Failure analysis of axle shaft of a fork lift

An axle shaft of fork lift failed at operation within 296 h of service. The shaft transmits torque from discrepancy to wheel through planetary gear arrangement. A section of fractured axle shaft made of induction-hardened steel was analyzed to determine the root cause of the failure. Optical microscopies as well as field emission gun scanning electron microscopy (FEG-SEM) along with energy dispersive spectroscopy (EDS) were carried out to characterize the microstructure. Hardness profile throughout the cross-section was evaluated by micro-hardness measurements. Chemical analysis indicated that the shaft was made of 42CrMo4 steel grade as per specification. Microstructural analysis and micro-hardness profile revealed that the shaft was improperly heat treated resulting in a brittle case, where crack was found to initiate from the case in a brittle mode in contrast to ductile mode within the core. This behaviour was related to differences in microstructure, which was observed to be martensitic within the case with a micro-hardness equivalent to 735 HV, and a mixture of non-homogeneous structure of pearlite and ferrite within the core with a hardness of 210 HV. The analysis suggests that the fracture initiated from the martensitic case as brittle mode due to improper heat treatment process (high hardness). Moreover the inclusions along the hot working direction i.e. in the longitudinal axis made the component more susceptible to failure.