CHAPTER-2

LITERATURE REVIEW
2.1 SURFACE IMPERFECTIONS:
Yogesh Chaubey , et al. (2015) have analyzed a premature failed system of
passenger car mathematically and metallurgically. Force and deflection analysis
has been performed on suspension system of Tata Indica car and at the same time
metallurgical analysis has been done on the basis of microstructure of suspension
system. The fatigue strength of suspension springs is vitally affected by material
properties, coating and environmental influences. It has been observed that the
system failed because of Poor surface finish, bad operating conditions and
excessive loading. From micro structural analysis it appears that the spring failed
prematurely due to oxide inclusions and inadequate shot penning process used to
impart residual compressive stresses on the surface The poorly shot peened surface
exhibited ferrite pearlite structure and the sufficiently shot peened surface
exhibited bainite structure inside the ferrite pearlite structure.
S. K. Das, et al. (2007) investigated on the premature failure of suspension
coil spring of a passenger car, which failed within few months after being put into
service. Besides visual examination, other experimental techniques used for the
investigation were micro structural analysis and fractography by scanning electron
microscopy (SEM), inclusion rating by optical microscopy, hardness testing,
residual stress measurement by X-Ray diffraction (XRD) and Instrumental
chemical analysis. The spring failed prematurely due to the inadequate shot
peening process used to impart residual compressive stresses on the surface.
Inherent material defect in association with deficient processing also led to the
failure of the spring. It was found that presence of excessive oxide inclusions in the
steel also lead to the failure of the spring.
 Y. Prawato, et al. (2005), researched on automotive suspension coil
springs, their fundamental stress distribution, material characteristics and
manufacturing failures. This paper includes validated numerical results with
experimental outcomes for improvement of fatigue life. For weight reduction of
springs efforts were made to employ spring materials with significantly larger
stresses. Simulations of failure mode were made by finite element analysis and its
outcome study by comparing with results obtained from experimental study.
Material cleanliness that was not a major issue decades ago now becomes
significant. Decarburization that was not a major issue in the past has become
essential to have better spring design. The causes of failure were insufficient load
carrying capacity, raw material defects such as excessive inclusion levels,
manufacturing defects such as delayed quench cracking and chemically induced
failure.

2.2 CRACKS:

Amit Gatfane, et al. have conducted performance analysis of leaf spring

with a crack. This work involves the study of behavior of EN 45 material steel leaf
spring with varying load and natural frequency prediction with and without crack.
Modal analysis was performed to analyze the effect of crack on the natural
frequency of the leaf spring using FFT analyser. The case is analyzed, using
simulation in ANSYS and the results validated by experimental testing on UTM
for Leaf Spring with and without crack. Graphite and carbon fibers demonstrate
better performance over steel material for leaf springs, however due to cost and
availability limits usage on wide scale. It was found that Cracks in leaf Springs
occur either due to extreme conditions or due to manufacturing defects. They occur
in very minute size under or beneath the surface. During service this crack expands
and when it reaches the surface the component may fail catastrophically over the
period of time during service.

McAdam (1926) first suggested that corrosion induced pits might act as
stress concentrators from which cracks could form. A large number of chemical or
electrochemical factors such as potential, passive film, pH, and composition of
environment are found to affect the pitting corrosion fatigue process. As well,
mechanical factors such as stress range, frequency, stress ratio (R), load waveform
and metallurgical factors such as material composition, microstructure, heat
treatment, and grain orientation can influence pitting corrosion fatigue processes.
Thus the corrosion further leads to formation of cracks and other defects on the
material.

2.3 CORROSION:
Viera Zatkalikova, et al.(2011) experimented on the effect of various types of
surfaces on pitting corrosion resistance of AISI 304 stainless steel. The samples of
the tested material are turned, blasted, peened, grinded and a half of them are
pickled to achieve higher purity of surfaces and better quality of passive film.
Eight types of different finished surfaces were tested by electrochemical and
immersion tests to determine corrosion behavior. The effect of mechanical and
chemical surface treatment on the resistance to pitting corrosion were carefully
analyzed. It was found that the chemical surface treatment improves the protective
passive film of stainless steels. The different results of electrochemical and
exposition tests carried out at normal working temperatures are connected with the
conversion of mechanism of the pitting corrosion process. In spite of the fact that
chemical treatment improves passive layer, its effect on susceptibility of stainless
steels to pitting corrosion in various conditions is different.
Katundi, et. al. (2012) investigated the dynamic behaviour of the corroded
specimens dynamically to simulate under the crash test conditions and
characterized the corrosion resistance in the steel sheets used in automotive
industry. They carried out simulated corrosion tests, wet humidity test and hot dust
dry cycle talk test in laboratory conditions. They exposed the samples to changing
climatic conditions in terms of humidity. It was also observed that the pitting
corrosion damage and crack initiation sites were developed and propagated.

B. Ravi Kumar, et al. (2003) analyzed the failure of a helical compression spring
employed in coke oven batteries. The surface corrosion product was analyzed by
X-ray diffraction (XRD) and scanning electron microscope - energy dispersive
spectroscopy (SEMEDS). Here used various testing procedure as chemical,
surface corrosion product, fracture surface analysis. The conclusion of this work
that the most probable cause of failure of the helical compression springs was
corrosion fatigue accentuated by loss of surface residual compressive stress.

Fu-Zhen xuan et al (2008) investigated the 30Cr2Ni4MoV rotor steel with deep
cryogenic treatments on corrosion resistance in high temperature water. For deep
cryogenic treated specimen, no apparent improvement is observed on the hardness and
corrosion resistance due to the limited carbon precipitate and austenite transformation.
The carbon content in this steel is 0.28%C. It is realized that precipitation of fine carbides
will reduce the internal stress in the martensite and thus minimize the susceptibility of
micro cracking. In fact, the lower content of carbon of 30Cr2Ni4MoV limits the carbon
precipitation. Hence, the corrosion resistance of 30Cr2Ni4MoV steel is not significantly
improved by deep cryogenic treatment.
2.4 HEAT TREATMENT:

Kalsi, et al. (2010) suggested that slow rate of lowering down to the lowest most
temperature would be helpful to achieve maximum improvement in wear
properties and to avoid any microcracking, the value may be to 1K/min. Still
further investigations would be needed to optimize the impact of this parameter on
various types of materials. They also observed that commonly applied values for
cooling rate vary from 0.35 to 3.0K/min. Generally, it is preferred to take cooling
rate as low as possible to avoid any type of risk of microcracking in the material.
Still, it is very difficult to conclude any optimal value for a particular material.

Zhirafar et al (2007) investigated the effect of cryogenic treatment on the mechanical

properties and microstructure of AISI 4340 steel. It is shown that in general, hardness and
fatigue strength of cryogenically treated samples are a slightly higher whereas the
toughness of the cryogenically treated samples is lower when compared to that of the
conventionally treated steel. Neutron diffraction shows the transformation of retained
austenite to martensite while carbide formation occurs simultaneously during tempering.
This is the key factor in improving hardness and fatigue resistance of the cryogenically
treated samples.

Tamas Reti et al (2002) found that the amount of retained austenite present in steel plays
a significant influence on the magnitude of the residual stresses and dimensional stability.
They also pointed out that the effect of retained austenite on component performance is
still a controversial issue. Some of the key factors influencing the retained austenite
transformation include grain size, quenching temperature, hardening temperature,
chemical composition, quenching cooling rates, and stress relieving or tempering.
Retained austenite causes a decrease in tensile an yield strength in steels and reduces the
maximum achievable surface compressive stress relative to the amount of this phase.
Preciado et al (2006) stated that because of rather low amount of austenite (less than
15%) retained by conventional quenching in the microstructure of alloy steels, it appears
that the cryogenic cooling would not cause additional microstructure improvements
compared to ordinary quenching. So, cryogenic treatment is necessary to transform
retained austenite into martensite, which is denser, smaller and distributed more
uniformly than austenite.

Molinari et al (2001) studied that carbide precipitation occurs with a higher

activation energy thus leading to a higher nucleation rate which in turn leads to
finer dimensions and a more homogenous distribution. A new phenomenon
referred as tempered martensite detwinning occurs in AISI M2 steel, which shows
a reduction of twins after soaking at -196C for 35h. Deep cryogenic treatment
reduces the wear rate of the hot work tool steel. This result is interpreted on the
basis of increased toughness, because in the presence of delamination, the ability
of materials to oppose crack propagation can really increase the mechanical
stability on the wear surface and load bearing capacity. Therefore, even if the deep
cryogenic treatment does not influence hardness, it increases both toughness and
wear resistance. This effect can have an important effect on the performances of
the tools and for the hot forming of steels, where wear resistance and toughness are
frequently the key properties.