Heat Treatment Methods for Cast and Forged Crane Wheels

AIST Crane Symposium September 2008

Presented By: Frank Petrek Xtek, Inc Cincinnati, Ohio USA Plzen, Czech Republic

Crane Wheel Failure Modes

Tread Diameter Spalling Tread Diameter Wear Flange Fracture Flange Wear

Objective is to manufacture a wheel that satisfies all 4 potential failures

Solution for Tread Diameter Spalling

Support Vertical Loading Material Strength
Mechanical Properties

Depth of Hardness
Diameter of Wheel Width of Rail Head

Objective is to avoid sub-surface shear failure

Solution for Tread Diameter Wear

Wheel Slides While Rolling Interface Requires Traction
No Lubrication

High Surface Hardness Depth of Hardness

Objective is to Resist Adhesive Wear

Solution for Flange Fracture

Stress Concentration in Transition from Tread to Flange Avoid Stress Riser
Smooth / Gentle Radius No Metallurgical Notch

Material Strength
Mechanical Properties

Depth of Hardness with Soft Core

Objective is to avoid formation of a surface crack that will propagate through fatigue

Solution for Flange Wear

Inside of Flange Slides On Side of Rail Head Ideal Interface has Lubrication
Lubrication Sticks

Metallurgical Solution
High Surface Hardness Depth of Hardness Without Through Hardening the Flange

Objective is to Resist Adhesive Wear

Heat Treatment Methods for Cast and Forged Crane Wheels

Cast steel Common Steel Grades Normalize and Temper Immersion Quench Rim Quench Flame/Induction Harden Selective Quench (Contour Harden) Surface Hardness BHN Surface Hardness HRc 220 X
42CrMo4 AISI 4140 42CrMo4 AISI 4140 42CrMo4 AISI 4140 AISI 4140

Forged steel
42CrMo4 ASTM A504 42CrMo4 AISI 4140 AISI 1055 AISI 1070

X X

X X X X

280 - 320 450 - 500 45 - 50

220

321 - 363 450 - 500 627 - 682 45 - 50 58 - 62

Immersion Quenching
General Heat Treatment to All Surfaces No Customized Properties Introduced into the Rim Surface Hardness and Hardness Depth Depend on Grade of Steel and Quench Medium

Rim Toughening
Process Derived From Railroads Material ASTM A504 Class C
Identical to Railroad Standard

Entire Wheel Heated Then Water Spray Quenched While Rotating Relatively Low Surface Hardness Good Toughness in Flanges Very Good Core Properties

Spin Hardening
Selective Heating
Flame Heating Induction Heating

Lowered into Quench While Rotation Continues Wide Variety of Steels Can Develop Significant Tread Hardness Depths Flange Properties Depend on Heating Controls

Contour (Case) Hardening

Controlled Atmosphere Furnace Heating
No Oxygen

Quenches Only Selected Surfaces Not a Carburized Process Optimizes High Surface Hardness for Wear With Tread Hardness Depth and Ductile Flange Core
Ideal Heavy Loads Ideal for High Cycle Cranes

Cast Wheel Heat Treatments

Normalize and Temper Immersion Quench Spin Harden
Flame Heat Or Induction Heat Lower into Quench While Rotation Continues

Forged Wheel Heat Treatments

Normalize and Temper Immersion Quench Rim Toughening Spin Harden
Flame Heat Or Induction Heat Lower into Quench While Rotating

Contour (Case) Hardening

Comparison of Heat Treatments Hardness Depths at Middle of Ranges

700

Brinell Hardness (BHN)

600 500 400 300 200 100 0

0.0 1.6 3.2 4.8 6.4 9.0 9.5 11.1 12.7

Depth Below Surface (mm)

ASTM A504 Class C (321 - 363 BHN) CONTOUR HARDENED (56-62 HRc) AISI 4140 (450-500 BHN) AISI 4140 Normalized (220 BHN)

ASTM A504 Class C Heat Treatment Hardness Depths versus AIST TR #6

400 350 300 250 200 150 100 50 0
0.0 1.6 3.2 4.8

Brinell Hardness (BHN)

286

267

6.4

9.0

9.5

11.1

12.7

14.3

Depth Below Surface (mm)

ASTM A504 Max Shear Depth (AIST TR#6 - 914 mm Dia.) ASTM A504 Max Shear Depth x 1.5 (AIST TR#6 - 914 mm Dia.) ASTM A504 Class C (321 - 363 BHN)

Comparison of Heat Treatments Contour Hardened and AISI 4140 Hardness Depths
700 600 500 400 300 200 100 0
0.0 1.6 3.2 4.8

Brinell Hardness (BHN)

338

315

6.4

9.0

9.5

11.1

12.7

14.3

Depth Below Surface (mm)

Contour Hardened Max Shear Depth (AIST TR#6 - 914 mm Dia.) Contour Hardened Max Shear Depth x 1.5 (AIST TR#6 - 914 mm Dia.) AISI 4140 (450-500 BHN) CONTOUR HARDENED (56-62 HRc)

Heat Treatment Methods for Cast and Forged Crane Wheels

Cast steel Common Steel Grades Normalize and Temper Immersion Quench Rim Quench Flame/Induction Harden Selective Quench (Contour Harden) Surface Hardness BHN Surface Hardness HRc 220 X
42CrMo4 AISI 4140 42CrMo4 AISI 4140 42CrMo4 AISI 4140 AISI 4140

Forged steel
42CrMo4 ASTM A504 42CrMo4 AISI 4140 AISI 1055 AISI 1070

X X

Users Objective: Match Material & Heat Treatment with the Crane Application

X X X X

280 - 320 450 - 500 45 - 50

220

321 - 363 450 - 500 627 - 682 45 - 50 58 - 62

700

Brinell Hardness (BHN)

600 500 400 300 200 100 0

0.0 1.6 3.2 4.8 6.4 9.0 9.5 11.1 12.7

Depth Below Surface (mm)

Heat Treatment Methods for Cast and Forged Crane Wheels

AIST Crane Symposium September 2008 Thank You for Your Attention!
Presented By: Frank Petrek Xtek, Inc Cincinnati, Ohio USA Plzen, Czech Republic