BMW Flange M0003114 Crack Issue

Highway Industries Ltd

7/29/22
 RAW MATERIAL TABLOUR FORM
  Heat No. : 82478 Highway Ind. Ltd.
  Dia : 60 MM Unit - 3, Mangli.
  Grade : SAE1045 Ludhiana
   

RESULTS
 
  Sr. No. ELEMENTS SPECIFICATION (%) ACTUAL (%)  

  1 CARBON 0.46 - 0.50 0.49  

  2 SILICON 0.15 - 0.35 0.24  

  3 MANGANESE 0.80 - 0.90 0.82  

  4 PHOSPHORUS 0.030 Max 0.016  

  5 SULPHUR 0.050 Max 0.016  

  6 CHROMIUM 0.15-0.20 0.17  

  7 COPPEER 0.35 Max 0.099  

  8 NICKEL 0.25 Max 0.081  

  9 MOLYBDENUM 0.06 Max 0.025  

  10 ALUMINUM - 0.026  

  11 NIOBIUM - 0.008  

  12 TITANIUM - 0.002  

  13 VANADIUM - 0.002  

CONCLUSIONS : Based on the specifications for the TDC it is concluded that all the results are within
specification.
7/29/22
 HEAT TREATMENT PROCESS PARAMETR TABLEUR
FORM (QUENCH TEMPER)

HARDENING TEMPERING HARDENING TEMPERING BELT

DATE TEMP TEMP BELT SPEED SPEED QUENCH TEMP

  840 - 850⁰C 620 - 630⁰C 22Hz 14Hz 35 - 39 ⁰C

14.2.22 840-843 619-622 22 14 37

15.2.22 841-845 618-620 22 14 38

16.2.22 840-843 618-621 22 14 37

18.2.22 841-845 619-622 22 14 37

19.2.22 842-545 618-625 22 14 39

20.2.22 841-843 618-624 22 14 36

CONCLUSIONS : Based on the specifications it is concluded that all the results are within
specification.
7/29/22
 HEAT TREATMENT INSPECTION REPORT
(QUENCH TEMPER)

AS QUENCH AS Q TEMPERED
DATE AS QUENCH HARDNESS MICROSTRUCTURE AS TEMPERED HARDNESS MICROSTRUCTURE

  229-265 HBW MARTENISTE 229 -265 HBW TEMPERED MARTENISTE

14.2.22 242-248 Martensite 247 Tempered Martensite

15.2.22 238-243 Martensite 242 Tempered Martensite

16.2.22 242-247 Martensite 245 Tempered Martensite

18.2.22 241-247 Martensite 244 Tempered Martensite

19.2.22 238-245 Martensite 245 Tempered Martensite

20.2.22 239-242 Martensite 246 Tempered Martensite

CONCLUSIONS : Based on the specifications it is concluded that all the results are within
specification.

7/29/22
 POLYMER CONCENTRAION INSPECTION
(QUENCH TEMPER)

DATE
POLYMER CONCENTRATION
  9 - 11 %
14.2.22 10.5
15.2.22 10
16.2.22 10.5
18.2.22 10.5
19.2.22 10.8
20.2.22 10.5
CONCLUSIONS : Based on the specifications it is concluded that all the results are within
specification.

7/29/22
 MICROSTRUCTURE

CORE 100X TEMPERED MARTENSITE CORE 500X TEMPERED MARETENSITE

CASE 100X FINE TEMPERED MARTENSITE CASE 500X FINE TEMPERED MARTENSITE

7/29/22
 INDUCTION HARDENING PROCESS PARAMETER
 
Alarm Limit / 11.2.22 12.2.22 13.2.22 14.2.22 15.2.22 16.2.22 17.2.22 18.2.22 19.2.22 20.2.22
Parameters
Specification limit
Machine No IH-MHT-05 IH-MHT-05 IH-MHT-05 IH-MHT-05 IH-MHT-05 IH-MHT-05 IH-MHT-05 IH-MHT-05 IH-MHT-05 IH-MHT-05 IH-MHT-05
coil should not touch
Coil center allignement
the part OK OK OK OK OK OK OK OK OK OK
Coil level at botttom 14.90mm OK OK OK OK OK OK OK OK OK OK
Total Cycle Time in Sec. 30 ~ 33 31.6 31.6 31.6 31.6 31.6 31.6 31.6 31.6 31.6 31.6
Program No. O0001 O0001 O0001 O0001 O0001 O0001 O0001 O0001 O0001 O0001 O0001
GH5L-C03,
Coil No. GH5R-C04 3, 4 3, 4 3, 4 3, 4 3, 4 3, 4 3, 4 3, 4 3, 4 3, 4
GH5L-S01,
Quench Pad No. GH5R-S02 1, 2 1, 2 1, 2 1, 2 1, 2 1, 2 1, 2 1, 2 1, 2 1, 2
GH5L-BF01,
Fixture No. GH5R-BF02 1, 2 1, 2 1, 2 1, 2 1, 2 1, 2 1, 2 1, 2 1, 2 1, 2
Air pressure Kg/cm2 3 minimum 5.16 5.15 5.14 5.14 5.16 5.14 5.14 5.16 5.14 5.14
Hardening                    
Power KW NA / 41 ~ 44 43 43 43 43 43 43 43 43 43 43
Heating Time Sec 9 ~ 11 10.01 9.95 9.95 9.95 9.95 9.95 9.95 9.95 9.95 9.95
Quench Time Sec 20 ~ 24 23.26 23.21 23.21 23.21 23.21 23.21 23.21 23.21 23.21 23.21
Quench flow rate LPM 28 ~ 36 32 32 32 32 32 32 32 32 32 32
Hi Quench P11
concentration % NA/ 9 ~ 11 9.75 9.25 9.25 9.25 9.5 9.5 9.5 9.5 9.5 9.25
P 11 %
Quench Pressure Kg/cm2 2 ~ 4 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5
Quench temp. ℃ 28 ~ 36 30.1 30.8 30.7 30.2 30.2 30.7 31 31 31.8 32
Heating Energy Counts 375 ~ 475 434.1 434.2 431.7 431.7 432.3 432.2 433.1 432.8 432.8 432.7
Frequency(Reference)
KHz NA / 70 ~ 95 85 85 85 85 85 85 85 85 85 85
Voltage(Reference) Volts NA / 95 ~ 125 115 115 115 115 115 115 115 115 115 115
TEMPERING                    
Power KW NA / 8 ~ 14 9 9 9 9 9 9 9 9 9 9
Heating Time Sec 6.0 ~ 7.0 6.56 6.56 6.44 6.44 6.44 6.44 6.44 6.44 6.44 6.44
Tempering Energy Counts 40 ~ 80 60.1 62.1 59.1 59.2 60.2 60.1 59.2 60.1 60.1 60.1
Frequency(Reference)
KHz NA / 80 ~ 110 100 100 100 100 100 100 100 100 100 100
Voltage(Reference) Volts NA / 10 ~ 30 20 20 20 20 20 20 20 20 20 20

CONCLUSIONS
7/29/22 : Based on the specifications it is concluded that all the results are within
specification.
 INDUCTION HARDENING INSPECTION REPORT

    11.2.22 12.2.22 13.2.22 14.2.22 15.2.22 16.2.22 17.2.22 18.2.22 19.2.22 20.2.22
Positions Specifications  
                 
Core Hardness HV30 234 ~ 272 HV30 244 248 249 246 252 242 243 252 250 247
Surface hardness HRC IH Area (56 ~ 59 HRC) 58 58   58 57 58 58 57 58 58

ECD @ 480 HV1 MP 1 at 7.8 mm: 0.7 ~ 2.50mm 1.89 1.81   2.03 1.73 1.78 1.79 1.74 1.71 1.75

  MP 2 at 11.0 mm: 0.7 ~ 2.50mm 1.28 1.01   1.51 1.41 1.11 1.44 1.31 1.45 143

  MP 3 at 3.2 mm: 0.7 ~ 1.50mm 1.07 1.06   1.19 0.91 0.81 0.89 0.83 1.01 1.12

No Hardening zone MP 4 ( 234 - 272 HV30 ) 250 241   242 244 249 242 245 247 244

Hardened Lengths 11+2.0mm 12.42 12.2     12.67 12.55 12.5 12.5 12.64 12.42

Fine Tempered

Fine Tempered

Fine Tempered
Fine Tempered

Fine Tempered

Fine Tempered

Fine Tempered
Fine Tempered

Fine Tempered

Fine Tempered
Martensite

Martensite
Martensite

Martensite

Martensite

Martensite

Martensite

Martensite

Martensite

Martensite
Case Microstructure at 100X &
500X Fine Tempered Martensite
Martensite

Martensite
Martensite

Martensite

Martensite

Martensite

Martensite

Martensite

Martensite

Martensite
Tempered

Tempered

Tempered

Tempered

Tempered

Tempered

Tempered
Tempered

Tempered

Tempered
Core Microstructure at 100X & Tempered Martensite
500X
CONCLUSIONS : Based on the specifications it is concluded that all the results are within
specification.

7/29/22
MAGNETIC CRACK DETECTION PROCESS PARAMETES

11.2.22 12.2.22 13.2.22 14.2.22 15.2.22 16.2.22 17.2.22 18.2.22 19.2.22 20.2.22

0.1 -0.4 ml
Powder Conc /100ml 0.25 0.3 0.3 0.3 0.25 0.25 0.3 0.25 0.3 0.3
Magnetize 5-10 gauss 8.1 7.1 7.6 8.4 7.4 8.3 7.6 8.4 7.5 7.7
De magnetised 0-2 gauss 0.9 0.8 0.9 0.8 0.5 0.8 0.6 0.9 0.6 0.7
Light intenisty 1000uW/cm2 1380 1430 1140 1920 2060 1380 1450 1510 1390 1420
Current 1000 -1200 1198 1200 1198 1198 1198 1198 1198 1198 1198 1198

proper idication
of minimum 3
lines om pie
Pie gauge gauge ok ok ok ok ok ok ok ok ok ok

proper idication
of crack on
master piece master piece yes yes yes yes yes yes yes yes yes yes
CONCLUSIONS : Based on the specifications it is concluded that all the results are within
specification.

7/29/22
MAGNETIC CRACK DETECTION INSPECTION REPORT

DATE CRACK PC
11.2.22 0
12.2.22 0
13.2.22 0
14.2.22 0
15.2.22 0
16.2.22 0
17.2.22 0
18.2.22 0
19.2.22 0
20.2.22 0
MCD 100 % DONE AND FOUND NO CRACK PC
7/29/22
 Material In transit Details

TOTAL : 101760
7/29/22
THANKS
7/29/22