PFANF8 (2002) 4:77-80 © ASM International

Hydrogen Induced Cracking of a Tappet Adjusting Screw

B.V. Krishna
(Submitted 27 March 2002; in revised form 28 May 2002)
The electroplated tappet adjusting screws used in diesel engines failed during initial bend testing. The
analysis of the failure showed that the fracture was nucleated from the subsurface of the screw. The fracture
surface was intergranular at the ID and OD region and microvoid coalesence in the center. The improper
baking after electroplating of the screw led to H2-induced blistering/cracking. The high strength of the
threaded region of the adjusting screw increased the failure propensity.

Keywords: electroplating, failure analysis, hydrogen damage, hydrogen embrittlement, hydrogen induced cracking

Background The Analysis

The failed tappet adjusting screws evaluated in Visual inspection of the fracture surface revealed
this analysis are for use in diesel engines. As the a dull and grainy fracture (Fig. 2a). The fracture
name suggests, the screws are used to adjust the surface also revealed some transition/difference in
tappet. These screws were cracking during the initial fracture surface gray level/shade on moving from the
bend testing required to qualify the screws for ID or OD toward the center of the screw. The general
service. The screws were manufactured from features of the fracture show that the fracture initi-
16MnCr5 steel as per DIN: 17210. The manufac-
tured screws were case carburized to increase the
wear resistance in the top/cup portion of the screw
(Fig. 1). After carburizing, the screws were electro-
plated with copper to a thickness of 8-10 µm. The
electroplated tappet adjusting screws failed during
5° bend tests required for qualification.
The details of screw specification are as follows:
Material: 16MnCr5 steel as per DIN: 17210
Composition: C-0.14-0.19%, Si-0.15-0.40%,
Mn-1.0-1.3%, P&S-0.035% max, Cr-0.8-1.1%
Mechanical Properties: Core Strength – 1000-
1200 MPa
Core hardness – 310-370 HV
Surface hardness in cup portion – 600-750 HV
Case depth – 0.15-0.20 mm

Fig. 2 Stereomicrographs of failed screws showing (a) dull and

Fig. 1 Schematic diagram of the tapped adjusting screw gray fracture surface, (b) Different gray levels demon-
showing various portions strating the different fracture modes in different regions

B.V. Krishna, Materials Science & Technology Division, Thapar Centre for Industrial Research and Development, Thapar Technology
Campus, P.O. Box 68, Bhadson Road, Patiala 147 001, Punjab, India. Contact e-mail: vamsi23@yahoo.com.

Practical Failure Analysis Volume 2(4) August 2002 77

 Hydrogen Induced Cracking of a Tappet Adjusting Screw
ated from the subsurface of the screw. The transition
from brittle to somewhat ductile is observed in ster-
eomicrographs of the sample (Fig. 2b).
The scanning electron microscopy (SEM) of the
fracture surface showed that fractures on both the
ID and OD of the screw differed from fractures at
Fig. 3 SEM micrographs of the fracture surface showing (a)
different types of fractures in different regions, (b) fracture
origin at the subsurface of the screw
Fig. 4 SEM micrographs of the fracture surface near ID
showing the transition from intergranular fracture to
microvoid coalescence.
78 Volume 2(4) August 2002
(continued)
the interior. The changes in the fracture mode were
from brittle at both surfaces to ductile in the center
(Fig. 3). The fracture apparently nucleated near the
subsurface of the screw as evidenced by the “lip”
seen in Fig. 3b. This type of nucleation is typical
for H2-induced cracking/blistering in electroplated
Fig. 5 SEM micrograph showing peeled off copper plating due
to hydrogen effusion
Fig. 6 SEM micrographs of the fracture surface showing (a)
brittle intergranular fracture near OD/ID, (b) dimple
fracture surface in the center
Practical Failure Analysis
carbon and low alloy steels. Observation of the
fracture surface at high magnification near the ID
clearly demonstrates the transition in the fracture
mode (Fig. 4). The region of brittle fracture is
attributed to hydrogen embrittlement due to
hydrogen uptake during plating and pickling. This
dissolved hydrogen diffused into the metal and
precipitated at the internal defects, inclusions,
interfaces, etc., and formed as nascent hydrogen. This
precipitation led to the formation of blisters and
the cracks (Fig. 4) in the metal, and pores in the
copper plating and also the peeling off of the plating
(Fig. 5) when precipitation occurred at the metal/
plating interface. The fracture surface near the ID,
OD, and edges of the oil hole was generally a brittle,
intergranular typical of hydrogen embrittlement
(Fig. 6a), while a typical dimple structure was
observed in the center of the failed screw (Fig. 6b).
The microstructure of the screw in the cup portion
was observed to be tempered martensite in the case
Fig. 7 Optical micrographs of the cup portion showing (a)
tempered martensite in the case region, (a) tempered
martensite and some ferrite (light) in the core
Practical Failure Analysis
and core region (Fig. 7). The microstructure of the
case in the failed region also consisted of tempered
martensite (Fig. 8). This indicates that the threaded
portion of the screw was carburized. These findings
were confirmed by hardness measurements at various
regions of the screw.
The case and core hardness in the cup portion of
the screw was measured to be 709 HV and 455
HV, respectively. The core hardness in this region
was higher than the specified value of 310-370 HV.
This could be due to improper tempering. In the
failed region, the hardness near the surface was 594
HV and the core hardness 350 HV. The high
hardness in the case is attributed to the carburizing
on the thread region along with the cup portion.
The hardness values obtained in various regions
suggests that the tappet adjusting screw was not
properly carburized and tempered. The hardness
values measured in various regions of the screws are
presented in Table 1. The case depth of the screw
Fig. 8 Optical micrographs of failed portion showing (a)
tempered martensite in the case region, (a) tempered
martensite and some ferrite (light) in the core
Volume 2(4) August 2002 79
 Hydrogen Induced Cracking of a Tappet Adjusting Screw (continued)

Table 1 Hardness and Case Depth of the coating acts as a barrier to effusion of hydrogen, a
Screw in Various Regions high temperature baking is required to remove the
hydrogen. The high hardness in the threaded region
Specified Cup Portion Failed Portion
accentuated the failure probability by hydrogen
Case 600-750 HV 709 HV 594
induced cracking/blistering. Since the strength of
Core 310-370 HV 455 HV 350
the threaded region was high, a small bend (5°)
Case depth, 0.15-0.20 0.25 0.27
mm during room temperature testing resulted in cracking
of the screws.

was measured according to IS 6416 (1988). The

measured case depth in various regions of the screw
was in the range of 0.25 to 0.27 mm.
The carbon and low alloy steels are susceptible to
hydrogen damage failures, especially when the
strength is above 1000 MPa. The high hardness/
strength of the current material increased the pro-
pensity of the screws to failure by hydrogen em-
brittlement. The source of hydrogen in the present
case was probably the copper electroplating. It is
well known that during electroplating processes
hydrogen may be picked up by the steel. This
hydrogen is typically removed by baking before the
component is put into service. Since the metallic
Conclusions
The tappet adjusting screws failed by hydrogen
embrittlement. This conclusion was confirmed when
a baking treatment at around 150-200 °C after plat-
ing, in conjunction with masking the threaded por-
tion of the screw to reduce the hardness after carbur-
izing, completely eliminated the problem.
Acknowledgments
The cooperation and help rendered by the staff
of the Materials Science & Technology Division,
TCIRD during the investigation is greatly ack-
nowledged by the author. The author is also thank-
ful to the director of TCIRD for permission to
publish the work.

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