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AMERICAN GEAR MANUFACTURERS ASSOCIATION AGMA 923--B05
Contents
Page
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Normative references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Metallurgical requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Tables
1 Metallurgical characteristics for through hardened gearing . . . . . . . . . . . . . . . 15
2 Metallurgical characteristics for carburize and hardened gearing . . . . . . . . . 17
3 Metallurgical characteristics for induction or flame hardened gearing . . . . . . 22
4 Metallurgical characteristics for nitrided gearing . . . . . . . . . . . . . . . . . . . . . . . . 27
Figures
1 Continuous carbide network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Semi--continuous carbide network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Discontinuous carbides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Dispersed carbides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5 Solid on shaft pinion blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
6 Bore style gearing blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7 Disc style gearing blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8 Web style gear blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
9 Intergranular oxidation in carburized gearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10 Non--martensitic transformation products in carburized gearing . . . . . . . . . . . 8
11 Tempered martensite and 5% retained austenite in carburized gearing . . . . 10
12 Tempered martensite and 20% retained austenite in carburized gearing . . . 10
13 Tempered martensite and 30% retained austenite in carburized gearing . . . 10
14 Variations in hardening pattern obtainable on gear teeth with flame or
induction hardening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Foreword
[The foreword, footnotes and annexes, if any, in this document are provided for
informational purposes only and are not to be construed as a part of AGMA Information
Sheet 923--B05, Metallurgical Specifications for Steel Gearing.]
In November, 1984, an ad hoc Metallurgy and Gear Rating Committee met to define the
factors required to qualify the various metallurgical quality grades that were to be introduced
into the gear rating standard that eventually became ANSI/AGMA 2001-- B88, Fundamental
Rating Factors and Calculation Methods for Involute Spur and Helical Gear Teeth.
In May, 1988, ANSI/AGMA 6033--A88, Standard for Marine Propulsion Gear Units -- Part 1,
Materials, was published using a short list of metallurgical factors in table form.
In September, 1988, ANSI/AGMA 2001--B88 was published using metallurgical factors in
table form.
Starting in July, 1992, AGMA representatives participated in writing ISO 6336--5,
Calculation of Load Capacity of Spur and Helical Gears -- Part 5: Strength and Quality of
Materials, which was a modification of the tables in ANSI/AGMA and DIN Standards.
In February, 1993, AGMA 6002--B93, Design Guide for Vehicle Spur and Helical Gears, was
published using a modified version of the tables used in ANSI/AGMA 2001--B88.
In September, 1993, the AGMA Metallurgy and Materials Committee accepted the task of
consolidating the various tables to avoid redundancies and conflicting requirements, and
started work on AGMA 923--A00, Metallurgical Specifications for Steel Gearing.
In January, 1995, a revised ANSI/AGMA 2001--C95 was published using a version of the
ANSI/AGMA 2001--B88 tables as revised by the AGMA Helical Gear Rating Committee.
In November, 1997, a revised ANSI/AGMA 2003--B97, Rating the Pitting Resistance and
Bending Strength of Generated Straight Bevel, Zerol Bevel and Spiral Bevel Gear Teeth,
was published using a version of the ANSI/AGMA 2001--B88 tables as revised by the AGMA
Bevel Gearing Committee.
The committee reviewed all metallurgical tables of the gear rating standards ANSI/AGMA
2001--B88, ANSI/AGMA 2003--A86, and ISO 6336--5:1996 and their proposed revisions to
develop consolidated tables describing the metallurgical characteristics associated with
each specific type of heat treatment and metallurgical quality grade. Effort was made to
reference ISO specifications where possible. The consolidated tables were submitted to
the gear rating committees for their agreement and are published here for reference by
other standards.
AGMAs goal is to develop a consistent metallurgical specification which reflects the quality
requirements for steel gearing. AGMA 923--A00 was such a document, and was intended to
be consistent with the applicable portions of ISO 6336--5:1996, to the extent possible while
the two standards were in parallel development. The AGMA Technical Division Executive
Committee approved the publication of AGMA 923--A00 in August, 2000.
This edition of the information sheet, AGMA 923--B05, incorporates changes to item 8,
microstructure, of table 1, Metallurgical characteristics for through hardened gearing. The
balance of the document remains unchanged. The AGMA Technical Division Executive
Committee approved the publication of AGMA 923--B05 in May, 2005.
Suggestions for improvement of this information sheet will be welcome. They should be
sent to the American Gear Manufacturers Association, 500 Montgomery Street, Suite 350,
Alexandria, Virginia 22314.
ACTIVE MEMBERS
C. Berndt . . . . . . . . . . . . . . . . . . . . . . . . . . Caterpillar, Inc.
I. Botto . . . . . . . . . . . . . . . . . . . . . . . . . . . . FFE Minerals
D. Breuer . . . . . . . . . . . . . . . . . . . . . . . . . Metal Improvement Company
R.J. Cunningham . . . . . . . . . . . . . . . . . . . Consultant
G. Diehl . . . . . . . . . . . . . . . . . . . . . . . . . . . Philadelphia Gear Corporation
D. Herring . . . . . . . . . . . . . . . . . . . . . . . . . The Herring Group, Inc.
D.R. McVittie . . . . . . . . . . . . . . . . . . . . . . Gear Engineers, Inc.
J. Mertz . . . . . . . . . . . . . . . . . . . . . . . . . . . Falk Corporation
R.L. Schwettman . . . . . . . . . . . . . . . . . . . Xtek, Inc.
M. Stein . . . . . . . . . . . . . . . . . . . . . . . . . . . Applied Process Southridge, Inc.
J.B. Walenta . . . . . . . . . . . . . . . . . . . . . . . Caterpillar, Inc.
L.L. Witte . . . . . . . . . . . . . . . . . . . . . . . . . . General Motors Corporation/Allison Transmission Division
ASTM A751--96, Test Methods, Practices, and ASTM E407--99, Practice for Microetching Metals
Terminology for Chemical Analysis of Steel and Alloys
Products
ASTM E415--99, Test Method for Optical Emission
ASTM A837--91(1996)1, Specification for Steel Vacuum Spectrometric Analysis of Carbon and
Forgings, Alloy, for Carburizing Applications Low--Alloy Steel
ASTM A866--94, Specification for Medium Carbon ASTM E428--92, Practice for Fabrication and
Anti--Friction Bearing Steel Control of Steel Reference Blocks Used in
Ultrasonic Inspection
ASTM A919--84 (1993)1, Terminology Relating to
Heat Treatment of Metals ASTM E709--95, Guide for Magnetic Particle
Examination
ASTM A941--99a, Terminology Relating to Steel,
Stainless Steel, Related Alloys, and Ferroalloys ASTM E1077--91, Test Methods for Estimating the
Depth of Decarburization of Steel Specimens
ASTM A956--97, Test Method for Equotip Hardness
Testing of Steel Products ASTM E1444--94a, Practice for Magnetic Particle
Examination
ASTM E3--95, Practice for Preparation of
Metallographic Specimens ISO 642:1979, Steel -- Hardenability test by end
quenching (Jominy test)
ASTM E8--99, Test Methods for Tension Testing of
Metallic Materials ISO 643:1983, Steels -- Micrographic determination
of the ferritic or austenitic grain size
ASTM E10--98, Test Method for Brinell Hardness of
Metallic Materials ISO 683--1:1987, Heat--treatable steels, alloy steels
and free--cutting steels -- Part 1: Direct--hardening
ASTM E18--98, Test Methods for Rockwell
unalloyed and low--alloyed wrought steel in form of
Hardness and Rockwell Superficial Hardness of
different black products
Metallic Materials
ISO 683--11:1987, Heat--treatable steels, alloy
ASTM E23--98, Test Methods for Notched Bar
steels and free--cutting steels -- Part 11: Wrought
Impact Testing of Metallic Materials
case--hardening steels
ASTM E45--972, Test Methods for Determining the
ISO 4967:1979, Steel -- Determination of content of
Inclusion Content of Steel
non--metallic inclusions -- micrographic method
ASTM E92--82(1997)2, Test Method for Vickers using standard diagrams
Hardness of Metallic Materials
ISO 6336--5:1996, Calculation of load capacity of
ASTM E110--82(1997)2, Test Method for spur and helical gears -- Part 5: Strength and quality
Indentation Hardness of Metallic Materials by of materials
Portable Hardness Testers
ISO 14104:1995, Surface temper etch inspection
ASTM E112--96, Test Methods for Determining after grinding
Average Grain Size
SAE/AMS 2300G, Premium Aircraft--Quality Steel
ASTM E125--63(1997), Reference Photographs for Cleanliness, Magnetic Particle Inspection
Magnetic Particle Indications on Ferrous Castings Procedure
ASTM E140--971, Hardness Conversion Tables for SAE/AMS 2301H, Cleanliness, Aircraft Quality
Metals (Relationship Among Brinell Hardness, Steel Magnetic Particle Inspection Procedure
Vickers Hardness, Rockwell Hardness, Rockwell
SAE/AMS 2304, Special Aircraft--Quality Steel
Superficial Hardness, Knoop Hardness, and
Cleanliness, Magnetic Particle Inspection
Scleroscope Hardness)
Procedure
ASTM E350--95(1997)1, Test Methods for
SAE/AMS--S--13165, Shot Peening of Metal Parts
Chemical Analysis of Carbon Steel, Low--Alloy
Steel, Silicon Electrical Steel, Ingot Iron, and SAE J419 Dec 83, Methods of Measuring
Wrought Iron Decarburization
ASTM E384--89(1997)2, Test Method for SAE J422 Dec 83, Microscopic Determination of
Microhardness of Materials Inclusions in Steels
SAE J423 Dec 83, Methods of Measuring Case banding: A segregated structure consisting of
Depth alternating, nearly parallel bands of different chemi-
SAE J864 May 93, Surface Hardness Testing with cal composition, typically aligned in the direction of
Files primary hot working. Segregation is frequently
expressed as a departure from the average
chemical composition. Elements which tend to
segregate are sulfur, phosphorus, carbon, silicon,
3 Definitions and manganese.
carburizing: A heat treatment process in which an controlling section: The section size which has the
austenitized steel is brought into contact with a greatest effect in determining the rate of cooling
carbonaceous atmosphere of sufficient carbon po- during quenching at a location where the specified
tential to cause adsorption of carbon at the surface hardness is required. Figures 5 through 8 illustrate
and by diffusion to create a concentration gradient. the controlling section size for various gearing
Carburizing is generally followed by quenching and configurations whose teeth are machined after heat
reheating (tempering) of an item to produce a treatment and whose hardness must be maintained
hardened and tempered case. at the roots of the teeth. The maximum permitted
section size for an alloy steel increases with the
case: The outer portion that has been made harder hardenability of the alloy steel.
than the inner portion (see core hardness) as a result
of altered composition, microstructure, or both, by
Teeth
treatments such as carburize and hardening,
induction hardening, flame hardening, and nitriding.
Note that a flat plate with thickness equal to the effective case depth: The distance from the
diameter of a round bar will cool slower than the bar. finished tooth surface to a specific sub--surface
The thickness of a plate equivalent in cooling rate to hardness value. Stock removal done after heat
that of a round bar (equivalent controlling section treating will reduce the as heat treated effective case
size) is 0.7 times the bar diameter. depth and potentially the surface hardness.
The controlling section size for the selection of an Carburize and hardened
appropriate type of steel and specified hardness The effective case depth is measured normal to the
combination must consider part configuration at the finished gear surface to a location where the
time of heat treatment. Special stock additional hardness number is 50 HRC (542 HK500 or 515
allowances, such as those used to minimize distor- HV500 min) by conversion from a microhardness test
tion during heat treatment, must be considered. result. Note that ISO 6336--5 uses 550 HV500 min,
which converts to 52.4 HRC or 583 HK500, as its
converted hardness: The hardness number re- criterion for determining the effective case depth. It
ported on a scale different from the scale used for is recognized that the effective case depth of
hardness testing. For example an actual microhard- carburize and hardened gear teeth varies with
ness test reading of 542 HK500 has a converted location on the gear tooth.
hardness of 50 HRC and would be properly reported
as 50 HRC (542 HK500) with the hardness number Induction and flame hardened
and scale in parentheses representing the actual For Grades 1 and 2 gearing, the effective case depth
testing result and method. is measured from the finished surface to a location
where the hardness number is equivalent to 10 HRC
core hardness: The hardness at the intersection of numbers below the specified minimum surface
the root circle and the centerline of the tooth at hardness. Grade 3 induction hardened gearing uses
mid--face width that was developed during the the carburize and hardened definition for its effective
hardening of carburized gearing. An alternative case depth definition. Note that ISO 6336--5 uses
location is given by ISO 6336--5, table 4, item 8. the distance from the surface to the location where
The material must have adequate hardenability for the hardness is equal to 80% of the specified
the required hardness and section size combination minimum surface hardness as its criterion for
for the required core hardness to be achieved. The determining the effective case depth.
quench severity must also be adequate in order to Nitrided
achieve the required core hardness. The effective case depth is measured from the
finished surface to a location where the hardness
The term core hardness is applicable to carburize
number is equivalent to 40.8 HRC (421 HK500 or 400
and hardened gearing. Induction, flame, and nitride
HV500 min) by conversion from a microhardness test
hardened gearing may use the term base hardness.
result. If the core hardness is more than 38.9 HRC
The core hardness of non--tooth portions (such as (391 HK500 or 380 HV500 min), core hardness plus 54
journal areas of carburize and hardened gearing), is HK500 or 50 HV500 min (4.6 HRC) may be used as the
definition of nitrided effective case depth. Note that hardness: See specific kind of hardness such as
this is the same definition used in ISO 6336--5. base, case, core or surface.
ferrite: A solid solution of one or more elements in hardness conversion chart: A published docu-
body--centered cubic iron. In carbon and alloy steels ment for use in converting from one hardness testing
this phase is stable at room temperature. scale to another.
flame hardening: A case hardening process in Hardness conversion charts should be used with
which only the surface layer of the work piece is great caution since discrepancies of 0.3 HRC
heated by a flame to above the upper transformation numbers at 30 HRC to 3.9 HRC numbers at 60 HRC,
temperature and immediately quenched. have been noted between various published conver-
sion charts. Therefore, it is suggested that the
free ferrite: The ferrite that is formed directly during conversion chart used for testing and reporting be
cooling without simultaneous formation of carbide. specified. Some of the more popular hardness
conversion charts are found in ASTM A370, ASTM
grain size: The dimensions of the grains, or E140, ISO 6336--5, and certain individual corporate
crystals, in a polycrystalline metal exclusive of documents and standards. For this document,
twinned regions and sub--grains when present. The ASTM A370 is used and should be used whenever
ASTM grain size is a designation bearing a relation- no other document is specified.
ship to average intercept distance at 100 diameters
magnification. Commercial grain size is categorized induction hardening: A surface hardening process
as either coarse (grain size 1--4) or fine (grain size 5 in which only the surface layer of the work piece is
or finer). heated by electrically induced currents to above the
upper transformation temperature and immediately
hardenability: The property of a ferrous alloy that quenched.
determines the depth and distribution of hardness
induced by quenching. intergranular oxidation (IGO): The preferential
oxidization of certain alloying elements along grain
hardened depth: For induction or flame hardened boundaries during gas carburizing. See figure 9 for a
gearing, alternative terminology for effective case photomicrograph of intergranular oxides (black
depth. constituent).
Unetched
400 X mag.
Figure 9 -- Intergranular oxidation in carburized gearing
linear indication: An indication with length at least non--martensitic structures: Inclusive terminolo-
three times its width. gy for ferrite, carbide, retained austenite, pearlite,
and bainite due to incomplete transformation to
marquench: Quenching into a liquid media whose
martensite or incomplete austenization. Retained
temperature is above the martensite start trans-
austenite is not included in the quantitative
formation temperature, typically 300 -- 500F (150 --
metallographic measurement of non--martensitic
260C), held at this temperature until temperature is
structures.
uniform throughout, and then cooled to form
martensite. Marquenching is used to achieve
non--martensitic transformation products: Inclu-
reduced distortion when compared to conventional
sive terminology for ferrite, cementite, pearlite, and
quenching.
upper bainite in the surface microstructure of
martensite: A generic term for microstructures carburize hardened gearing due to incomplete
formed by the diffusionless phase transformation of transformation to martensite. See figure 10 for a
austenite. Martensite is characterized by an acicular photograph of non--martensitic transformation prod-
or needle--like pattern in the microstructure and is ucts in martensite.
the hardest of the austenitic transformation products
in steel. normalizing: The heating of a ferrous alloy to a
suitable temperature above the transformation
microsegregation: The non--uniform distribution of
range and then cooling, typically in air, to a
alloying elements, impurities, or phases observed
temperature substantially below the transformation
primarily in the microstructure of the material.
range.
nitriding: The introduction of nascent nitrogen into
a suitable solid ferrous alloy by holding at a suitable pearlite: A microstructural constituent consisting of
temperature in contact with a nitrogenous material. lamellar ferrite and cementite resulting from the
Adsorption of nascent nitrogen produces case transformation of austenite at temperatures above
hardening without quenching. the bainite range.
5% nital etch
400 X mag.
determined at a location 1/4 of tooth height above the of three points HRC from actual HRC measurements
root. per ASTM E18. The significance and interpretation
of those results needs to be agreed upon between
Grain size -- Per ASTM E112 or ISO 643.
the parties.
Hardenability -- Per ASTM A255 or ISO 642
Intergranular oxides -- In the unetched condition,
end--quench test or by hardenability calculation per
see metallography and figure 9.
ASTM A255.
Magnetic particle -- Per ASTM E1444 regardless of
Hardness -- Listed below are each method and the
form, or alternatively ASTM E125 for raw castings,
associated processes which are tested by that
ASTM A275 for raw forgings, or ASTM E709 for
method.
finished gearing.
ASTM E10, Brinell hardness testing
Mechanical testing -- Per ASTM E8 for tensile
-- Through hardened parts testing and ASTM E23 for impact testing (also see
-- Base hardness of flame, induction, or nitride hardness).
hardened parts Metallography -- Performed at a magnification of
ASTM E18, Rockwell hardness testing 400 -- 600 diameters. Metallographic samples shall
be prepared per ASTM E3 and etched per ASTM
-- Through hardened parts
E407, except for intergranular oxidation which shall
-- Carburize and hardened parts be evaluated in the unetched condition.
-- Flame and induction hardened parts Microhardness -- See hardness.
-- Nitrided parts Microsegregation -- Analyzed per ASTM A534.
ASTM E92, Vickers hardness testing Acceptance criteria is not specified but is to be
-- Through hardened parts agreed upon.
-- Flame and induction hardened parts Nonmetallic inclusions -- Per any of the following
methods:
-- Nitrided parts
-- SAE/AMS 2301, for aircraft steels
ASTM E384, Microhardness testing
-- ASTM A534, for carburizing bearing steels
-- Carburize and hardened parts
-- ASTM A866, for through hardening bearing
-- Flame and induction hardened parts
steels
-- Nitrided parts -- ASTM E45, for inclusion count
If standard bench top hardness testing cannot be -- ISO 4967, by comparison to micrographic
accomplished as stated in ASTM E10 or ASTM E18, diagrams, Method B, Plate II with 0.3 in2 (200
portable testing may be accomplished by ASTM mm2) inspection area
E110 or other appropriate methods.
-- SAE J422, by comparison to micrographic
Measurement of surface hardness per ASTM E18 is diagrams
used as a nondestructive method to evaluate the Surface carbon -- Per one of the following methods:
conformity of individual work pieces to the surface
hardness requirements. The measurement method Method 1 -- Spectrometric
should be appropriate for the size and configuration Per ASTM E415.
of the work pieces. The teeth area requirements for
Method 2 -- Combustion
hardness measurements include the root of the
tooth. Alternate methods of hardness measure- The combustion method utilizes chips from a ma-
ment, including file testing in accordance with SAE chining cut of 0.001 -- 0.004 inch (0.02 -- 0.10 mm)
in thickness on a carbon control specimen. The
J864 or ISO 6336--5, annex D, may be used.
chips from this cut are collected and analyzed by
Due to the state of the art of alternate microhardness combustion for carbon content per ASTM E350.
testing methods, results may vary by the equivalent The specimen should be machined dry with high
speed cutting tools on centers, and at least one control range. The process control test coupons
gram of clean chips free of contamination should may be made of various steel grades, different sizes,
be used for analysis. and differing geometry depending on the parameter
to be monitored and the heat treat facilitys quality
Both methods require that prior to carburizing the
process control specimen, sufficient stock be ma- control plan. Process control test coupons are not
chined from the surface to be carburized, in order intended to be used for final acceptance.
to remove all material with non--uniform surface
The properties of a process control coupon may be
chemistry. correlated by experience to the properties of the
Surface temper -- Per ANSI/AGMA 2007--B92 or finished gearing with regard to hardness and case
ISO 14104. depth. The process control test coupon
microstructure may be correlated to the condition of
Test coupons -- Microstructure, microhardness and the finished gear. The method of correlation should
core hardness characteristics may be determined be documented.
from either actual parts or test coupons. See 4.2 for
the specific type of test coupon (process control or Process control test coupons may be used to
representative). determine surface carbon concentration, carbon
penetration, carbon gradients, nitride depth, white
Ultrasonic inspection -- Ultrasonic inspection is layer thickness, intergranular oxidation depth, and
recommended for large parts to detect flaws before process repeatability. Shim stock is often used to
incurring the expense of machining. When ultrason- monitor atmospheric carbon potential. Variations
ic inspection is specified, the following guidelines from expected process control limits are used as
shall apply: indicators of unacceptable heat treat process varia-
-- For wrought products the straight beam pro- tions. As long as the process control test coupons
cedures described in ASTM A388 shall apply. Ei- are within expected control limits, the parts being
ther the flat bottom hole or back reflection method heat treated should have the expected metallurgical
may be used. properties.
The sensitivity for the flat bottom hole method The process control test coupon for carburize and
shall utilize standard test blocks per ASTM E428 hardening should have minimum dimensions of 5/8
with the reflector size as specified in tables 1 inch (16 mm) diameter by 2 inches (50 mm) long and
through 4 of this information sheet. The metal test is suitable for gearing 4.5 normal diametral pitch (5.6
distance for the blocks shall be 4.000 inches module) and finer. A 1 inch (25 mm) diameter by 2
(101.6 mm). This sensitivity shall be used when inches (50 mm) long coupon may be used for
radially scanning the portion of the wrought mate- coarser pitch (module) carburized gearing to 1.5
rial that will comprise the tooth area. The tooth normal diametral pitch (17 mm module). The size of
area includes only those portions of the gearing the coupon for coarser than 1.5 normal diametral
material where the teeth will be located to a depth pitch (17 module) gearing should be agreed upon,
below the finished tooth tips of at least 1.5 times and should approximate the inscribed diameter at
the tooth height. The balance of the part may be mid height of the tooth cross section. The coupon
scanned using a distance amplitude correction length should be a minimum of 2 times the diameter.
curve (DAC) whose construction is detailed in Test disks or plates may be used whose minimum
ASTM A388. thickness is 70 percent of the appropriate test bar
diameter. The minimum inscribed diameter on a test
-- For cast products the straight beam proce- disc (or plate dimensions) should be three times its
dures described in ASTM A609 shall apply. The thickness.
back reflection method shall be used.
For determination of case hardness, case depth,
4.2 Test coupons and case microstructure, the process control test
4.2.1 Process control test coupons coupon should be examined on a section normal to
its axis and at least one diameter from the end of the
Process control test coupons are used to monitor test coupon. Case hardness is to be measured by a
various heat treatment process parameters, their microhardness method at a depth 0.002 to 0.004
variation, their interactions, and to verify that these inch (0.05 to 0.10 mm) below the surface. Any
parameters are maintained within their expected post--heat treat stock removal must be considered.
4.2.2 Representative test coupon ratings. Refer to the applicable gear rating
standards for specific gear ratings.
The representative test coupon shall be from the
same grade of alloy steel with similar hardenability Individual customers and manufacturers may have
as the production part, but need not necessarily be specific modifications to the metallurgical grade
from the same heat of steel. Representative test requirements or special material and processing
coupon proportions of a minimum diameter of 6 conditions that are not covered in these tables.
divided by the normal diametral pitch (6 times These modifications and special conditions are
module) but not less than 5/8 inch diameter (16 mm), permissible with mutual agreement.
and a minimum length 2 times its diameter, as used The following tables establish reasonable minimum
in ISO 6336--5, are recommended. A representative limits for each material and metallurgical character-
test coupon may contain a tooth form that will be istic that will allow gearing, which meet dimensional
used to verify the heat treat process. tolerances, to meet the minimum expectations of the
gear rating design standards. As individual gearing
With customer approval, representative test coupon designs increase in size and complexity of features,
proportions of a minimum diameter of 3 divided by they become more difficult to manufacture, heat
the normal diametral pitch (3 times module) but not treat, and inspect. This document, as a general rule,
less than 5/8 inch diameter (16 mm), and a minimum does not differentiate based on gearing size.
length 2 times its diameter, as used in ISO 6336--5, However, where necessary, specific notation is
are recommended. made to reflect the special processing methods,
A representative test coupon should have the same techniques and inspections required for large gear
heat treat condition prior to carburizing as the part(s) manufacturing.
represented. This coupon should remain with the All requirements for a metallurgical quality grade
part(s) represented throughout the entire heat treat must be met in order to use the stress value, from the
process, with the possible exception of heat AGMA rating standard, for that grade. This can be
treatments prior to carburizing. accomplished by specifically certifying each require-
ment where necessary, or by establishing practices
The representative test coupon, when positioned in
and procedures to obtain the requirements on a
a heat treat load in the same general area but
production basis. It is not the intent of this document
separate from the piece part, is intended to represent
that all requirements for metallurgical quality grade
the metallurgy of the heat treated tooth section. The
be certified, but that practices and procedures be
microstructure at the center of the minimum size established for their compliance on a production
representative test coupon approximates the core basis. Intermediate values are not classified since
microstructure of the tooth section. the effect of deviations from the quality standards
cannot be evaluated easily. Specific sampling plans
and test methods need to be addressed by either the
manufacturer, the customer, or both.
5 Metallurgical requirements
The various characteristics are listed in the order in
which that characteristic is typically evaluated during
The metallurgical characteristics identified in the the manufacturing sequence. Each individual
tables of this clause are intended to be used for all characteristic has the same item number in tables 1,
steel gearing. Metallurgical characteristics defined 2, 3 and 4 whenever it is used, regardless of which
in the tables of this clause are intended to assure the table it appears. Some characteristics are only
quality of the finished gear teeth.
applicable to specific heat treat methods. Therefore,
Individual AGMA rating standards may have specific some item numbers are not used in some tables.
modifications to the metallurgical characteristics Characteristics that are typically evaluated at the
grading; but the intent is to formalize the assump- same time are grouped by having the same number
tions and definitions on which the various AGMA before the decimal point, and modified with different
standards are based. These characteristics should numbers after the decimal point for the individual
be compatible, wherever possible, with ISO 6336--5. characteristics evaluated at that time.
Users of this document must be aware that the 5.1 Through hardened gearing
Grade 1, Grade 2 and Grade 3 gearing produced by The major metallurgical characteristics that affect
different heat treatment processes have different through hardened gearing performance are shown
in table 1. The minimum acceptable requirements be met to qualify for the stress number associated
for each factor for metallurgical quality Grades 1 and with that metallurgical quality grade.
2 are specified. All criteria in any given grade must
Table 1 (concluded)
5.2 Carburize and hardened gearing minimum acceptable requirements for each factor
The major metallurgical characteristics that affect for metallurgical quality Grades 1, 2 and 3 are
carburize and hardened gearing performance are specified. All criteria in any given grade must be met
shown in table 2. Neither carbonitrided nor nitrocar- to qualify for the stress number associated with that
burized gearing is covered by this document. The metallurgical quality grade.
Table 2 (continued)
Item Characteristic1) 2) Grade 1 Grade 2 Grade 3
9 Ultrasonic inspection4) 7)
Wrought material. Inspection recommended to the Inspection required to the following
Either method is acceptable. following limits: limits:
-- Flat bottom hole (FBH) Not specified. -- No indications giving a signal re- -- No indications giving a signal re-
technique sponse greater than an 8/64 inch sponse greater than a 5/64 inch
(3.18 mm) reference standard. (1.98 mm) reference standard.
-- No indications giving a signal -- No indications giving a signal re-
response greater than 50% of the sponse greater than 50% of the ref-
reference standard if accompanied erence standard if accompanied by
by a 50% loss of back reflection. a 50% loss of back reflection.
-- No indications which are -- No indications which are continu-
continuous over an area twice the ous over an area twice the diameter
diameter of the search unit. of the search unit.
-- Back reflection technique Not specified. -- No indications giving a signal re- -- No indications giving a signal re-
sponse greater than 15% of back sponse greater than 10% of back
reflection. reflection.
-- No multiple indications that lower -- No multiple indications that lower
the amplitude of the first back re- the amplitude of the first back re-
flection by more than 40%. flection by more than 20%.
-- No traveling indications whose -- No traveling indications whose
amplitude is greater than 10% of amplitude is greater than 10% of
back reflection and length is great- back reflection and length is great-
er than 0.75 inch (19 mm). er than 0.50 inch (13 mm).
Castings
-- Back reflection technique Not specified. -- ASTM A609 Level 1 from outside
surface to 1.5 times tooth height
below finished tooth tips.
-- ASTM A609 Level 2 greater than
1.5 times tooth height below fin-
ished tooth tips.
11 Tempering after case Recommended. Required.
hardening
12 Surface hardness in tooth area. Should meet the following characteristics:
Alternative method of inspec-
tion is case hardness.8) 9) 10)
-- Tooth flank 55--64 HRC or 58--64 HRC or equivalent 58--64 HRC or equivalent
equivalent
-- Tooth root
-- Normal diametral pitch 3 53 HRC minimum or 56 HRC minimum or equivalent 58 HRC minimum or equivalent
(module 8) and coarser equivalent
-- Normal diametral pitch 55 HRC minimum or 58 HRC minimum or equivalent 58 HRC minimum or equivalent
finer than 3 (module 8) equivalent
13 Case depth considering Should meet the following characteristics:
subsequent stock removal
13.1 Effective case depth in finished Minimum and maximum effective case depth requirements for the tooth should be specified in
condition 10) 11) accordance with the appropriate rating standard.
13.2 Effective case depth minimum Not specified. 50% of minimum specified effective 66% of minimum specified effective
at root radius, as determined by case at 1/2 tooth height case at 1/2 tooth height
bending strength rating.10) 11) recommended. recommended.
12)
(continued)
Table 2 (continued)
Item Characteristic1) 2) Grade 1 Grade 2 Grade 3
15 Surface carbon (typical)15)
For up to 2.5% total nominal 0.60 -- 1.10%C 0.60 -- 1.10%C 0.60 -- 1.00%C
alloy content
2.5% to 3.5% total nominal 0.60 -- 1.10%C 0.60 -- 1.00%C 0.60 -- 1.00%C
alloy content
Over 3.5% total nominal alloy 0.60 -- 1.10%C 0.65 -- 0.95%C 0.65 -- 0.95%C
content
16 Surface microstructure consid- The first 0.002 -- 0.003 inch (0.05 -- 0.08 mm) of case microstructure in the tooth area should
ering subsequent stock remov- meet the surface hardness requirement of the specific grade and also meet the following sur-
al 12) 16) face related characteristics and the requirements of Item 17:
16.1 Intergranular oxidation (IGO) Not specified.
(see figure 9)
Minimum specified effective
case depth
inch (mm)
at less at less Maximum allowable depth Maximum allowable depth
least than least than inch (mm) inch (mm)
---- 0.030 ---- (0.75) 0.0007 (17) 0.0005 (12)
0.030 0.060 (0.75) (1.50) 0.0010 (25) 0.0008 (20)
0.060 0.090 (1.50) (2.25) 0.0015 (38) 0.0008 (20)
0.090 0.120 (2.25) (3.00) 0.0020 (50) 0.0010 (25)
0.120 ---- (3.00) ---- 0.0025 (60) 0.0012 (30)
16.2 Non--martensitic transforma- Not specified.
tion products (see figure 10)17)
Minimum specified effective
case depth
inch (mm)
at less at less Maximum allowable depth Maximum allowable depth
least than least than inch (mm) inch (mm)
---- 0.030 ---- (0.75) 0.0007 (17) 0.0005 (12)
0.030 0.060 (0.75) (1.50) 0.0010 (25) 0.0008 (20)
0.060 0.090 (1.50) (2.25) 0.0015 (38) 0.0008 (20)
0.090 0.120 (2.25) (3.00) 0.0020 (50) 0.0010 (25)
0.120 ---- (3.00) ---- 0.0025 (60) 0.0012 (30)
16.3 Decarburization. Any of the
following methods are
acceptable.
-- Method 1. File testing. Not specified. Gear tooth surfaces must be file hard to the minimum surface hardness.
-- Method 2. Reduction of sur- Not specified. Maximum 3 HRC points or equiva- Maximum 1.5 HRC points or equiv-
face hardness by two load lent below maximum measured alent below maximum measured
method or reduction of case hardness by conversion, but hardness by conversion, but
hardness.10) measuring at least 58 HRC or measuring at least 58 HRC or
equivalent by conversion in the equivalent by conversion in the
finished state. finished state.
-- Method 3. Metallographic Not specified. No partial decarburization appar- No partial decarburization appar-
evaluation. ent on active tooth profile. No fer- ent on the gear tooth. No ferrite (to-
rite (total decarburization) is per- tal decarburization) is permissible
Minimum specified effective missible in the case microstructure in the case microstructure of the
case depth of the gear tooth. gear tooth.
inch (mm)
at less at less Maximum allowable depth in root
least than least than inch (mm)
---- 0.030 ---- (0.75) 0.0007 (17)
0.030 0.060 (0.75) (1.50) 0.0010 (25)
0.060 0.090 (1.50) (2.25) 0.0015 (38)
0.090 0.120 (2.25) (3.00) 0.0020 (50)
0.120 ---- (3.00) ---- 0.0025 (60)
17 Case microstructure consider- The microstructure of the first 20% of the minimum specified effective case depth should be pre-
ing subsequent stock removal, dominantly tempered martensite. Additional requirements for the case microstructure are given
disregarding corner effects 12) in Item 16 and the following case related characteristics:
(continued)
Table 2 (continued)
Table 2 (continued)
(continued)
Table 2 (concluded)
NOTES:
15) Optimum pitting resistance is best achieved at surface carbon levels above the eutectoid carbon for a given alloy chemistry.
16) If excessive, salvage may be possible by processes such as shot peening per Item 23 or by grinding provided the integrity of the
gearing is not compromised.
17) At maximum allowable depths the surface may not be file hard and may not have the expected residual stress profile.
18) Bainite, observable at 200X, that extends from the core microstructure into the case area is considered a ratable characteristic.
This bainite is the result of slower heat extraction rates due to part section size, mass of furnace load, marginal agitation, elevated
quenchant temperatures, and generally follows alloy segregation and material flow lines. The bainite that results in a fine pepper
structure at 400 -- 600X, but is still not resolvable at 800X, is considered nonratable (trace).
19) Maximum limit of microcracks (Item 17.5) for Grade 3 gearing may be difficult to achieve if cold treatment is used to transform the
retained austenite level to 30% maximum.
20) Removal of defects that exceed the stated limits is acceptable, provided the integrity of the gear is not compromised.
21) Cracks in nonfunctional areas require engineering disposition.
22) Limits: maximum of one indication per inch (25 mm) of face width with a maximum of five such indications on any one tooth flank.
Indications less than 1/32 inch (0.8 mm) are not considered.
23) It is recommended that ANSI/AGMA 2004--B89 be reviewed to determine if the benefits of surface residual compressive stress
achieved by shot peening may be beneficial to the particular application. Shot peening of the flanks of gear teeth should be reviewed to
ensure that no detrimental effects are caused to the gear set.
5.3 Induction or flame hardened gearing Grades 1, 2 and 3 are specified. Grade 3 is restricted
The major metallurgical characteristics that affect to contour spin induction Type A (Contour) harden-
induction or flame hardened gearing performance ing only. All criteria in any given grade must be met to
are shown in table 3. The minimum acceptable qualify for the stress number associated with that
requirements for each factor for metallurgical quality metallurgical quality grade.
Table 3 (continued)
Item Characteristic1) 2) Grade 1 Grade 2 Grade 3
Spin induction Type A
(Contour) only
7 Mechanical properties prior to Not specified. 28 HRC minimum. Other mechani- 30 HRC minimum. Other mechani-
surface hardening. See also cal testing is required only if speci- cal testing is required only if speci-
Item 14. 6) 7) fied. fied.
8 Microstructure prior to surface Not specified. Sound metallurgical practice dictates that the core microstructure re-
hardening3) quirements are maintained in the tooth area to a depth twice the minimum
specified effective case depth or 0.100 inch (2.5 mm), whichever is less,
below the minimum specified effective case depth. The microstructure
in this zone should be predominantly tempered martensite that is free of
blocky ferrite, pearlite, and measurable bainite observable at 400--600X.
Below this zone the core microstructure should be primarily tempered
martensite and free of blocky ferrite with the following limits:
Controlling section size, Non--martensitic structures,
inch maximum
at least less than
---- 5 5%
5 10 10%
10 15 20%
15 ---- Hardness must be obtained at
roots with 900F minimum temper
Table 3 (continued)
Item Characteristic1) 2) Grade 1 Grade 2 Grade 3
Spin induction Type A
(Contour) only
10 Overheating, especially at the Avoid surface temperatures that result in grain growth, incipient melting or unfavorable
tooth tips and end faces 8) residual stresses. Larger chamfers minimize this problem.
11 Tempering after surface 1 hour minimum at temperature furnace temper is required.9)
hardening
12 Surface hardness on a repre- 50 HRC minimum or 54 HRC minimum as required by 58--64 HRC or equivalent
sentative surface. Alternative rating standard.
method of inspection is case
hardness. 7) 8)
13 Case depth considering subse- Should meet the following characteristics:
quent stock removal. Also see
Item 19. 7) 8) 10)
13.1 Effective case depth in finished Minimum and maximum effective case depth should be Minimum and maximum effective
condition specified in accordance with the rating standard. A case depth should be specified in
hardening pattern per figure 14 shall be specified. accordance with the rating stan-
dard. Figure 14 Type A contour
pattern only shall be specified.
13.2 Effective case depth minimum Not specified. 50% of minimum specified effective 100% of minimum specified effec-
at root radius, or on representa- case at 1/4 tooth height above the tive case at 1/4 tooth height above
tive sample with same root recommended. the root recommended, and 66% of
geometry and material as work minimum specified effective case
piece, as determined by at the root.
bending strength rating.
14 Base hardness after surface Not specified. 28 HRC minimum 30 HRC minimum
hardening.
Also see Item 7. 6) 7) 8) 10)
17 Case microstructure consider- The first 20% of the case microstructure should be predominantly tempered martensite. The
ing subsequent stock removal, microstructure should be free of undissolved pearlite observable at 100X and measurable
disregarding corner bainite observable at 400 -- 600X.
effects8) 10) 11)
The following case microstructure characteristics for each grade must be met:
17.3 Microstructure of case along Primarily fine Primarily fine acicular tempered Primarily fine acicular tempered
flank (for pitting resistance acicular marten- martensite. Non--martensitic struc- martensite with no non--martensitic
rating). site. tures anywhere in the case should structures.
not exceed 5%.
17.5 Microstructure at root (for Primarily fine Primarily fine acicular tempered Primarily fine acicular tempered
bending strength rating). acicular marten- martensite. Non--martensitic struc- martensite. Non--martensitic struc-
site. tures anywhere in the case should tures anywhere in the case should
not exceed 10%. not exceed 5%.
19 Heat affected zone. Also see Induction and flame hardening heat treatments have a characteristic heat affected zone that
Item 13. 8) 10) is caused by the surface heating process. This zone can have lower hardness and different
microstructure than the base material. The case depth specification should be established
to avoid gear failure which might initiate in this zone.
20 Surface temper etch inspection Not specified. FB2, which allows light tempering FB1, which allows light tempering
of ground teeth on 25% of functional area. on 10% of functional area.
21 Surface cracks 12) 13) Cracks, bursts, seams and laps are not permissible in functional areas of finished gearing.
22 Magnetic particle inspection of Inspection to the following limits:
finished gearing5) 12) 13) 14)
-- Below the pitch line Not specified. No indications. No indications.
-- Above the pitch line
Normal
diametral pitch Module
at less more at Indication, maximum Indication, maximum
least than than most inch mm inch mm
---- 3 8 -- -- Not specified. 1/8 3.2 3/32 2.4
3 10 2.5 8 3/32 2.4 1/16 1.6
10 ---- -- -- 2.5 1/16 1.6 1/32 0.8
(continued)
Table 3 (concluded)
Item Characteristic1) 2) Grade 1 Grade 2 Grade 3
Spin induction Type A
(Contour) only
23 Shot peening 15) Shot peening per SAE/AMS--S--13165 may be used to increase surface residual
compressive stress.
NOTES:
1) See clause 3 for definitions and clause 4 for test methods.
2) The metallurgical requirements assume homogeneous composition. In practice, microsegregation and banding occurs in steels.
This microsegregation can produce variations in microstructure and properties that need to be assessed.
3) The grade requirements for non--metallic inclusion, ultrasonic, and microstructure characteristics apply only to those portions of the
gear material where the teeth will be located to a depth below the finished tooth tip of at least 1.5 times the tooth height.
4) A 7 to 1 minimum reduction ratio is recommended. For large gearing where this reduction ratio is not physically obtainable, lesser
reduction ratios may be used down to a minimum of 3 to 1.
5) In--process ultrasonic and/or magnetic particle inspection of gearing blanks is recommended for large diameter parts to detect
flaws before incurring the expense of further machining.
6) Mechanical properties, including core hardness, may not be the same after induction or flame hardening as they were before induc-
tion or flame hardening.
7) See ASTM A370, ASTM E140 or ISO 6336--5, annex C for hardness conversion tables.
8) See clauses 3 and 4 for a discussion on test coupons.
9) Induction tempering is recommended for Grade 3 as a crack preventing stress relief heat treatment prior to furnace tempering.
10) The hardness pattern, depth, facilities and process method must be established, documented and verified to be repeatable. The
process equipment and methods must be sufficiently accurate to reproduce the specified results. Excessive case depth can generate
unfavorable residual stress conditions.
11) Microstructure analysis of induction hardened test specimens have shown indications of undissolved pearlite or ghost pearlite.
This is especially true with rapid (short) heating cycles. This ghost pearlite should not be present.
12) Removal of defects that exceed the stated limits is acceptable, provided the integrity of the gear is not compromised.
13) Cracks in non--functional areas require engineering disposition.
14) Limits: maximum of one indication per inch of face width with a maximum of five such indications on any one tooth flank. Indications
less than 1/32 inch (0.8 mm) are not considered.
15) It is recommended that ANSI/AGMA 2004--B89 be reviewed to determine if the benefits of surface residual compressive stress
achieved by shot peening may be beneficial to the particular application. Shot peening of the flanks of gear teeth should be reviewed to
ensure that no detrimental effects are caused to the gear set.
Spin hardening
Induction coil Induction coil
Inductor coil or flame head or flame head
Type B Type B
Grades 1 and 2 only Grades 1 and 2 only
Flank and root hardening (tooth to tooth)
Inductor or flame head
Type A
Grades 1 and 2 only
NOTE:
-- Type A indicates that flanks and roots are hardened for contour or non--contour patterns.
-- Only spin hardening Type A (Contour) is applicable to Grade 3.
-- Type B indicates that the flanks are hardened only to the form diameter.
-- For Type B the full active profile must be hardened with the transition zone not in the root fillet area.
Figure 14 -- Variations in hardening pattern obtainable on gear teeth with flame or induction
hardening
(continued)
Table 4 (continued)
(continued)
Table 4 (concluded)
Item Characteristic1) 2) Grade 1 Grade 2 Grade 3
17 Case microstructure consider- The first 20% of the case microstructure should be predominantly tempered martensite with
ing subsequent stock removal, interspersed nitride. The microstructure should be free of blocky ferrite, pearlite, and mea-
disregarding corner effects surable bainite.
20 Surface temper inspection The normal inspection methods, as defined in ANSI/AGMA 2007--B92 or ISO 14104, are not
applicable to nitrided gearing. Care must be taken when grinding nitrided surfaces to ensure
that no harmful surface conditions are produced in the grinding process.
21 Surface cracks 11) 12) Cracks, bursts, seams and laps are not permitted in Cracks, bursts, seams and laps are
functional areas of finished gearing. not permitted in any area of finished
gearing.
22 Magnetic particle inspection of Inspection recommended to the Inspection required to the
finished gearing 6) 11) 12) 13) following limits: following limits:
-- Below the pitch line Not specified. No indications. No indications.
Bibliography
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Steel Gearing, or indicated for additional information.
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John Wiley & Sons, New York, 1979
ASM Handbook, Volume 1 -- Properties and selec-
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ASM International, Materials Park, Ohio, 1990 Principles, ASM International, Materials Park, Ohio,
1996
ASM Handbook, Volume 4 -- Heat treating, ASM
International, Materials Park, Ohio, 1991 Parish, Geoffrey, Carburizing: Microstructures and
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Boyer, Howard E., Ed., Hardness Testing, ASM
1999
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Practical Data for Metallurgists, 14th edition, The
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Van Nostrand, New York, 1973
Heat Treaters Guide -- Practices and procedures for
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