Do cracked jaws of the four-jaw chuck of a large lathe pose a danger?

All the jaws of a four-jaw chuck mounted on the faceplate of a large lathe were received by the material testing laboratory to undergo metallurgical failure analysis. Each of the four jaws exhibited cracks in the fillet radius between one of the gripping surfaces and the long horizontal part. The cracks were just visible to the unaided eye und had been discovered by an alert mechanic. One of the jaws was selected for further material analysis for which the crack was opened to undergo fractographic evaluation. The analysis also involved the evaluation of the material using optical emission spectrometry, the preparation of a metallographic sample, and hardness testing. The cracks occurred as a result of repeated overload at the crack initiation sites located in the fillet radius. This was not a single overload event which would not have caused the jaws to crack, but a series of overload events. The situation did not pose a safety hazard to the staff since the soft and tough core of the case-hardened jaws would have retarded, if not stopped, crack growth. A sudden disastrous failure of the jaws by breaking off, for example, and extremely heavy components crashing down as a result were not an imminent threat. This dangerous failure scenario would have been enabled if the jaws had been through-hardened. Instead, casehardening heat treatment had been applied which is the correct choice for this type of component.