FAILURE INVESTIGATION AND OPTIMIZATION OF S.G.

IRON
SLEEVE YOKE SUBJECTED TO TORSIONAL LOAD
Vrajesh R Suvarna1, Nitin N Bhopale2 and Bharat J Chauhan1
1
Department of Metallurgical & Materials Engineering, The M.S. University of Baroda,
Vadodara, 2Mahindra Sona Ltd. (MSL), Satpur, Nashik
Address Details: 3-Krishna Colony, Nr. Swati Society, Navrangpura, Ahmedabad-380014
Contact Email ID: vrajeshrs@gmail.com Mobile: 9974306303
ABSTRACT:

The object of this project is to minimize the failure of Sleeve Yoke casting used in trucks where it is
subjected to torsional load. S.G. Iron 700/3 grade is the material used for this application. The
specification for this part is T.S. of 700 N/mm2, % Pearlite- min 75% and a min- 3% elongation. The
microstructure shall be of finely dispersed graphite nodules, surrounded by ferrite in a fine pearlitic
matrix. During the failure investigation of the Sleeve Yoke, it was observed that it had failed near the lug
region in most of the parts. The manufacturing process of Sleeve yoke was casting and machining
followed by welding of a Welch plug below the universal joint. The microstructure and hardness of the
failed parts were found to be satisfactory as per required specification.

INTRODUCTION:

Automobile transmission system consists of

several components which sometimes suffer
from different stresses (failures). Sleeve Yoke
assembly are one of the most important part in
propeller shaft. This Sleeve Yoke assembly is
always subjected to torsional load. Sleeve yoke
is a rotating part and sometimes suffers from
fatigue by the application of variable torque. In
this study, failure analysis and optimization of a
Sleeve Yoke of an automobile power
transmission system are carried out. The MOC
(material of construction) of Sleeve Yoke is S.G.
Iron 700/3 grade casting.

These Sleeve yoke castings as shown in figure

1, have failed in warranty period. These parts
are used in the propeller shaft of heavy duty
trucks for transmitting torque from transmission
end to rear end.

The object of this project is to investigate the

failure of Sleeve Yoke and improve its reliability.

Figure 1: Sleeve Yoke failed in warranty

1
Sleeve Yoke Function:
The Sleeve yoke is an important component of
any drive shaft assembly. The sleeve yoke
assembly is what allows drive shafts to flex or
slip with their given application. It’s main
function is to transmit torque while
reciprocating, from the transmission end to the
rear axle assembly. It provides a sliding action
to adjust for changes in the drive-length. The
Slip yoke is also essential for allowing u-joints
to rotate properly with the drive shaft.
Function of Drive Line Assembly:
In most land vehicles in use today, a driveshaft
assembly is provided for transmitting rotational
power from an output shaft of a transmission to
an input shaft of an axle assembly so as to
rotatably drive one or more wheels of the
vehicle. To accomplish this, a typical driveshaft
assembly is connected between the
transmission output shaft and the axle
assembly input shaft.
The ends of the driveshaft assembly are
connected to the output shaft of the
transmission and the input shaft of the axle
assembly by respective universal joints. Such
universal joints are well known in the art and
provide a rotational driving connection
therebetween, while accommodating a limited
amount of angular misalignment between the
rotational axes of the various shafts. Not only
must the drive shaft assembly accommodate a
limited amount of angular misalignment, but it
must also typically accommodate a limited
amount of axial movement between the
transmission output shaft and the axle
Figure 3: Drive-line assembly [6]
2
Figure 2: Sleeve Yoke [6]
assembly input shaft. A small amount of such
relative axial movement frequently occurs when
the vehicle is operated. To address this, it is
known to provide one or more slip yokes in the
drive shaft assembly.
A typical sleeve/slip yoke includes a generally
cylindrical barrel portion having a bore formed
therethrough with a female splined inner
surface. The female splined inner surface of the
barrel portion of the slip yoke cooperates with
the male splined outer surface of the
transmission output shaft to provide a rotatable
driving connection between the slip yoke and
the transmission output shaft, while allowing a
limited amount of relative axial movement
therebetween.
The slip yoke further includes a lug portion
comprising a pair of lug ears which extend from
the end of the barrel portion. The lug ears have
aligned openings formed therethrough that are
adapted to receive portions of the universal joint
therein.
Figure 4: Photo of Sleeve Yoke
assembly at rear end of drive shaft
EXPERIMENTAL WORK:

Hardness Test: Hardness Test was carried

out for 40 nos. of Sleeve Yoke Castings failed
in warranty. 6 269
Equipment: Brinell Hardness Tester 7 285
8 241
Load 3000 kg 10mm ball dia 9 229
10 217
A & B are two different suppliers of Sleeve yoke 11 241
Casting. Hardness specified range: 229-285
12 241
BHN. In some of the failed parts, supplier
couldn’t be identified (as shown in table 1c) due Table 1c: Hardness values of
failure of the casting near the lug where the failed parts (supplier unknown)
name of the casting supplier is cast. Hardness
measurement was carried out for 40 numbers of Supplier Not identified
broken/failed parts received from customer that
had failed in warranty. Sr No. Hardness observed:
1 285
Table 1a: Hardness values of
2 285
failed parts supplied by A
3 285
Supplier A 4 269
Hardness reqd. 229-285 BHN 5 285
Sr No. Hardness
6 269
observed:
1 285 7 269
2 229 8 269
3 285
9 285
4 285
5 241
6 269
7 241
8 255 HARDNESS OBSERVATION:
9 241
10 255 Except for 3 parts (no. 2, 3 and 10 supplied by
11 241 B), hardness for all parts is OK as per specified
12 285 range.
13 255
Hence from hardness test it is clear that
14 255
hardness was not the reason for the failure of
15 255
these castings for all suppliers.
16 269
17 241 No pattern was observed in the hardness
18 269 values of failed casting.
19 255

Table 1b: Hardness values of

TYPES OF FAILURE:
failed parts supplied by B
The sleeve yoke supplied by both A & B have
Supplier B failed in different patterns. They are:
Sr No. Hardness
observed: Failure Type 1: In failure type 1, single lug is
1 269 broken. The bright and sparkling surface shows
2 207 a brittle mode of fracture.
3 302
4 285
5 285
3

Figure 5: Failure Type 1
Failure Type 2: In failure type 2 there is a
crack in one of the lugs near the cross-hole or a
part of the lug is broken. This type of failure is
also called ear failure.
Figure 6: Failure Type 2
Failure Type 3: In failure type 3, both the lugs
are OK. They are not damaged, but the part
might have failed due to the failure of bearing
cup (its mating component).
Figure 7: Failure Type 3
4
Failure Type 4: In Failure type 4, both the lugs
are broken. In most of the parts the name of the
supplier cannot be identified. The bright and
sparkling fracture surfaces of the failed parts
are signs of brittle fracture.
Figure 8: Failure Type 4
Failure Type 5: In Failure type 5, no fracture
observed near the lugs. Bore of the sleeve yoke
has failed.
Figure 9: Failure Type 5
Visual Observation:
Most of the failed parts were visually observed
after a certain period of time after its failure.
Hence the fracture surfaces were not clear due
to the presence of dust, oil and grease.
Amongst all the failed parts, type 1 and type 4
fracture pattern was observed repeatedly. Out
of 40 failed parts, 10 nos. had type 1 fracture
and 14 nos. had type 4 fracture.
MICROSTRUCTURE EXAMINATION:
Microstructure comparison between failed part
and OK part is shown below at 100X
magnification.
Equipment used: OLYMPUS
MICROSCOPE & METAL POWER
ANALYTICAL IMAGE-ANALYSER
Microstructure for Failed Part Sr No. 2 Etched sample for phase analysis,
(B): microstructure found OK with 79% pearlite and
21% ferrite.
As polished, un-etched sample microstructure
found OK with nodularity 87% as shown in
figure below.

Figure 13: Etched micro-structure of

OK part at 100X mag.
Figure 10: Un-etched micro-structure
of failed part at 100X mag. Observation based on micro-structure:
Etched sample for phase analysis, Pearlite content of failed part is higher
microstructure found OK with 91% pearlite and compared to OK part. Nodularity and Nodule
9% ferrite. count found to be satisfactory as per
specification.

CHANGE OF MATERIAL GRADE TO S.G.

600/3:

Figure 11: Etched micro-structure of

failed part at 100X mag.

Microstructure for OK Part Sr No. 4

(LP):
As polished, un-etched sample microstructure
having nodularity 85% as shown in figure below.

Figure 14a: Part No. 4(A)

Figure 12: Un-etched micro-

Figure 14b: Bearing cup and
structure of Ok part at 100X mag.
Journal Cross of Part no. 4(A)

5
Part No. 4 (A) failed due to the breakage of TORSIONAL FATIGUE TEST:
bearing cup. The Sleeve Yoke was found to be
OK. The microstructure of this OK part was
compared with failed parts. As observed in
microstructure of failed sample, pearlite content
is on the higher side as compared to OK parts.
This increases the hardness of the part, but the
elongation is decreased. Hence the impact
properties of S.G. Iron is affected. An OK part of
S.G. iron casting has a bull’s eye
microstructure.
Figure 16 Torsional Fatigue Test

As shown in figure, torsional fatigue test is

performed on two Sleeve Yoke Castings of
600/3 grade to check for durability and fatigue
strength of new grade.

Figure 15: Bull’s eye microstructure [2] Table 3: Result of Torsional Fatigue Test

In a typical Bull’s eye structure, an envelope of Test No. 1 2

ferrite surrounds the graphite nodules. Set Torque +/- 4950 Nm +/- 4950 Nm
Both the graphite nodules and their ferrite Required No. 1,00,000 1,00,000
envelops are embedded in a pearlitic matrix. of Cycles
Cycles 94,005 84,624
The crack propogation energy is found to
increase with an increase in the ferrite volume Completed
fraction.

Thus allowing a thick ferrite ring while retaining As shown in table no. 3 Sleeve Yoke Casting
a pearlitic microstructure may produce a S.G. failed to meet test requirement.
Iron, which is able to combine a strength and
ductility and thus toughness.

Hence based on this observation, a trial batch

of S.G. Iron 600/3 Sleeve Yoke was made and
tested at R&D for torsional fatigue test.

Table 2: Comparison of S.G.

Iron grade: 600/3 & 700/3
Figure 17: Sleeve Yoke 1 & 2
Material Old New failed in torsional fatigue test
properties of: Grade: Grade: SG
SG 700/3 600/3
EDS ANALYSIS ON FRACTURE
Tensile 700 600
Strength N/mm2 N/mm2 SURFACE:
Elongation 3% 3% As shown in figure and table below, EDS
Hardness 229-285 197-269 Analysis is performed on fractured surface of
failed Sleeve Yoke.
Micro- 75% min. 60% min.
structure pearlitic pearlitic

6
 Figure 19: SEM Images on
Figure 18: EDS Analysis on fracture fracture surface (mag. 52X to
surface 500X)
Table 4: EDS Analysis result
Observation from SEM:
Elements Wt. (%)
Carbon 40.58 Figure 19a: low magnification view of crack
Oxygen 15.44 surface showing micro cracks and porosities on
Sodium 0.58 relatively rough fracture surface.
Magnesium 1.07
Figure 19b: shows higher magnification view of
Aluminium 2.03
crack surface showing quasi-cleavage fracture.
Silicon 5.00
Sulphur 0.67 CHEMICAL COMPOSITION:
Chlorine 0.50
Potassium 0.41 Table 5: Chemical Composition by wet analysis
Calcium 1.03
Iron 32.70 Part OK Parts FAILED Parts
Observation from EDS result: No.
C 3.220 3.570 3.080 3.501
 EDS ANALYSIS was performed on Si 2.600 1.982 2.500 2.080
fracture surface of Sleeve Yoke S 0.008 0.086 0.011 0.092
 High content of Carbon> Iron> Oxygen P 0.045 0.096 0.040 0.050
 Oxygen content indicates formation of Mn 0.240 0.321 0.330 0.261
oxides. Cu 0.900 0.724 0.970 0.982

SCANNING ELECTRON MICROSCOPE: Result: Chemical Composition found to be

INSTRUMENT UTILIZED: PEMTRON MAKE as per specification
SS-100

TENSILE TEST REPORT:

Table 6: Tensile Test for OK Parts

Table: Tensile Test for Failed Parts SAMPLE ID UTS N/mm2 Elongation,
%
NDPL-11 718 5.3
NDPL-10 685 3.93
LP-2 820 6.87
LP-17 775 6.93
LP-4 893 5.37

7
 Table 7: Tensile Test for Failed Parts Exploded graphite is normally found in thicker
section castings with slow cooling rates or at
SAMPLE ID UTS Elongation, very high carbon equivalent (C.E.) levels. It is
N/mm2 % also caused by excess rare earth additions,
LP-11 734 3.27 particularly when high purity charges are used.
LP-8 872 3.97
U-1 777 2.97 GRAPHITE FLOATATION MICRO:
LP-12 835 5.6
LP-13 701 2.9 This is caused when large, low density graphite
nodules are formed during the solidification of
thick section or otherwise slow cooling castings.
Observation from Tensile Test: Tensile
Readings are also as per specified grade 700/3 The nodules, being of a lower density than the
matrix, tend to float towards the surface of the
casting and thus can have a negative effect on
the mechanical properties (and surface finish) in
RESULTS AND DISCUSSION: that region.
EXPLODED GRAPHITE MICRO: Near the top surface of casting

Exploded Graphite Micro-structure was

observed at some locations in the Sleeve Yoke.

Graphite degeneracy such as exploded

graphite appears as precipitates where the
nodular form is replaced by star-like or flower-
like shape.

Figure shows exploded graphite micro-structure Figure 21: Floatation of graphite

observed at 100X magnification. micro-structure

Exploded Graphite As shown in figure, graphite floatation micro-

structure is observed only at the top portion of
the casting. Hence the microstructure of these
failed parts indicate high carbon equivalent,
which is one of the causes for failure of the
Sleeve yoke.

Location of micro (top)

Figure 20: Exploded graphite micro-

structure Parting line (center)
Figure 22: Failed Sleeve Yoke with
Exploded Graphite microstructure was
observed at one particular side of the Sleeve graphite floatation
Yoke. Micro-structure at other locations did not
have exploded graphite. Hence the Carbon content in these Castings is
very high, not as per section thickness of the
casting.

8
Guideline to Carbon and Silicon Levels:
As shown in figure, total C plus 1/3 Si should
not exceed 4.55, to avoid graphite floatation.
Carbon and Silicon values must be as per
section thickness of Casting as given in Table
No. 8.
A welch plug or other sealing device is
provided to close the end of the bore
adjacent to the lug portion. The Welch plug
prevents the entry of dirt, water, and other
contaminants into the region where the
splined members engage one another. The
Welch plug is pressed into the hub end of
the slip yoke bore and retained in place by
welding, staking, threading or snap-type
fitting. Figure No. 24 shows a Welch plug
made of low carbon steel welded to Sleeve
Yoke Casting by CO2 welding process.

Micro-structure near HAZ:

A small sample near the Heat affected zone
(HAZ) was cut and polished, for checking
the micro-structure.

HAZ
Figure 23: Typical Carbon and Silicon
Ranges for S.G. Iron Castings [5]
𝐒𝐢
𝐓. 𝐂. + ≤ 𝟒. 𝟓𝟓%
𝟑

Figure 25: Specimen in as

𝐒𝐢
𝐓. 𝐂. + ≥ 𝟑. 𝟗% mounted condition in longitudinal
𝟕 section
Table 8: Ideal Composition for SGI 700/3 Figure 26 shows the micro-structure near
grade as per section thickness [5] heat affected zone (HAZ).

Overall Thickness: mm
12 25 50 100 150
C 3.7 3.6 3.45 3.4 3.3
Si 2.45 2.35 2.25 2.15 2
Mn max. 0.25 0.3 0.3 0.3 0.3
Cu max. 0.8 1 1.2 1.4 1.6

WELDING OF WELCH PLUG:

Figure 24: Welding of Welch

Plug
Figure 26: Micro-structure near HAZ

9

Observation from Micro-structure:
Micro-structure photographs of etched sample
upto 200X magnification are as shown in fig. no.
26. Micro-structure near HAZ clearly indicates
presence of carbides and martensite.
When S.G. Iron castings are repaired or joined
by fusion welding their high carbon content can
cause the formation of carbides in the fusion
zone (FZ) and martensite in both the FZ and
heat affected zone (HAZ) adjacent to the FZ.
The formation of hard brittle phases in the FZ
and HAZ can cause a significant deterioration in
both machinability and mechanical properties.
Hence Sleeve Yoke Castings are not suitable to
Welding Process.
MICRO-HARDNESS TEST:
Figure 27: Micro-hardness reading
Micro-hardness Test was performed near HAZ
of micro sample.
Hardness values near HAZ was 860 hv
because of the presence of carbides and
martensite.
Modification of Welch Plug:
To avoid the serious defects caused due to
welding of Welch Plug, this welch plug was
replaced by snap type welch plug. As shown in
figure no. 28, Welch Plug made of Spring Steel
is pressed into a groove provided on the Sleeve
Yoke.
10
Figure 28: New Snap Type Welch
Plug
CONCLUSION:
Exploded graphite and graphite floatation
micro-structure indicates high carbon. This
affects the impact strength of the casting,
making the parts more brittle.
Welding of welch plug on sleeve yoke forms
hard and brittle phases like carbide and
martensite near fusion zone(FZ) and heat
affected zone(HAZ), which initiates cracks in
the casting.
RECOMMENDATIONS:
Modification of carbon addition in the charge, by
using correct C.E. value depending on the
section thickness of the casting as discussed in
Table no. 8.
Welding process of welch plug should be
replaced by snap-type fitting process to avoid
the formation of brittle phases like carbides and
martensite due to welding.
LIST OF REFERENCES:
[1] ASM Handbook vol-9 Metallography and
Microstructures
[2] ASM Handbook vol-15 Casting
[3] ASM Handbook vol-1 Properties and
Selection: Irons, Steels, and High Performance
Alloys
[4] Research paper IRJET Volume: 02 Issue:07-
03-15: “Failure analysis and Optimization of
Universal Joint Yoke subjected by Torsion and
Shear” by Avinash C Vasekar, Ranjitsinha R.
Gidde.
[5] S.G. Iron Technology Production Practices &
Applications, 3rd edition, Jan 2010 by
N.Ramamurthi, Kastwel Foundries
[6] Research Paper IRJET Volume:03 Issue:10
Ovt-2016 “Failure Analysis of Yoke Joint
Assembly” by Mr. Anuj A. Muley, Dr. M. J.
Sheikh, Dr. G. V. Thakre.