Metallurgical analysis of handling tool lifting eye weldment and surface crack formatio

Sands, R. R.

English

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THE m ! f l / w i  - COMPANY 
LAUNCH SYSTEMS BRANCH 
AERO -SP ACE DTv I Si o N 
DOCUMENT NO. T5-6539-81 
VOLUME -OF., 
TITLE “ T A L L U R G I C A L  A N A L Y S I S  OF, H A N D L I N G  MOL, FORWARD BOOSTER 
A S S E M B U Y  L I F T I N G  ETE, F. T. 370-7-Oi+0-2-5 .. 
MODEL NO. S A T  V/3-K CONTRACT NO. N A S 8 - 5 6 0 8  , 
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ISSUE NO. .- ISSUED. TO 
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APPROVED 
AP P ROV ED 
APPROVED 
APPROVED 
BY 
BY 
BY 
BY 
T. J. Kornell 
,/ 
REV. SYM.,- 
S-406- 10-5 R E V .  7 /64  
https://ntrs.nasa.gov/search.jsp?R=19670018181 2020-03-12T11:39:08+00:00Z
Bomw 
R. D. Strohl 
S. J. LuBlaac,  Jr. 
J. S. Hemurdez 
J. J. Eckle 
W. J. Wugh 
R .  A. Morehouse 
E. Tuseth 
R .  R .  Sand8 
NASA 
R. McDaniel 
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Distribution 
5-731.2 
5-7474 
5-7474 
5-7470 
5-7400 
5-7351 
5-73 50 
5-7996 
R-P&VELVNR 
F. Uptagrafft R-P&V"E 
Scientific and Technical Information Facility 
Marshall Space Flight Cmter 
H~nt8Vi1.18, Alabama (Attn: MSIlP) 
Scientific and Technical Information Facility 
P. 0. Box 33 
College Park, Maryland 20740 
a 
u-99 
LT-39 (2) 
LT-3 9 
LT-47 
LS-76 
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LT-26 
Ls181 (2) 
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DESCRIPTION 
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ABSTRACT 
The lifting eye we’ldment after proof load testing showed repeated 
presence of cracks. The Inetallurgical test revealed stremgth below 
drawing requirements and decarburization on top and bottom surfaces 
of the tool. 
i n  present conditions, nmgnaflux inspection should be perfomed after 
each mading and any c r u c h  remo~eti, 
It was recoaended that ,  i f  the part i s  to be used 
KEY WORDS 
Decarburization 
Hardenability 
1 .o 
2.0 
3.0 
4.0 
5.0 
TABLE OF CONTENTS 
Distribution 
Change R e c r o d  
Revision 
Abstract 
Table of Contents 
List of Figures 
Object 
Background 
Cone lusions 
Recommdations 
Procedures 6. Results 
ii 
iii 
i v  
V 
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vii 
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v i  I 
LIST OF FIGURES 
7 
SUBJECT 
Photos Showing Decarburired Condition 
Tabulation of Hardness Survey 
PAGE 
3 
4 
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1.0 
2.0 
3 . 0  
I+. 0 
5.0 
The l i f t i n g  e p  weldraent was delivered t o  t h e  W 8 P laboratory f o r  
indicated by t h e  s t r e s s  unit: A 1. 
Metallurgical Anal pis.  w a s  removed froa a wBb area 
hole was left  i n  the  Webb. 
To determine metal1ur@.cat condition of l i f t i n g  eye w e l d m m t  and 
possible cause of numemud cracks. 
BACKGROUND 
The l i f t i n g  eye weldmont a f t e r  proof load t e s t ing  has been found 
part, showed no cracks on the  IID" and llF1f vehicle too l  but crack8 
were fo& on 501. 
depth of less t h a n  .10 inch. 
and t h e  repeated presence of' cracks i n  other  e f f ec t iv i ty  tools, it 
waa determined t o  evaluate t h e  nmterial of the  tool. 
----I- 4 -----& - a - m P l * * v  inrnwtinn ~f the to contain surraca ua-mbrn-. n 1 O b u . . w  _____  
These cracks were removed by grinding t o  a 
As a re su l t  of the  above findings 
CONCLUSIONS 
1) The general. weakness of t h e  4130 plate due t o  surface laps and 
.010"depth of 100% decarburization is d i r e c t l y  related t o  t h e  
surface cracking of t h e  par t .  
2) The material w a s  90% below drawing strength roquireaents due 
t o  the inherant low hardemability of the  4130 steel plate .  
RECOWDAT IONS 
1) If part is t o  be used i n  t h e  present condition magnaflux in- 
spection should bo performad after each loading and any re- 
su l t an t  crack8 should be removed t o  preclude multiple loading 
propagation. 
t o  qualify t h e  part f o r  function. 
Any rework d a m  on the  part should be reviewed 
2) If the part is t o  be :empp+c! all new parts should use t he  
following material procurement and hea t  treatment processing 
drawing cal louts .  
a )  
b )  
AIS1 4335 Uod. Stee l  Plate per A S  6434 
Heat treat assembly t o  125-145 kai per BAC 5617.- 
docarburiration on any surface .003 inch. 
PROCEDURES AND RESULTS 
. 
5.0 PROCEbURlGS AND RBSULTS (Continued) 
A spectrographic 8n8lpir and a carbon analysis run on part of 
the sample , idsn t i f id  the  material a8 4130 stool. 
The metallographic s t ruc ture  and a SOOg DPH hardno88 survey 
(Figure #2) showed 100% decarburization .01O1l deep (Figure # l )  
an t he  top  and bottom surface while t h e  top surface showed partial 
aecsriburiraicion anoi'ner .oi2 io .CL~!! G-pei.. 
Figure #1 shows a lap  i n  t h e  decarburised surface.  
defect could be inherent in the  as received p l a t e  o r  could be 
induced by surface impact. 
This type of 
The crack as shown could propagate catastrophical ly  o r  i n  a fa t igue  
manner and therefore should be removed p r io r  t o  loading of the part. 
lOOX 
Top Surface Cross Section 
Note Seam In Decarburized Surface 
l o o X  
Top Surface Cross Section 
Note Depth of 10% Decarburization 
And Par t ia l  Decarburization 
1. oox 
Rottoru Surface Cr ss Section 
Figure 81 
, . 
DIAMOND PYRAMID HARDNESS LOAD OW. 
Rb- _--_ -__- ----_ L2 FfLAR DP" Rc - INCH= L1 __--  c__ ---_--__----- 
-- - -__ -- 
- -  -- w--__---- -  TOP OF SAMPLE -- - - - - ------ -- - 02 
-006 359--3a--- 360 - 92 
- 98 
162- -__I_- - - - 403 zs- 400 
203 
*003 -- 
196 90 .009 363 368 366 
347 95 
.012 334 332 333 
.015 345 346 220 
.018 330 328 329 243 21.5 99 
.021 332 328 330 241 21.0 98 
.200 328 327 327 245 22.0 99 
.400 330 33 1 330 242 21.0 98 
332 338 33 5 23 2 19.0 97 
. 3 18 330 324 251 23.0 100 
.400 334 338 336 23 1 19.0 97 
101 
25.0 101 
.200 315 
.021 3 18 314 3 16 264 
102 .018 315 314 314 267 25.5 
243 21.5 98 
376 88 
.015 327 332 329 
,012 381 378 184 
412 416 152 79 
137 
.009 . 439 74 
414 80 
452 426 
.003 413 154 
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- 
237 - 
315 315 265 25.0 
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BOTTOM _-- OF S A W U  
P i y n  #a 


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