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Report Nº: 052.

20_A
TEST REPORT Date: 09.11.20

Walterscheid Welsberg AG Page: 1 of 10


Enclosures: 2 pages 7

Report Title: DUJ B320 - Inspection of 3 DUJ's Carraro after field failure

Identification: Program phase Local project n° WPG project n° Windchill n°


D GL0005 0000036668

Purpose: Carraro returned 3 DUJ's after field failure (2 DUJ’ failed, 1 DUJ still ok)
Information from customer:
In questi giorni abbiamo avuto delle segnalazioni da un nostro cliente di rottura di doppi giunti su 15 assali
per lo stesso problema con poche ore di esercizio. Double joint 451799:
Released original document stored in the Windchill test report database

- Cod 3300: lato sinistro dell'assale anteriore (guardando il pignone) rotto in entrambe le crociere
con 15 h di lavoro.
- Cod 3173: semiasse non rotto situato nella parte sinistra dell'assale posteriore con 43 h di lavoro.
Inserito per valutare eventuali segni di inizio cedimento.
- Cod 6542736: rotto solo la giunzione crociera-forcella sempre ad un numero non elevato di ore.

Per il momento, sono stati resi nr. 3 doppi giunti, come descritto sopra e che vorremmo venissero analizzati
da voi per cercare di capire il motivo della failure con poche ore di esercizio.
Si allegano qualche foto, in due in particolare si evince uno smusso dello scanalato con diversa angolazione
e diametro di inizio ( anche essendo lo stesso codice/forcella ).

Procedure: General inspection and photo documentation.

Requirement: ---

Parts: 3 DUJ B320; Part no.: 713659; Drawing no.: 0300035763_J; Customer no.: CA451799

Summary: General investigation:

Part no.: 05220-01 (cod 3300 - LH – front axle) – failure after 15h
Failed parts: long yoke shaft lugholes, pinion lugears, double yoke lughole

Part no.: 05220-02 (cod 6542736) – running time unknown


Failed parts: long yoke shaft lughole

Part no.: 05220-03 (cod 3173 - LH – rear axle) – running time 43h
No failure of unit

Photo documentation on the following pages.

Conclusions: Test criteria: passed not passed not applicable

Remark: Enclosures:
Met analysis (LAB-20-022 and LAB-20-023)

Distribution: Prepared by:


G. Messner
WEL H. Oberparleiter
M. Irschara Approved by
K. Oberkofler H. Oberparleiter
R. Stolzlechner
Customer: Security Rating:

Carraro RESTRICTED
TEST REPORT REPORT Nº: 052.20_A

Walterscheid Welsberg AG PAGE: 2 of 10

1. Test parts

Test part: DUJ B320 - 00713659

Characteristic Long yoke shaft Short yoke shaft / Pinion Double yoke

Part-No. 00708901 00702335 00540754

Drawing-No. 0300081103_D 0300032927_F 0300009753_E

Supplier (forging, manuf…) Sapes Valbormida

Deviation from Drawing

Material 41CrS4HH STD 032109-003 18NiCrMo5 STD 032152-003 3C50H STD 032149-003

Cast Code B2 6U

Spline (manuf. process)

Design of shaft (version)

Central lubrication

Comment / Remark

Characteristic Journal spider Bearing

Part-No. 00710078 00710105

Drawing-No. 0300082258_G 0300082299_L

Supplier (forging, manuf…) GMB

Deviation from Drawing

Material SCr420

Cast Code F3 9A

Lubrication none (blind hole)

Type of bearing sheet metal

Sealing of bearing

Grease

Comment / Remark
TEST REPORT REPORT Nº: 052.20_A

Walterscheid Welsberg AG PAGE: 3 of 10

DETAILED PHOTOGRAPHS – PICTURES FROM CARRARO

Photo nº 1 Photo nº 2
Part no.: 05220-01 and 02 – long yoke shafts – front face Part no.: 05220-01 – field failure after 15h

Photo nº 3 Photo nº 4
Part no.: 05220-01 – field failure after 15h Part no.: 05220-01 – field failure after 15h

Photo nº 5 Photo nº 6
Part no.: 05220-02 – field failure – running time unknow Part no.: 05220-02 – field failure – running time unknow
TEST REPORT REPORT Nº: 052.20_A

Walterscheid Welsberg AG PAGE: 4 of 10

DETAILED PHOTOGRAPHS – UNIT NO. 05220-01 (cod 3300 - LH – front axle) – failure after 15h

Photo nº 7 Photo nº 8
Part no.: 05220-01 – complete DUJ Part no.: 05220-01 – failed parts

Photo nº 9 Photo nº 10
Part no.: 05220-01 – double yoke failed Part no.: 05220-01 – long yoke shaft – failure of lugholes

Photo nº 11 Photo nº 12
Part no.: 05220-01 – long yoke shaft – bearing seat Part no.: 05220-01 – long yoke shaft - splines
TEST REPORT REPORT Nº: 052.20_A

Walterscheid Welsberg AG PAGE: 5 of 10

DETAILED PHOTOGRAPHS – UNIT NO. 05220-01 (cod 3300 - LH – front axle) – failure after 15h

Photo nº 13 Photo nº 14
Part no.: 05220-01 – pinion failed Part no.: 05220-01 – pinion - spline

Photo nº 15 Photo nº 16
Part no.: 05220-01 – pinion – lugear failed Part no.: 05220-01 – double yoke with unit pack – side of
long yoke shaft

Photo nº 17 Photo nº 18
Part no.: 05220-01 – double yoke – side of short yoke shaft Part no.: 05220-01 – double yoke with marking
TEST REPORT REPORT Nº: 052.20_A

Walterscheid Welsberg AG PAGE: 6 of 10

DETAILED PHOTOGRAPHS – UNIT NO. 05220-02 (cod 6542736) – running time unknown

Photo nº 19 Photo nº 20
Part no.: 05220-02 – complete DUJ Part no.: 05220-02 – failure on long yoke shaft side

Photo nº 21 Photo nº 22
Part no.: 05220-02 – failure on long yoke shaft side Part no.: 05220-02 – side of pinion

Photo nº 23 Photo nº 24
Part no.: 05220-02 – long yoke shaft – failure of lugholes Part no.: 05220-02 – long yoke shaft - splines
TEST REPORT REPORT Nº: 052.20_A

Walterscheid Welsberg AG PAGE: 7 of 10

DETAILED PHOTOGRAPHS – UNIT NO. 05220-02 (cod 6542736) – running time unknown

Photo nº 25 Photo nº 26
Part no.: 05220-02 – pinion Part no.: 05220-02 – unit pack on long yoke shaft side

Photo nº 27
Part no.: 05220-02 – double yoke with marking
TEST REPORT REPORT Nº: 052.20_A

Walterscheid Welsberg AG PAGE: 8 of 10

DETAILED PHOTOGRAPHS – UNIT NO. 05220-03 (cod 3173 - LH – rear axle) – running time 43h

Photo nº 28 Photo nº 29
Part no.: 05220-03 – complete DUJ Part no.: 05220-03 – DUJ no failure

Photo nº 30 Photo nº 31
Part no.: 05220-03 – unit pack – side of long yoke shaft Part no.: 05220-03 – unit pack – side of short yoke shaft

Photo nº 32 Photo nº 33
Part no.: 05220-03 – long yoke shaft Part no.: 05220-03 – long yoke shaft - splines
TEST REPORT REPORT Nº: 052.20_A

Walterscheid Welsberg AG PAGE: 9 of 10

DETAILED PHOTOGRAPHS – UNIT NO. 05220-03 (cod 3173 - LH – rear axle) – running time 43h

Photo nº 34 Photo nº 35
Part no.: 05220-03 – pinion Part no.: 05220-03 – double yoke with marking
TEST REPORT REPORT Nº: 052.20_A

Walterscheid Welsberg AG PAGE: 10 of 10

2. Drawings:

DUJ B320 – 713659


Report No. : LAB-20-022
LABORATORY REPORT Date : 12.11.2020
Page : 1 of 3
Walterscheid Welsberg AG
Annexe: /

REPORT TITLE:

Investigation: DOUBLE HOOKE'S JOINT returned from Carraro.


WAL internal production order: GB053427.

Program / Project: Kramer Front code 3300 left side

Objective: (Components, procedure)

DOUBLE HOOKE'S JOINT size B320, part no. 00713659, drawing no. 0300035763_J.
Carraro no. CA451799.

Comments / Background:

Lug hole broken with 15 hours of work.

Summary / Results: Test Criteria: passed not passed not applicable

Summary of Results:

The characteristics examined correspond to the specifications.

Results and details please see enclosed documentation.

Pictures/Comments

Name Signatures

Distribution: Prepared by: Kirchler R.

Approved by: Lanznaster P.


Lanznaster P.
Security Rating:

Unclassified

Restricted
Tel.: +39 0474 580 531
E-mail: patrick.lanznaster@walterscheid.com
Secret

C:\Users\guenther.messner\AppData\Local\Microsoft\Windows\INetCache\IE\5TC53GZF\LAB-20-022e DOUBLE HOOKE`S JOINT part 00713659 drawing 0300035763_J Carraro Reklamation
(1).docx
Schliff Nr.: W20059
Report No. : LAB-20-022
LABORATORY REPORT Date : 12.11.2020
Page : 2 of 3
Walterscheid Welsberg AG
Annexe: /

Table 1 Hardness testing results of the still existing circlips.

Circlip Characteristics Requirement Results Assessment

1 Hardness acc. to DIN 472 47 ÷ 54 HRC 47,8 HRC ü

2 Hardness acc. to DIN 472 47 ÷ 54 HRC 47,6 HRC ü

Note: The circlips were present in all remaining lug hole and correctly mounted.
One lug hole of the short yoke shaft is missing.

Fig. 1

Description:

The bearing cups exerted


great pressure on the
circlips.

Investigation: Long yoke shaft drawing no. 0300081103 part. no. 00708901.

Table 2 Chemical composition:

Requirement: 41CrS4HH STD 032109-003


Result: The material corresponds to the Walterscheid STD 032109-003 for 41CrS4HH

Requirement acc. to STD 032109-003 for 41CrS4HH


% C Si Mn P S Cr Ni Mo Cu Al Ti V
Minimum 0,380 / 0,600 / 0,020 0,900 / / / / / /
Maximum 0,450 0,400 0,900 0,035 0,040 1,200 / / / / / /
Results 0,421 0,185 0,681 0,007 0,022 1,091 0,079 0,019 0,105 0,024 <0,001 0,004

C:\Users\guenther.messner\AppData\Local\Microsoft\Windows\INetCache\IE\5TC53GZF\LAB-20-022e DOUBLE HOOKE`S JOINT part 00713659 drawing 0300035763_J Carraro Reklamation
(1).docx
Schliff Nr.: W20059
Report No. : LAB-20-022
LABORATORY REPORT Date : 12.11.2020
Page : 3 of 3
Walterscheid Welsberg AG
Annexe: /

Table 3 Mechanical Properties:

Characteristics Requirement Results Assessment

956N/mm²
Tensile strength on the shaft 930 ÷ 1080N/mm²
(282HB10/3000)
ü
974N/mm²
Tensile strength in the lug hole area 930 ÷ 1080N/mm²
(288HB10/3000)
ü

Microstructure in the lug hole area Hardened and tempered Hardened and tempered see pic. 2 ü
Remark:
Determination of tensile strength by Brinell hardness test and converted acc. to DIN EN ISO 18265 tab. A.1.

Pic. 2

500 : 1

Descrizione:

Microstructure in the lug hole


area

Requirement
Hardened and tempered

Result:
The microstructure after
hardening and tempering
corresponds.

C:\Users\guenther.messner\AppData\Local\Microsoft\Windows\INetCache\IE\5TC53GZF\LAB-20-022e DOUBLE HOOKE`S JOINT part 00713659 drawing 0300035763_J Carraro Reklamation
(1).docx
Schliff Nr.: W20059
Report No. : LAB-20-023
LABORATORY REPORT Date : 11.11.2020
Page : 1 of 4
Walterscheid Welsberg AG
Annexe: /

REPORT TITLE:

Investigation: DOUBLE HOOKE'S JOINT returned from Carraro.


WAL internal production order: GB053427.

Program / Project: Claim 301090097 Kramer code 65402736

Objective: (Components, procedure)

DOUBLE HOOKE'S JOINT size B320, part no. 00713659, drawing no. 0300035763_J.
Carraro no. CA451799.

Comments / Background:

Breakage of the lug hole at the long yoke shaft after a minor number of hours.

Summary / Results: Test Criteria: passed not passed not applicable

Summary of Results:

The characteristics examined correspond to the specifications.

Results and details please see enclosed documentation.

Pictures/Comments

Name Signatures

Distribution: Prepared by: Kirchler R.

Approved by: Lanznaster P.


Lanznaster P.
Security Rating:

Unclassified

Restricted
Tel.: +39 0474 580 531
E-mail: patrick.lanznaster@walterscheid.com
Secret

C:\Users\guenther.messner\AppData\Local\Microsoft\Windows\INetCache\IE\PLYS4QDS\LAB-20-023e DOUBLE HOOKE`S JOINT part 00713659 drawing 0300035763_J Carraro Reklamation
(1).docx
Schliff Nr.: W20059
Report No. : LAB-20-023
LABORATORY REPORT Date : 11.11.2020
Page : 2 of 4
Walterscheid Welsberg AG
Annexe: /

Table 1 Hardness testing results of the still existing circlips

Circlip Characteristics Requirement Results Assessment

1 Hardness acc. to DIN 472 47 ÷ 54 HRC 49,3 HRC ü

2 Hardness acc. to DIN 472 47 ÷ 54 HRC 48,1 HRC ü

3 Hardness acc. to DIN 472 47 ÷ 54 HRC 47,1 HRC ü

4 Hardness acc. to DIN 472 47 ÷ 54 HRC 46,9 HRC ü

5 Hardness acc. to DIN 472 47 ÷ 54 HRC 47,1 HRC ü

6 Hardness acc. to DIN 472 47 ÷ 54 HRC 48,0 HRC ü

7 Hardness acc. to DIN 472 47 ÷ 54 HRC 47,5 HRC ü

8 Hardness acc. to DIN 472 47 ÷ 54 HRC 49,7 HRC ü

Note: The circlips were present in all lug hole and correctly mounted.

Fig. 1

Description:

The bearing cups exerted


great pressure on the
circlips.

C:\Users\guenther.messner\AppData\Local\Microsoft\Windows\INetCache\IE\PLYS4QDS\LAB-20-023e DOUBLE HOOKE`S JOINT part 00713659 drawing 0300035763_J Carraro Reklamation
(1).docx
Schliff Nr.: W20059
Report No. : LAB-20-023
LABORATORY REPORT Date : 11.11.2020
Page : 3 of 4
Walterscheid Welsberg AG
Annexe: /

Investigation: Long yoke shaft drawing no. 0300081103 part. no. 00708901.

Table 2 Chemical composition:

Requirement: 41CrS4HH STD 032109-003


Result: The material corresponds to the Walterscheid STD 032109-003 for 41CrS4HH

Requirement acc. to STD 032109-003 for 41CrS4HH


% C Si Mn P S Cr Ni Mo Cu Al Ti V

Minimum 0,380 / 0,600 / 0,020 0,900 / / / / / /


Maximum 0,450 0,400 0,900 0,035 0,040 1,200 / / / / / /
Results 0,413 0,183 0,672 0,008 0,021 1,085 0,079 0,017 0,105 0,021 <0,001 0,003

Table 3 Mechanical Properties:

Characteristics Requirement Results Assessment

974N/mm²
Tensile strength on the shaft 930 ÷ 1080N/mm²
(288HB10/3000)
ü
1068N/mm²
Tensile strength in the lug hole area 930 ÷ 1080N/mm²
(216HB10/3000)
ü

Microstructure in the lug hole area Hardened and tempered Hardened and tempered see pic. 2 ü
Remark:
Determination of tensile strength by Brinell hardness test and converted acc. to DIN EN ISO 18265 tab. A.1.

C:\Users\guenther.messner\AppData\Local\Microsoft\Windows\INetCache\IE\PLYS4QDS\LAB-20-023e DOUBLE HOOKE`S JOINT part 00713659 drawing 0300035763_J Carraro Reklamation
(1).docx
Schliff Nr.: W20059
Report No. : LAB-20-023
LABORATORY REPORT Date : 11.11.2020
Page : 4 of 4
Walterscheid Welsberg AG
Annexe: /

Pic. 2

500 : 1

Descrizione:

Microstructure in the lug hole


area

Requirement
Hardened and tempered

Result:
The microstructure after
hardening and tempering
corresponds.

C:\Users\guenther.messner\AppData\Local\Microsoft\Windows\INetCache\IE\PLYS4QDS\LAB-20-023e DOUBLE HOOKE`S JOINT part 00713659 drawing 0300035763_J Carraro Reklamation
(1).docx
Schliff Nr.: W20059