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Manufacturing and Testing Specification for Ductile Iron Gears Manufacturing procedures, process control, and properties of these castings must fall within guidelines of ASTM A536 with the additional requirements outlined below. If the supplier has reasons to suggest alternate specifications for improved manufacturing procedures or improved casting performance it is incumbent on the supplier to contact the appropriate FFEM representative and design engineer.

Reference(s):

Vendor shall verify that all documents listed below are available before commencing manufacture. As a minimum, the gear casting shall satisfy the requirements of the following engineering documents: AGMA/ANSI 2004-B89 Gear Materials and Heat Treatment Manual ED 40.736.007 Hardness Testing of Gears ASTM A609 Std. Practice for Ultrasonic Examination of Castings ASTM E125 Reference P hotographs f or M agnetic P article Indications ASTM E1030 Std. Method for Radiographic Examination ASTM E709 Std. Guide for Magnetic Particle Examination ASTM A802 Std. Practice for Steel Casting, Surface Finish ASTM A536 Std. Spec. For Ductile Iron Castings Gear Assembly Drawings Gear Detail Drawings Separate Parts List (SPL)

CONTENTS

1.0 2.0 3.0 4.0 5.0

INTRODUCTION INSTRUCTIONS MANUFACTURING MATERIALS CHEMICAL ANALYSIS

6.0 7.0 8.0 9.0 10.0

HEAT TREATMENT MECHANICAL PROPERTIES AND TESTING ULTRASONIC TESTING MAGNETIC PARTICLE INSPECTION VISUAL SURFACE INSPECTION

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VENDOR TEST REPORT REQUIREMENTS

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INTRODUCTION 1.1.

This specification establishes the requirements for manufacturing and inspection of ductile iron girth gears gears. and applies to either full ring or segmented gears, such as quarter or half segment

2.0.

3.

4.0.

INSTRUCTIONS 2.1.

Gear casting may be heat treaded and shall be thermally stress relieved. Time and temperature at the stress relieving operation shall be sufficient to assure that residual stresses are as low as practicable.

2.2.

Casting shall be free of sand, scale extraneous appendage,s and hard areas resulting from air arcing and gas cutting which could adversely affect machining. Casting shall also be free of cracks, hot tears, cold laps, shrinkage, unfused chaplets and “DROSS”.

2.3.

Casting must be sound and without defects of any consequence, including “DROSS”.

2.4.

Casting chemistry shall be such that its hardenability and the proposed heat treatment will produce in the tooth root a hardness and mechanical properties within the specified range.

MANUFACTURING 3.1.

The melting, molding, pouring and shake-out procedures required to produce the casting(s) are optional to the foundry. However, FFE Minerals USA Inc. reserves the right of calling for any of the above-mentioned procedures when necessary.

3.2.

Weld repairs and thermal cutting shall not be permitted.

3.3.

It is expected that the Vendor will follow all other procedures, examinations, and tests that are normally carried out in accordance with sound manufacturing and industry practice.

MATERIALS 4.1.

Gear material is Ductile Iron or Nodular Graphite Cast Iron as per ASTM A536 grades: 65-45-12, 70-50-05, 80-55-06, 100-70-03, or 120-90-02.

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Alternative or equivalent materials may be supplied where agreed in contract.

CHEMICAL ANALYSIS 5.1.

Refer to Contract Specific Detail drawing for gear rim hardness range . Note: Casting chemistry shall be such that its hardenability and the proposed heat treatment will produce in the tooth root a hardness and mechanical properties within the specified range.

5.2.

Carbon, Silicon, and Phosphorus content shall be controlled as follows: TotalCarbon

3.00%Min.

Silicon

2.35%Max.

Phosphorus

0.05%Max.

TotalCarbon

OR

Silicon

3.00%Min. 2.50%Max.

Phosphorus

0.03%Max.

Note: By minimizing silicon and phosphorus, the intent is to increase impact resistance. Similarily maintaining carbon above 3.00% the intent is to avoid cementite, which tends to lower impact resistance. 5.3.

6.0.

7.0.

Chemical analysis report should be based on a test-block. Chemical analysis report shall include all alloy elements comprising the heat.

HEAT TREATMENT 6.1.

The casting may be Normalized and Tempered to obtain the specified hardness and mechanical properties.

6.2.

Furnace charts and charts from attached thermocouplesare required to be supplied with all heat treatment cycles.

6.3.

Thermocouple probes need to be placed on all castings when normalizing and tempering or heat treating. The positioning of the probes is to be determined by the foundry to ensure uniform heat treatment of castings.

MECHANICAL PROPERTIES AND TESTING 7.1.

The supplier shall make every effort to achieve both hardness and mechanical properties, in accordance with purchase order requirements. In the event of conflict between these two attributes, mechanical properties shall be subordinate

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to hardness requirements. The supplier shall notify FFEM USA Inc., during the contract review stage, regarding any concerns that both attributes will not be attained. TABLE I (*)

BRINELL HARDNESS (for reference only)

ASTM GRADE

HEAT TREATMENT (recommended)

(BHN)

TENSILE STRENGTH MINIMA PS(IMpa)

YIELD ELONGATI STRENGT ON IN 2" H MINIMA (%) PS(IMpa)

65/45/12

156-217

Ferritic-Perlitic Annealed

65,000 (450)

45,000 (310)

12

70/50/05

180-220

Ferritic-Perlitic Annealed

70,000 (485)

50,000 (345)

05

80/55/06

187-255

NT-Perlitic/ Ferritic

80,000 (550)

55,000 (380)

06

100/70/03

241-302

NT-Perlitic

100,000 (690)

70,000 (485)

03

120/90/02

240-300

NT-Perlitic or Q.T. Martensitic

120,000 (830)

90,000 (620)

02

(**)FFEM

265-340

NT-Pearlitic or

120,000

90,000

03

(830)

(620)

GRADE

QT- Martensitic

NT - Normalized and Tempered Notes:

Q.T. - Quenched and Tempered

1. The minima shall be determined from a tensile test. 2. The test coupons must be taken from the rim or a heavy section of the casting. 3. Test coupons shall remain attached to the casting until all heat treat operations have been completed. 4. The casting must have sufficient coupons in the event the casting must be reheat treated.

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(*) For “as-cast” rim thicknesses equal to or less than 5 1/2”(139.7 mm). (**) For “as-cast” rim thicknesses thicker than 5 ½” (139.7 mm).

7.2.

TENSILE TESTING 7.2.1. Tensile testing is carried out in accordance with ASTM A536 (“Y” Block ). All gears shall have a tensile test carried out from an integral test block as cast and heat treated with the product. 7.2.2. Preparation of the test bar is in accordance with ASTM A536. Test bars and castings to be stamped with the casting’s heat number. 7.2.3. The test blocks must be taken from the rim or a heavy section of the casting. 7.2.4. The casting must have sufficient test blocks in the event the casting must be reheat treated. 7.2.5. Test blocks shall remain attached to the casting until all heat treat operations have been completed. 7.2.6. Acceptance Criteria:

8.0.

7.2.6.1.

For ASTM A536, acceptance shall be according to the Table I of item 7.0. above.

7.2.6.2.

The results of a faulty tensile specimen can be discounted. If an apparently sound tensile specimen fails, it can be discounted if two (2) retests produce acceptable results.

ULTRASONIC TESTING 8.1.

Ultrasonic testing shall be performed on all cast gears after rough machining.

8.2.

Ultrasonic equipment, straight beam probes, 1 MHZ and/or 2 MHZ, shall be calibrated.

8.3.

The areas to be examined by ultrasonics are 100% of the areas indicated in Figures 1 thru 6. All volumes specified shall be inspected thru two perpendicular surfaces.

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The Inspection Method is in accordance with ASTM A609/A609-89, Procedure A. As-cast surfaces shall be prepared to the extent necessary to permit efficient coupling with the transducer. 8.4.1. 90% of Back Wall Reflection (BWR) will be used for UT criteria. 8.4.2. Calibration for Zone 1 UT shall be made utilizing a 3 mm flat bottom hole. 8.4.3. Calibration for Zone 2 UT shall be made utilizing the standard 6 mm flat bottom hole.

8.5.

Acceptance Criteria: 8.5.1. Zone 1 UT: Level 1, ASTM A609. 8.5.2. Zone 2 UT: Level 2, ASTM A609. Note: Zone volumes shall be examined using straight beam probes. The primary scan shall be carried out using a compression probe of 1 MHZ to 2 MHZ frequency and crystal diameter in the range of 10 to 25 mm.

8.6.

Failure to meet the specified ultrasonic level will require further engineering evaluation to be completed. Rejection shall not be based on ultrasonic results only. Further assessment may be completed such as radiography examinations. Radiography testing may be completed at the option and expense of the foundry in order to help determine acceptance or rejection of the casting based on the combined results of ultrasonic and radiographic testing. Radiography testing method shall be in accordance with ASTM E1030. The acceptance level shall be agreed upon between the foundry and the customer. It is dependent on such factors as section thickness, design application, etc.

8.7.

Longitudinal Acoustic Velocity must be 5,500 m/sec minimum in order to assure that good nodularity was achieved. The area to be inspected shall be tested through two (2) perpendicular directions.

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Ultrasonic Test Areas

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Ultrasonic Test Areas

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Ultrasonic Test Areas

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Ultrasonic Test Areas

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Ultrasonic Test Areas

Figure 5. Spring-Mounted T-Section

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MAGNETIC PARTICLE TESTING 9.1

Magnetic Particle Inspection shall be performed according to ASTM E709-91 using dry method.

9.2

Castings shall be free of the following discontinuities as per ASTM E125-63.

Acceptance Criteria ZONE 1

Type

TypeDiscontinuity

Degree

I

LinearDiscontinuity (Hot Tears / Cracks/ Dross)

Not Acceptable

II

Shrinkage

1

III

Inclusions

1

V

Porosities

1

ZONE 2

Type

TypeDiscontinuity

I

LinearDiscontinuity (Hot Tears / Cracks/ Dross)

Not Acceptable

II

Shrinkage

2

III

Inclusions

2

V

Porosities

2

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ZONE 3

Type

TypeDiscontinuity

Degree

I

LinearDiscontinuity (Hot Tears / Cracks/ Dross)

Not Acceptable

II

Shrinkage

3

III

Inclusions

3

V

Porosities

2

Linear Discontinuities: An indication whose length is equal to or greater than three times its width shall be classified as a linear discontinuity. 9.3

Magnetic Particle Test areas:

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Figure 1. Flange-Mounted Y-Section Zone 1

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Figure 5. Flange Mounted, Y-Section Zone 3

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Figure 16. Spring Mounted, T-Section, Zone 2

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VISUAL SURFACE INSPECTION 10.1

The visual inspection method is based on ASTM A802/A802M-89.

10.2

Acceptance Criteria

SurfaceFeature

11.0

Page:

Level

A.

Surface Texture

3

B.

Non-metallic Inclusions

C.

Gas Porosity

D.

FusionDiscontinuities

1

E.

ExpansionDiscontinuities

3

2 2

F. Inserts

1

G.

ThermalCutSurfaces

N/A

H.

MechanicallyPrepared Surfaces

J.

Weld Surfaces

3 N/A

VENDOR TEST REPORT REQUIREMENTS 11.1

Report of as-cast surface conditions in accordance with ASTM A-802.

11.2

Report all non-conformances to this specification for FFEM review and disposition.

11.3

Vendor must supply the following certified documents: 11.3.1 Mechanical test report including:

Tensile Strength Yield Point Elongation in 2" Brinell Hardness Printing Date - 19 Oct 2006

(PSI) or (MPa) (PSI) or (Mpa) (%) Number (BHN)

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11.3.2 Chemical analysis report of all elements based on a cast-on coupon sample. 11.3.3 Magnetic particle testing report clearly stating that casting conforms to this

ED 40.736.000 11.3.4 Ultrasonic testing report clearly stating that casting conforms to this ED 40.736.000 11.3.5 Heat treatment records, (furnace and attached thermocouples charts) of all heat treatment procedures to which casting has been subjected. 11.3.6

11.4

All documents to show:

P.O. Number Contract Number Drawing Number Vendor Serial Number

It is expected that the vendor will follow all other procedures, examinations and tests that are normally carried out in accordance with sound manufacturing and industry practice.

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