INVESTIGATIVE SUMMARY

Cardwell Westinghouse
433 West 83rd St
Chicago, IL 60620

Report No.:
Date:
Order No.:
Page:

237863A
9/21/2015
101336
1 of 5

Attention: Mr. Shaun Whalen

Supplement to SGS MSi Report 237863: Additional material specification provided by Client.

BACKGROUND
One (1) fractured side bearing cage was submitted to our laboratory for a metallurgical investigation. The
part reportedly failed in the field after approximately two years of service. The material was identified as
austempered ductile iron (ADI) per the client material specification SK-3086. No further background
information was available. We were requested to determine the nature of the failure and verify the grade
and chemical composition.

SAMPLE IDENTIFICATION
Client ID
TST-0265

Part Description
SBX-45 Side Bearing Cage (Housing)

Client Specification
SK-3086

Material
ADI

PERFORMED TESTING
Visual and Stereoscopic Examination
Metallographic (Microstructural) Examination
Chemical Testing
Tensile Testing
Charpy Impact Testing
Hardness Testing

CONCLUSIONS
1. Based upon the performed tests, examinations and supplied background information, it is our
opinion the cage failed due to a single-event brittle overload. No evidence was observed of any
pre-existing defects or detrimental microstructural conditions that could have contributed to the
failure.
2. Visual examination of the fracture surfaces revealed a flat, dull and fibrous appearance with no
evidence of a progressive fatigue failure mechanism. Stereoscopic examination revealed a radial
pattern originating from the inner surface at the base of the cage, which was identified as the
fracture initiation site. No evidence was observed of any pre-existing casting defects that could
have contributed to the failure. The overall fracture features were characteristic of a single-event
brittle overload fracture.

Cardwell Westinghouse
Report No. 237863A
Page 2 of 5

CONCLUSIONS (cont.)
3.

Metallographic examination indicated the fracture exhibited a mixed mode of intergranular and
transgranular crack propagation through the entire thickness, typical of rapid overload. No
evidence was observed of any pre-existing casting defects or detrimental microstructural
condition, such as graphite degradation, at the ID surface that could have contributed to the failure.

4.

The observed microstructure and the chemical, tensile, Charpy impact and hardness test results
conformed to the client specified minimum requirements of SK-3086.

SUMMARY of TEST RESULTS

Visual and Stereoscopic Examination
1.

The submitted cage was received with a dual fracture originating from the base of the cage at the
lug slot (see Photo 1). A section of the cage fractured away and was not available for
examination. The fracture surfaces were heavily oxidized and rusted. The fracture surfaces were
ultrasonically cleaned in a slightly alkaline (soap) solution for further examination.

2.

Visual examination after cleaning revealed both fracture surfaces exhibited a flat, dull and fibrous
appearance with no evidence of a progressive fatigue failure mechanism. Stereoscopic
examination revealed a radial pattern originating from the inner surface at the base of the cage
(see Photo 2). No evidence was observed of any pre-existing casting defects that could have
contributed to the failure. The overall fracture features were characteristic of a single-event brittle
overload fracture.

ID Surface

Photo 1: As-received cage showing dual fractures originating

from the ID surface at the base (arrows)

Photo 2: Exposed fracture surface showing the cracking

originated from the ID surface.
Magnification: 7X

Cardwell Westinghouse
Report No. 237863A
Page 3 of 5
Metallographic Examination
1.

A cross section through one of the fractures was removed and prepared for metallographic
examination.

2.

Metallographic examination indicated the fracture exhibited a mixed mode of intergranular and
transgranular crack propagation through the entire thickness, typical of rapid overload (see
Photos 3 and 4). No evidence was observed of any pre-existing casting defects or detrimental
microstructural conditions, such as graphite degradation, at the ID surface.

3.

Examination of the sample in the unetched condition revealed a uniform distribution of nodular
graphite (see Photo 5). The graphite nodularity, nodule count, form type and size were rated in
accordance with ASTM 247, Plates I and III with the following results:

4.

Sample ID

% Nodularity

Nodule Count/mm2

Graphite Form

Size Class

SB Cage

90%

125

Type 1 / 2

5/6

Examination of the sample in the etched condition revealed a typical ADI microstructure
consisting of acicular ferrite and austenite with less then 2% carbide (see Photo 6).

Photo 3:
Magnification: 100X;
Etchant: 3% Nital
Fracture at the ID surface (right of Photo).

Photo 4:
Magnification: 100X;
Etchant: 3% Nital
Cracking propagated both intergranularly and transgranularly
through the wall thickness of the cage

Cardwell Westinghouse
Report No. 237863A
Page 4 of 5

Metallographic Examination (cont.)

Photo 5:
Magnification: 100X;
Etchant: None
SB Cage - Nodular Graphite Morphology.

Photo 6:
Magnification: 500X;
Etchant: 3% Nital
SB Cage - Representative microstructure.

Chemical Testing
1.

The chemical test results are shown in Table 1 below.

Table 1 - Chemical Testing*

Element
Carbon
Manganese
Phosphorus
Sulfur
Silicon
Nickel
Chromium
Molybdenum
Copper
Magnesium

SB Cage
3.73 %
.44
.021
.014
2.16
<.01
.05
<.01
<.01
.04

* Carbon and Sulfur analysis performed in accordance with ASTM E1019.

Other elements determined by optical spectrometer in accordance with ASTM E415.

Cardwell Westinghouse
Report No. 237863A
Page 5 of 5

Tensile Testing
1.

Tensile test results conformed to the specified minimum tensile requirements per SK-3086.

2.

The tensile testing results are shown in Table 2 below.

Table 2 - Tensile Testing*

SB Cage
182
146
3

Tensile Strength, ksi

Yield Strength, ksi (.2% offset)
% Elongation in 1 (4D)

SK-3086
175 min.
125 min.
2% min.

Testing performed in accordance with ASTM A370 and E8.

Charpy Impact Testing

1.

The average of the Charpy impact test results (21 ft-lbs) for the cage conformed to the specified
minimum requirement of 15 ft-lbs per SK-3086.

2.

The results are shown in Table 3 below.

Table 3 - Charpy Impact Testing*

Test Temperature:
Specimen Size:
Notch Type:
Sample
SB Cage

+ 72F
10 x 10 mm
None
Absorbed Energy, ft-lbs
14
18
22
22

Average, ft-lbs**
21

* Testing performed in accordance with ASTM E23 using a digitally encoded 700 ft-lb impact tester.
** Average of three highest values.

Hardness Testing
1.

The Brinell hardness of the cage measured 415 HBW, which fell into the typical hardness range
of 344 441 HBW per SK-3086.

Prepared By:
Reviewed By:

Frank Guerrieri, Staff Metallurgical Engineer

John J. Fruscione, Senior Metallurgical Engineer