent manner when all manufacturing phases and the nitriding process are held constant. The amount and direction of growth or move. ‘ment must be determined for each part 5.1 The nitriding process affects the rate of nitrogen absorption and the thickness of the white layer. $2 The variables in the process are the combination of ammonia dissociation and temperature, and time of ni- ‘tiding 53 A two stage nitriding process generally reduces the thickness of the white layer. The white layer thickness Is, also dependent upon the analysis of steel 6. Case Depth 61 The case depth is defined as the depth at which the case hardness and core hardness are equal as measured normal to the tooth surface at the mid-working depth at ‘mid-face width on a normal tooth section 62 The case depth is to be determined using a micto- hardness tester, At least three hardness tests must be made beyond the depth at which core hardnets is obtained to assure that the case depth has been reached 6.3 A test bar of 1/2 in, to 1 in. diameter by 3 x diameter, in length can be used for determining tho case depth of -33- nitrided parts. The test bar must be of the same analysis range and must be processed in the same manner as the parts it represents, 64 Sectioning of an actual part to determine case depth reed only be performed when the results of the test bar are cause for rejection, or the surface hardness of the parts do not agree within 3 Re points of the surface hardness of the test bar 7. Surface Hardness 7.1 The surface hardness obtainable is dependent upon the analysis of material used, the core hardness after nitriding, and the case depth. 7.2 Surface hardness must be measured by a superficial hardness tester or microhardness tester. 7.3 Approximate minimum hardnesses which can be ob- tained on selected materials are as follows. Minimum Surface ne Hardness Re Seale 4140 48 4150 48 4340 46 Nitraltoy 60 244 per cent Chrome 54 I percent Cr, 1 percent Mo 2 8. Specifications 81 Parts which are to be nitrided should specify the following: a. Material grade b. Preheat treatment ©. Minimum surface hardness 4. Minimum case depth ¢. Minimum thickness of white layer if required. £. Areas to be protected from nitriding if required AGMA 240.01 ~ October, 1972Number AGMA 110.03, AGMA 112.04 AGMA 115 01 AGMA 121.02 AGMA 123.01 AGMA 124 01 AGMA 201.02 AGMA 208 02 AGMA 209.03, AGMA 210.02 AGMA 211.02 AGMA 212.02 AGMA 220.02 AGMA 221.02 AGMA 222,02 AGMA 226.01 AGMA 230.01 AGMA 246.014 AGMA 250.03, AGMA 390.03, The user of this Standard (AGMA 240 01) may find these other AGMA Standards of value as reference data: Title Gear-Tooth Wear and Failure (ANSI B6 12-1964) ‘Terms, Definitions, Symbols, and Abbreviations Reference Information ~ Basic Gear Geometry Single-Thread Coatse-Pitch Hobs Maultiple-Thread Coarse-Pitch Hobs Wormgear Hobs 7 Tooth Proportions for Coarse-Pitch Involute Spur Gears (ANSI B6 1-1968) System for Straight Bevel Gears (ANSI BS 13-1965) ‘System for Spiral Boval Gears ‘Surface Durability (Pitting) of Spur Gear Teeth Surface Durability (Pitting) of Helical and Herringbone Geat Teeth ‘Surface Durability (Pitting) Formulas for Straight Bevel and Zerol Bevel Gear Teeth Rating the Strength of Spur Gear Teeth Rating the Strength of Helical and Herringbone Gear Teeth Rating the Strength of Stiaight Bevel and Zerol Bevel Gear Teeth Information Sheet — Geometry Factors for Determining the Strength of Spur, Helical, Herringbone and Bevel Gear Teeth ‘Surface Temper Inspection Process Recommended Procedure for Carburized Aerospace Gearing ‘Specification — Lubrication of Industeial Enclosed Gear Drives AGMA Gear Handbook — Volume I — Gear Classification, Materials and Measuring Methods fo: Unassembled Gears ‘A more complete list of AGMA Standards published by the American Gear Manufacturers Association is available upon request PusLisHeo ey AMERICAN GEAR MANUFACTURERS ASSOCIATION 1920 MASSACHUSETTS AVENUE. NVW, WASHINGTON, 0.C. 20008 PRICE $8.00 €