400 Commonwealth Drive, Warrendale, PA 15096-0001 U.S.A. Tel: (724) 776-4841 Fax: (724) 776-0790 Web: www.sae.org SAE TECHNICAL PAPER SERIES 2006-01-3578 Mechanical Properties of Gear Steels and Other Perspective Light Weight Materials for Gear Applications Hong Lin, Robert R. Binoniemi, Gregor y A. Fett, Thomas Woodard and Mick Deis Dana Corporation Reprinted From: Advanced Material s, Designs, Concept s and Technologies in Commercial Vehicles (SP-2058) Commercial Vehicle Engineering Congress and Exhibition Chicago, Illinois October 31-November 2, 2006 Downloaded from SAE International by Univ of California Berkeley, Thursday, July 26, 2018The Engineering Meetings Board has approved this paper for publication. It has successfully completed SAE's peer review process under th e supervision of the session organi zer. This process requires a minimum of three (3) reviews by industry experts. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. For permission and licensing requests contact: SAE Permissions 400 Commonwealth DriveWarrendale, PA 15096-0001-USAEmail: permissions@sae.orgTel: 724-772-4028 Fax: 724-776-3036 For multiple print copies contact: SAE Customer Service Tel: 877-606-7323 (inside USA and Canada)Tel: 724-776-4970 (outside USA)Fax: 724-776-0790Email: CustomerService@sae.org ISSN 0148-7191 Copyright © 2006 SAE International Positions and opinions advanced in this paper are those of the author(s ) and not necessarily those of SAE. The author is solely responsible for the content of th e paper. A process is available by which discussions will be printed with the pap er if it is publishe d in SAE Transactions. Persons wishing to submit papers to be considered for presentation or publicat ion by SAE should send the manuscript or a 300 word abstract to Secretary, Engineering Meetings Board, SAE. Printed in USADownloaded from SAE International by Univ of California Berkeley, Thursday, July 26, 2018ABSTRACT To improve fuel economy and possibly reduce product cost, light weight and high power density has been adevelopment goal for commercial vehicle axlecomponents. Light weight materials, such as aluminumalloys and polymer materials, as well as polymer matrixcomposite materials have been applied in variousautomotive components. However it is still a hugechallenge to apply light weight materials in componentswhich are subject to heavy load and thus have highstresses, such as gears for commercial vehicle axles ortransmissions. To understand and illustrate thischallenge, in this paper we will report and review thecurrent state of art of carburized gear steels propertiesand performance. The properties and performance datainclude the following: /g2/g3Monotonic tensile data: Young /g2/g19/g3/g20/g17/g21/g22/g18/g22/g19/g23/g3/g19/g12/g14/g13/g19/g19/g3 strain curve, yield strength, ultimate tensilestrength, and elongation, /g2/g3Strain controlled fatigue data and cyclic stressstrain curve, /g2/g3Fracture toughness and fatigue crack growthrates data, /g2/g3Stress life (S-N) curves in as heat treated andshot peened conditions. Besides the above purely materials dependentproperties, contact fatigue performance of a gear steelwill also be reported. Contact fatigue is a surface failuremode which not only depends on materials, but alsodepends on other tribological factors, such as surfacefinish and lubricant. Then the properties and performance data of several perspective light weight materials will be reviewed andcompared with those of carburized gear steels. Theselight weight materials include a powder metal, analuminum alloy, and a polymer matrix compositematerial. Finally challenges and potential barriers inapplying the light weight materials in power transmissiongear applications will be discussed. INTRODUCTION Due to