Failure Analysis of Cracking Gypsum Kiln Conveyor Chain

Failure Analysis was Performed on Cracking Links on a Conveyor Chain – used for Material Transfer in a Gypsum Kiln.

The links were fabricated from AISI-SAE 1045 steel in the hardened and tempered condition, with Rockwell C Hardness (HRC) values measured at 41 to 43 HRC. The cracking was observed primarily at the side link pin and sleeve holes that exhibited notches from the punching operation. Limited cracking was observed in the rollers. Excessive wear and galling was also observed on the bearing surfaces of the link pins that exhibited low hardness.

Chains are assumed to be subjected to impact loads during service, and when excessively hard, become notch sensitive and susceptible to brittle fracture. The chain links failed due to the presence of notches in the highly stressed pin and sleeve holes, coupled with high hardness of the links that initiated fatigue cracking at the notches.

We recommended utilizing hardness over 32 HRC to increase toughness and still provide sufficient strength and wear resistance for this application. In addition, we recommended that the chains exhibited smooth links and sleeve hole surfaces to eliminate notches. Additionally – that individual chain components should exhibit hardness within approximately 5 HRC points of each other to minimize galling and wear.

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