Laboratory Report

Experiment Number: Internship – Exercise 1

Experiment Name: Assessment of chemical composition
Experiment Date: 23.04.2020
Instructors: Martin Ernst M.Sc.
Course Name: Material Testing and Failure Analysis

Submitted to
Prof. Dr.-Ing. Peter Sommer

Submitted by
Name: XXXXX
Student ID: 12345

Report Submission Date: dd.mm.yyyy

Laboratory: Dr. Sommer Materials Technology, Hellenthalstraße 2, D-47661 Issum, Germany

Phone: +49 (0) 2835-9606-0, Fax: +49 (0) 2835-9606-60
E-Mail: info@werkstofftechnik.com, www.werkstofftechnik.com
Material Testing and Failure Analysis Student ID: 12345

1. Introduction

The objective of the experiment was to investigate whether the chemical composition of the
material fulfilled the requirements of the standard or not.

The chemical composition assessment is a standard way to find out the material which was
used for production. Chemical composition is one of the preliminary examinations that is
carried out at the beginning of a failure investigation. A deviation from standard chemical
composition could be a reason for poor hardenability, weak tempering resistance or too low
hardness.

Trace elements also determine the mechanical properties of a material. According to the
standard, a certain amount of some trace elements is necessary or unavoidable. Aluminium
and nitrogen create Alumininitrides which are responsible for a fine grain structure. Too high
copper and nickel contents can cause cracking when parts are quenched and tempered.

A 3.1 test certification (according to DIN EN 10204) for steel bars (270 mm Ø x 6500 mm)
which is manufactured from the case hardening steel 18CrNiMo7-6 (material number 1.6587)
was used to assess the chemical composition. All standards allow a limit deviation to the melt
analysis when measuring directly on the workpiece. The extraction of a 3.1 test certification
for steel bars (270 mm Ø x 6500 mm) is shown in Error! Reference source not found..

Table 1: 3.1 test certification for steel bars (270 mm Ø x 6500 mm)

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Internship 01 – Measuring and assessment of chemical compositions
Material Testing and Failure Analysis Student ID: 12345

2. Experiment

A pinion shaft (sun gear of a planet gearbox) failed due to the crack formation at the tooth
root position (Figure 1). According to the supplier information, the pinion shaft was
manufactured from the case-hardened steel 18CrNiMo7-6 (Material Number: 1.6587). A 3.1
test certification (Error! Reference source not found.) for steel bars (270 mm Ø x 6500
mm) was compared and analyzed according to DIN EN 10204.

At the beginning of failure analysis, the chemical composition is always checked in order to
exclude any mistake in the material.

(a)

(b)

Figure 1: Failed pinion shaft. (a) whole part, (b) close view of crack area

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Internship 01 – Measuring and assessment of chemical compositions
Material Testing and Failure Analysis Student ID: 12345

3. Results

The chemical composition was determined outside of the case hardening zone using an optical
emission spectrometer (OES, Spectrolab CCD) according to process instruction VA7-
11:2016-10 (*). The measuring results of chemical composition are shown in Table 2.
Please fill in the nominal standard chemical composition (see appendix), and fill in the results
of the test certificate (table 1)

Table 2: Results of the chemical composition according

Nominal analysis C Si Mn P S Cr Mo Ni Cu Al N
% % % % % % % % % % %
according to
standard
0.15 0.15 0.50 max. max. 1.50 0.25 1.40 max.
min
max 0.21. 0.40 0.90 0.025 0.035 1.80 0.35 1.70 0.40

Certificate results 0.17 0.15 0.55 0.008 0.002 1.65 0.30 1.53 0.10 0035 0.0118

Our test results 0.17 0.17 0.54 0.008 0.003 1.66 0.28 1.53 0.11 0.034 0.0120

Pb Nb Zn Sb Sn V Ti Ca B H O
% % % % % % % % % ppm ppm

Trace elements

Certificate results <0.003 0.0020 <0.01 <0.002 <0.0005 1.8 <20.0

Our test results <0.001 <0.003 0.002 0.0020 0.008 <0.01 <0.002 <0.0005 0.001 0.4 4.8

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Internship 01 – Measuring and assessment of chemical compositions
Material Testing and Failure Analysis Student ID: 12345

4. Answering the questions

4.1. In which standard is this steel defined?

Answer

The standard of the steel is DIN EN 10204.

4.2.Which elements are not defined in this standard?

Answer

4.3.Why would be important to get data of trace elements?

Answer
Trace elements are used to improve mechanical characteristics of the materials. They also
determine the mechanical properties of the materials. These elements can be used to improve
toughness, Weldability, Corrosion Resistance etc. For example Aluminum us used to improve
toughness behavior of steels at low temperature. Calcium is used for inclusion shape control
in steel in order to improve the properties through the thickness.

4.4. Final decision on your assessment concerning the chemical composition.

Answer

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Internship 01 – Measuring and assessment of chemical compositions