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How were the cracks discovered? Visual examination? Penetrant inspection?

I have an old copy of "Engineering Alloys" (1954 edition) which shows a tensile strength of 30,000 psi for Meehanite E. Brinell hardness is shown as 140. It is also noted that Grade E was superceded by grade GE.

I consider myself fortunate to have seen both the 4014 Big Boy and the 3985 Challenger run west of Chicago. What surprised me the most was how quiet they are at speed.

I took mine in 1981. Back then (Indiana) there was not a specific test for metallurgical engineering--the test was just for general knowledge that an engineer would be expected to have. One reference book I used the most was the Bosch Automotive Handbook. My experience was similar to to what...

The MIG 25 had stainless steel wing skin. This was discovered when we got the chance to examine one that a defector had flown to Japan.

With sand or pm cast, you have the option of machining test bars from castings, given sufficient section size. This is not feasible with die castings because of the inherent porosity.

Mechanical properties for aluminum die castings are based on separately cast test bars. It is a stretch to correlate those properties to the actual properties of the component. You need to establish some critical property like a burst test or load test of the actual part. The use of properties...

I understood the original poster to be inquiring about a splined shaft, not a gear. At one of my previous places of employment, we turned out splined axle shafts for automotive use. All 1050 steel, all induction hardened, water quenched. Some also received straightening.

Normally, induction hardened shafts are water quenched. And SAE 1050 would be a more typical steel than 1144 for this purpose.

Back to the original query--the max hardness a steel can be hardened to is entirely dependent on carbon content. The max hardness at depth below the surface is dependendent on section size, alloy content and quench media.

I am thinking that these roller bearing assemblies are permanently greased, i.e. there is no periodic lubing, unlike the old friction type bearings.

I worked for a CV joint company. Hytrel was the material we used for boots.

It would help if you would provide a description of the part and the intended service environment.

350F is a typical ageing temperature for 6061-Txxx. If you stress relieve on top of this, you will reduce the mechanical properties of the product. What are you trying to accomplish? What is the product form?

It just looks like the fracture is dirty. Try sticking it in an ultrasonic cleaner for about 30 seconds.

Aircraft wheel bearings I have worked with have all had case hardened rollers. Base material was 8617.

How would HD galvanizing cause hydrogen embrittlement?

I see. In that case, I would inclined to coat the bead area with your zinc phosphate coating and let it go at that. When I worked in the aircraft wheel and brake business, procedure was to strip the paint during overhaul in order to facilitate penetrant inspection, then re-paint, which obviously...

You need to take this up with your customer.

I once worked on the aluminum wheels on my Jeep Cherokee. They had a painted (gray) center spoke section and the rim was aluminum with a clear finish which was peeling. I stripped the edges of the rims and buffed them to a shiny finish. This sounds similar to your situation and as you have...