Metallurgical and Mechanical Examination of Fatigue-Induced Fracture in a Conveyor Drum Shaft

This work investigates the fatigue failure mode of a shaft used in a conveyor system for mining applications through visual inspection, metallographic examination, fracture analysis, and mechanical testing. It was observed that a misalignment of about 5° between the shaft and the conveyor drum system promoted intensive contact with the parts. The combination of misalignment and overload was the leading cause of the localized plastic deformation, which resulted in the shaft fracture. A metallurgical examination revealed ferritic and pearlitic microstructures for an AISI 4140 grade steel. This suggested that the heat treatment on the steel was not adequate for the application. Therefore, it can be inferred that no preventive or corrective maintenance inspections were performed during the shaft's operational production period.

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Journal
Materials Research
Published
2025-01-01
DOI
https://doi.org/10.1590/1980-5373-mr-2025-0286
Primary Topic
Mechanical Failure Analysis and Simulation
Type
article
Field-Weighted Citation Impact
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article

Metallurgical and Mechanical Examination of Fatigue-Induced Fracture in a Conveyor Drum Shaft

Hamilton Ferreira Gomes de Abreu, Eden Santos Silva, Jhonatan Peres de Sousa, Antonio Enrique Salas Reyes et al.
Materials Research
Mechanical Failure Analysis and Simulation
article

Metallurgical and Mechanical Examination of Fatigue-Induced Fracture in a Conveyor Drum Shaft

Hamilton Ferreira Gomes de Abreu, Eden Santos Silva, Jhonatan Peres de Sousa, Antonio Enrique Salas Reyes, Samuel Filgueiras Rodrigues, Maria Verônica Gonçalves Rodrigues, Gedeon Silva Reis, Ângela Oliveira, Marcos Natan da Silva Lima, João Carlos Ferreira, Isaac Araújo Furtado
article en

Abstract

This work investigates the fatigue failure mode of a shaft used in a conveyor system for mining applications through visual inspection, metallographic examination, fracture analysis, and mechanical testing. It was observed that a misalignment of about 5° between the shaft and the conveyor drum system promoted intensive contact with the parts. The combination of misalignment and overload was the leading cause of the localized plastic deformation, which resulted in the shaft fracture. A metallurgical examination revealed ferritic and pearlitic microstructures for an AISI 4140 grade steel. This suggested that the heat treatment on the steel was not adequate for the application. Therefore, it can be inferred that no preventive or corrective maintenance inspections were performed during the shaft's operational production period.

Materials ResearchVol. 28(suppl 1)
Universidade Federal do Ceará (BR), Universidade Federal do Piauí (BR), Instituto Federal do Tocantins (BR), Instituto Federal do Maranhão (BR)
Coordenação de Aperfeiçoamento de Pessoal de Nível Superior, Conselho Nacional de Desenvolvimento Científico e Tecnológico, Fundação de Amparo à Pesquisa e ao Desenvolvimento Científico e Tecnológico do Maranhão
Openalex Percentile: Top 89%
Mechanical Failure Analysis and Simulation
DOIOpen Access PDFOpenAlex
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