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MSEE2017 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 301 (2018) 012042 doi:10.1088/1757-899X/301/1/012042
1234567890‘’“”

Failure Analysis of JL466Q Crankshaft

Xiaodan Zhang, Nan Li, Zhiqiang Luo, Xiaoxiao Pang and Jikang Li
Central Iron and Steel Research Institute, College South road 76th. Haidian District,
Beijing, China.
Email: zhangxiaodan@nercast.com

Abstract. Failure analysis of JL466Q crankshaft has been done through the chemical
component analysis, mechanical properties testing, macrographic examination and
microstructure analysis. The results show that crankshaft cracking is formed by quenching
stress.

1. Introduction
The materials of cracked crankshaft were 40Cr steel. 40Cr steel is one of the most widely used steel in
machinery manufacturing [1]. The work flow was raw materials, forging, normalizing, shot, flaw
detection, rough machining, and quenching, tempering, machining and finished product. After a
crankcase production process it was assembled to the engine and began test. Then it spilled oil and the
crankshaft is longitudinal cracked. The macrophotos of crankshaft were shown in figure1.

Figure 1. Macrophotos of crankshaft (a) integral view (b) partial view

2. Test Results and Analysis

2.1. Chemical Analysis

A sample taken from crankshaft was analyzed see Table 1. It is 40Cr steel. The chemical
composition meets requirement.

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MSEE2017 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 301 (2018) 012042 doi:10.1088/1757-899X/301/1/012042
1234567890‘’“”

Table 1. Chemical composition of the crankshaft (wt, %)

C Si Mn P S Cr Ni Cu Mo
Crankshaft 0.39 0.27 0.75 0.013 0.017 1.03 0.025 0.074 0.0061
GB /T 0.37- 0.17-
0.5-0.8 ≤0.025 ≤0.025 0.8-1.1 ≤0.30 ≤0.25 ≤0.1
3077 0.44 0.37

2.2. Fractography Analysis

2.2.1 Macroscopic appearance. Break apart from the cracked place, the macroscopic appearance was
shown in figure 2. The fracture surface was flush, and there was no plastic deformation, so it was
identified brittle fracture. It could be seen that the fracture is black because of the crankshaft oxidized
when the tempering process.

Figure 2. Macrophotos of fracture

2.2.2 Microscopic appearance. Using scanning electron microscope investigated the microscopic
appearance of fracture, as shown in figure 3 to figure 5. The fracture original surface was covered by a
large area of oxide layer. It could be observed crystallographic features, but the morphology of grain
was blunt. After pickling the crystallographic features were more obvious.

Figure 3. Microphotos of original fracture

2
MSEE2017 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 301 (2018) 012042 doi:10.1088/1757-899X/301/1/012042
1234567890‘’“”

Figure 4. Energy spectrum analysis of original fracture

Figure 5. Microphotos of fracture (after pickling)

2.3. Metallography Investigation

Using metallographic microscope investigated the microstructure of crankshaft, as shown in figure 6
to figure 7. The microstructure of crankshaft in intact section and cracking section were all tempered
sorbite. It could find no abnormal microstructure. The cracks on both sides had no decarburization and
branch.

Figure 6. Microstructure of crankshaft (intact section)

3
MSEE2017 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 301 (2018) 012042 doi:10.1088/1757-899X/301/1/012042
1234567890‘’“”

Figure 7. Microstructure of crankshaft (cracking section)

3. Discussion
Analyzing the cracked crankshaft comprehensively, it could find that the microstructure of crankshaft
in intact section and cracking section were all tempered sorbite. The cracks on both sides had no
decarburization and branch. The fracture had no plastic deformation. It could be observed
crystallographic features. All of these results were in line with quench crack characteristics. The
fracture surface was oxidized because that the cracks should not be occurred during the tempering
process.
In the quenching process, austenite transfers to martensite. Due to the martensitic transformation is
non-proliferation of shear-type transformation, the crystal orientation and specific volume between
new and old are different. There is a large internal stress during the quenching. Martensite is hard and
it is difficult to eliminate stress by plastic deformation. So adjacent grains cause stress concentration at
grain boundaries, expand into grain boundary cracks with the effect of quenching stress.

4. Conclusion
(1) Chemical analysis results show that the chemical composition meets the requirements.
(2) The microstructure of crankshaft in intact section and cracking section were all tempered
sorbite. It could find no abnormal microstructure. The cracks on both sides had no decarburization and
branch.
(3) The fracture was oxidized when the tempering process and showed crystallographic features.
(4) According to a comprehensive analysis, the cracks formed by quenching stress.

5. Acknowledgments
I would like to express my gratitude to all those who helped me during the writing of this article. I
gratefully acknowledge the help of my colleague, Ms. Li, who has offered me valuable suggestions in
the studies.

6. References
[1] Wang C, Zhao M and Wang D Analysis of an unusual crankshaft failure 2005 J. Eng. Fail. Anal.
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