M aster Program

M etallurgy and M aterial Engineering

Universitas I ndonesia
October 2012
Background
Fish bone diagram
Scope of investigations
Examinations
Results and discussions
Conclusions
Recommendations
References

2
Component of a motorcycle that is "Gear Shift Shaft Com" produced by PT.
Y which acts as a supplier of automotive components for PT. ISI has been
damaged during use. Observations indicated that the damage occurred in
the weld joint where the welds are not fused between the plates with the
shaft. This causes the gearshift cannot be used for change the gear position,
from position 1to position 2, 3and 4.

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People Assembly Maintenance

Failure

Environment Material Manufacture

People Heat Treatment Welding

Manufacture

Metal Forming Machining Electroplating

People Filler

Welding

Design Welding Method Surface

Preparation 4
Visual examination
Chemical composition using OES
Micro-hardness testing (Vickers)
Metallography testing (macro and microstructure)
Examination using SEM
Micro-chemical composition test using EDS

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 Figure 1. Sample Shaft Com Gear Shift as received

Plate Metal

Shaft Metal Damage here

Figure 2. Sample Failed Shaft Com Gear Shift as received

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 Table 1. Chemical composition results on as received components

C Si Mn S P Cr Ni V Mo Cu Al
Material
(%) (%) (%) (%) (%) (%) (%) (%) (%) (%) (%)

AISI 1045M 0.42- 0.15- 0.035

0.6-0.9 0.03 - - - - - -
(S45C) 0.48 0.35 max

SHAFT 0.50 0.197 0.661 0.010 0.015 0.067 0.057 0.001 0.025 0.134 0.006

0.045 0.04
SPCC 0.12 max - 0.5 max - - - - - -
max max

PLATE 0.10 0.009 0.348 0.013 0.005 0.023 0.020 0.001 0.005 0.044 0.045

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Table 2. Hardness* testing results on welding
components

Hardness of
Location Location Sample
(HV)
1. Base Metal 1 166 SHAFT
2. Plate surface 613
PLATE
3. Base Metal 2 243
4. Weld Metal 367
5. Fusion Line 689 Figure 3. Scheme of hardness testing on
6. HAZ 396 welding components

* Hardness testing was conducted by Vickers

micro-hardness

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 Figure 4. Macroscopic of shaft com gear shift (good sample),
Figure 6. Macroscopic of shaft com gear shift on the right side
magnification 7X, 2% nital etch
(good sample), magnification 10X,
2% nital etch

Figure 5. Macroscopic of shaft com gear shift on the left side (good Figure 7. Macroscopic of failedshaft com gear shift (rejected), magnification
sample), magnification 10X, 2% nital etch 10X, 2% nital etch
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The microstructure of base metal of the
plate sample shows typical of ferrite-
pearlite structures (Figure 8).
Bainite structure in HAZ area (Figure 12)
and bainite structure in weld area
(Figure 11) are imposed by the
observation.
The hardness of weld area and HAZ are
approximately 367 and 396 HV, which
indicated the range of hardness of
bainite structure.

(Figure 8)

The HAZ structure is taken from

the near plate area, so the
structure is also contain a number
of carbon that diffused from the
carbonitrided area of the plate
during the performance of the (Figure 12) (Figure 11)
weld.
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Figure 13 indicates the formation of nitrides and carbide in the fusion line.
These phases are produced by carbonitrided process during manufacture of the
plate and ascertained by the hardness of the area, approximately 689 HV (see
table 2), that value of hardnesstend to be large and isbrittle.

Figure 10. The microstructure of (Figure 13) Weld

carbonitided plate surface. Nital etch Plate
area 11
Figure 9. SEM image in weld area (good sample) with Quadrant Back Figure 10. SEM image in weld area with Secondary Electron
Scattering Detector (QBSD), 45X Detector (SE1), 80X

Figure 11. SEM image in weld area with Secondary Electron Detector (SE1), 100X 12
Figure 12. SEM image in weld area with Secondary Figure 13. SEM image in weld area with Secondary Electron
Electron Detector (SE1), 30X Detector (SE1), 200X

The figure 9, 10, 11, and 12 are show that the specimen contains porosity and
Zn that presence in the weld area.
The gap between the specimen is prepared to allows the gas resulted by
vaporization zinc to out from the weld. The porosity, spread uniformly in the
welding area.
This causesthe mechanical properties of the material decreases significantly .
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To ascertain the presence of Zn in weld area,
EDS is performed. Zn
Table 3. EDS results on welding components

Element Element %
C 1.71
O 41.62
Si 0.47
Cl 2.20
Zn
Ca 0.23
Ti 0.95
Fe 27.66
Zn 25.16

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Galvanized steel is widely used for car bodies due to its
corrosion resistance.
It is associated with serious problems related to the welds
quality when welding is applied as a process to a joint.
In the shaft used for gear shaft com, material is galvanized. It
may cause defects in weld area.

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Zn has higher vapor pressure than Fe, the higher
value of vapor pressure of Zn are tend to have
contributed to the explosion (> 102 mmHg at T =
1300oC)
The problem of welding continued-zinc coated
products lies in the different of vaporization and
melting point of Zn compared to steel.
Arc can be contaminated by zinc in its vapor
state, results in an unstable and erratic arc and
produced a few of porosity in the weld bead, Porosity in the weld bead
because zinc in its vaporized state cannot escape
or trapped in the weld area.
The pores resulting from the aforementioned
process influence the mechanical characteristics,
leading to defective welds.

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 pore
Tvapor = 900oC
Tweld > 1300oC

Zn(s) Zn(g) Zn

Figure 21. Schematic of welding process

Figure 22. Fillet weld or lapped joint of

continued-zinc product

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 The test result shows the presence of carbide
hardness in fusion line (Brittle), with hardness
approximately 689 HV.
The fusion line contained nitride and carbide
phase that cause high hardness and brittle
materials. This causes the material have high
sensitivity to crack.
The carbon equivalents of each parent material
are:

CE Shaft : 0.5 + 0.11 + 0,008 + 0.0134 + 0.00625 + 0.0038 = 0.64

CE Plate : 0.1 + 0,058 + 0.000375 + 0.0046 + 0.00125 + 0.00133 = 0.16

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Zn vapor trapped in the area of weld metal makes the
porosity in the weld metal, coupled with the phases of
carbide and brittle nitrides at the fusion line area, making a
failure component on the connection between shaft and
plate. When the product receives load, the connection
between the shaft and the plate contained porosity and
brittle phase in, will instantly broken.

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The recommendations we conduct in this case are:
Galvanizing steel should have To avoid the porosity and leak of
special surface preparation, such as penetration of the material, the hybrid
grinding the area subjected to be laser-arcwelding processcan be applied.
welded to remove the zinc layer on
the surface.

Cold Galvanizing after welding process

(OPTIONAL-NOT RECOMMENDED)

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Do preheat before weld the materials. All heat treatment must do at
temperature under melting point of Zn. Because of carbon equivalent in
shaft 0.64, preheat and interpass temperature should do between 250-
300oCin areas other than the plate.

Table 4. The relationship between carbon equivalent and preheat and

interpass temperatures are recommended

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 The price comparisons of the recommendation given above are as shown
inTable 4.

Type of Recommendation Notes

Low cost but will
Surface preparation by
decrease production We have to eliminate the risk
grinding (defects) of the product ALARP.
rate.
Use hybrid laser-arc High cost, High
welding Investment
High cost, decrease
Preheat before weld
production rate
Cold Galvanizing after
High Cost Surface Preparation by Grinding
grinding

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Table 5. List of material which can remove abrasively Zn layer and carbonitrided area,
with hardness value and the price

Boron Carbide is recommended because the price as cheap as chromium carbide

but boron carbide has more hardnessvalue than chromium carbide, so the longer
life timesit takes to wear boron carbide than to wear chromium carbide.

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 People Filler

Welding

Design Welding Method Surface

Preparation

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Process Design Carbonitriding

Engineering Plate
concept Metal Welding Q.C of End
Forming Process Product product
Basic Design Shaft

Galvanizing
Modified Process
Design Carbonitriding

Engineering
Plate
concept
Metal Grinding Welding Q.C of End
Forming Process Process Product product
Basic
Shaft
Design

Galvanizing
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Sperko Engineering Services, Inc. 1999. Welding Galvanized Steel Safely.
http://www.nakedwhiz.com/weldinggalvanized.pdf. Accessed September 25 2012, 11.14 WIB.
http://www.slbgroup.com/pdf/balltinfotech/thrustballtech.pdf. Accessed September 25th 2012, 12.01
WIB.
JIS S45C composition. http://www.meadinfo.org/2010/03/s45c-jis-mechanical-properties.html. Accessed
September 25th 2012, 11.30 WIB.
Welding Handbook. 2009. Kobe Steel, Ltd.
http://www.kobelcowelding.com/20100119/handbook2009.pdf. Accessed September 16th 2012, 15.30
WIB.
Cheolhee Kim, Woongyong Choi, Jeonghan Kim, and Sehun Rhee. 2008. Relationship between the
Weldability and the Process Parameters for Laser-TIG Hybrid Welding of Galvanized Steel Sheets. Materials
Transactions, Vol. 49, No. 1 (2008) pp. 179 to 186.
M. Pouranvari. 2011. Analysis of Fracture Mode of Galvanized Low Carbon Steel Resistance Spot Welds.
International Journal of Multidisciplinary sciences and engineering, vol.2, No.6, September 2011.
Hongping Gu and BorisShulkin. Remote laser welding of zinc-coated sheet metal; component in a lap
configuration utilizing humping effect. Stronach Centre for Innovation, Magna International Inc. Aurora,
Ontario, L4G 7G6, Canada.
http://astralloy.infomedia.net/pdf/plate_outwear.pdf. Accessed October 6th 2012, 23.00 WIB.
http://www.3m.com/product/information/Superabrasive-Wheels.html. Accessed October 7th 2012, 00.11
WIB.
http://www.alibaba.com.

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