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Falk Cast Gear Blanks Product Sheet

Falk Cast Gear Blanks

Rexnord Falk Mill Products
For more than 100 years,
Rexnord Falk Mill Products
have provided high-quality
solutions for a diversified
range of industries. With a Cast gear blanks engineered for longer life On-time deliveries Rexnords scheduling
base of over 5,000 installed system ensures your Falk Cast Gear Blanks are
ring gears and pinions, the and durability.
finest heavy-sectioned, large Rexnords Falk Cast Gear Blank offering is built delivered when and where they need to be.
steel castings, and some of the
on the companys years of ring gear expertise in Proven steel alloys through decades of
largest machining capabilities, testing, Rexnord offers reliable hardenability
Rexnord Falk Mill Products multiple industries. Ideal for large diameter and
of its Falk Cast Gear Blanks with a variety of
are your solution for some high-power applications, Falk Cast Gear Blanks
of the worlds most rugged Falk Gear Alloys.
applications. are high-quality products that ensure your ring Proven testing Rexnord believes in
gears have a longer life in rugged environments. the importance of testing our products
throughout the manufacturing process with
Mining Choose Falk Cast Gear Blanks for: nondestructive testing methods. We use a
Higher strength blank material no mixture of in-house equipment and qualified
structural welding processing is needed in third-party inspectors to ensure durability,
cast gear blanks, greatly reducing the risk for reliability and accuracy.
catastrophic failures. Longer and more trouble-free operation
Smooth transitions between changes than fabricated gear blanks as a result
in section thickness provide you with of proven Falk Gear Alloys, homogenous
reduced stress concentrations. material, higher strength blank material,
Homogenous material you receive and smooth transitions between changes in
material with more uniform physical structural section thickness, Falk Cast Gear Blanks offer
properties, resulting in no discontinuities, a more trouble-free operation when compared
unlike fabricated gear blanks that require to fabricated gear blanks.
structural welding processes.
Falk Cast Gear Blanks Capabilities

As an ISO 9001:2008-certified facility, Rexnords Falk Foundry is dedicated

to accommodating all of your Falk Steel Casting needs, including:

Controlled heat treatment MAGMASOFT solidification simulation software used to

Deep pit carburizers predict solidification and ensure casting integrity
Through hardening capabilities On-site machine shop for roughing of cast gear blanks up to:
Computer-controlled furnace: 30 x 40 x 15 feet (9.1 x 12.2 x 50-foot (15.2 meters) vertical turning center
4.6 meters) 24-foot (7.3 meters) slab mill
Water quench tank: 24 x 24 x 11 feet (7.3 x 7.3 x 3.4 meters) 12-inch (305 millimeters) horizontal boring bar
Complete inspections Large drill press
Dimensional checks Handles machined parts up to 250,000 pounds (113,000
Dye penetrant kilograms)
Dry and wet magnetic particle inspection On-site pattern shop provides ability to quickly modify
Nondestructive and destructive testing patterns to suit prototypes and design changes
Ultrasonic inspection Fully developed Falk Steel Alloys as well as customer-
Laser scanning requested materials
Portable coordinate measurement capabilities Molding
Fully equipped materials lab Flasks up to 15 feet (4.6 meters) diameter
Pits up to 36 x 80 x 7.5 feet (11 x 24.4 x 2.3 meters)

Falk Cast Gear Blank sizes for your application:

Outside diameter 3 to 50 feet (15.2 meters) Number of segments one- to twelve-piece gears
Face width up to 42 inches (1,065 millimeters) Consult factory for custom applications
Semi-finished weight 250 to 250,000 pounds
(113-113,000 kilograms)

Chemical Analysis of Rexnords Falk Steel Alloys and similar SAE grades

Percent Percent Percent Percent Percent

Carbon Manganese Chromium Nickel Molybdenum
Moly-Telastic 0.30-0.40 0.70-1.00 0.40-0.65 - 0.15-0.25
SAE 4135 0.33-0.38 0.70-0.90 0.80-1.10 - 0.15-0.25
Falk No. 1 Gear Alloy 0.27-0.37 0.70-1.00 0.60-0.90 0.60-0.90 0.30-0.40
SAE 8630 0.28-0.33 0.70-0.90 0.40-0.60 0.40-0.70 0.15-0.25
Falk No. 2 Gear Alloy 0.17-0.23 0.70-1.00 0.60-0.90 0.60-0.90 0.30-0.40
SAE 8620 0.18-0.23 0.70-0.90 0.40-0.60 0.40-0.70 0.15-0.25
Falk No. 3 Gear Alloy 0.30-0.37 0.70-1.00 0.60-0.90 0.60-0.90 0.40-0.50
No Similar SAE Grade
Falk No. 4 Gear Alloy 0.38-0.45 0.70-1.00 0.60-0.90 0.60-0.90 0.40-0.50
SAE 8640 0.38-0.43 0.75-1.00 0.40-0.60 0.40-0.70 0.15-0.25
Falk No. 6 Gear Alloy 0.38-0.45 1.05-1.35 0.90-1.20 0.60-0.90 0.55-0.60
No Similar SAE Grade
Falk phosphorus (0.030 percent max) and sulfur (0.025 percent max) are less than ASTM A148 permitted maximums of 0.050
percent and 0.060 percent, respectively. Silicon content is typically 0.450 percent.
Falk No. 2 Gear Alloy also contains 0.040-0.060 percent vanadium for grain refinement. Vanadium additions are also available
for other grades when required.

866-REXNORD/866-739-6673 (Within the US) 414-643-2366 (Outside the US)

2013 Rexnord GR5-018 Printed in USA 03/13