AISI 1040 Steel Flange

1,We Manufacturing processes are primarily classified into four types: 1:Forging, 2:Casting, 3:Cutting, 4:Rolling. 2,We can manufacture in accordance with these standards. Standards: GB Series (Chinese Standards), JB Series (Machinery Standards), HG Series (Chemical Industry Standards), ASME B16.5 (American Standards), BS4504 (British Standards), DIN (German Standards), and JIS (Japanese Standards). Internationally, there are two primary systems of pipe flange standards: the European system, represented by the German DIN standards (including those of the former Soviet Union), and the American system, represented by the US ANSI pipe flange standards. Other common standards include: the Chinese Ministry of Machinery Industry standards (JB series), the Ministry of Chemical Industry standards (HG series), the Chinese National Standard *GB/T 9112–9124-2010 Steel Pipe Flanges*, as well as US standards (ASME B16.5), British standards (BS4504), German standards (DIN), Japanese standards (JIS), and marine standards (CBM), among others. The nominal pressure ratings for the PN series are designated by "PN" and comprise the following nine levels: PN2.5, PN6, PN10, PN16, PN25, PN40, PN63, PN100, and PN160. The nominal pressure ratings for the Class series are designated by "Class" and comprise the following six levels: Class150, Class300, Class600, Class900, Class1500, and Class2500. Flange Classification 1. **According to Chemical Industry Standards:** Flanges are classified as follows: Plate Flat Welding Flange (PL), Necked Flat Welding Flange (SO), Necked Butt Welding Flange (WN), Integral Flange (IF), Socket Welding Flange (SW), Threaded Flange (Th), Butt Welding Ring Loose Flange (PJ/SE), Blind Flange (BL), Flat Welding Ring Loose Flange (PJ/PJ), and Lined Blind Flange (BL(s)). 2. **According to Petrochemical (SH) Industry Standards:** Flanges are classified as follows: Threaded Flange (PL), Butt Welding Flange (WN), Flat Welding Flange (SO), Socket Welding Flange (SW), Loose Flange (LJ), and Blind Flange (no specific designation). 3. **According to Machinery (JB) Industry Standards:** Flanges are classified as follows: Integral Flange, Butt Welding Flange, Plate Flat Welding Flange, Butt Welding Ring Plate Loose Flange, Flat Welding Ring Plate Loose Flange, Lap Joint Ring Plate Loose Flange, and Blind Flange. 4. **According to Connection Method/Type:** Flanges are classified as follows: Plate Flat Welding Flange, Necked Flat Welding Flange, Necked Butt Welding Flange, Socket Welding Flange, Threaded Flange, Blind Flange, Necked Butt Welding Ring Loose Flange, Flat Welding Ring Loose Flange, Ring-Type Joint (RTJ) Flange and Blind Flange, Large-Diameter Plate Flange, Large-Diameter High-Neck Flange, Figure-8 Blind Plate, Butt Welding Ring Loose Flange, etc. 5. **According to the Component Being Connected:** Flanges can be classified into Vessel Flanges and Pipe Flanges. 6. **According to Structural Type:** Flanges include Integral Flanges, Threaded Flanges, Flat Welding Flanges, Butt Welding Flanges, Lap Joint (Loose/Swivel) Flanges, and Blind Flanges. A flange—also referred to as a flange plate or rim—is a component used to connect shafts to one another, or, more commonly, to join the ends of pipes. Flanges are also utilized at the inlet and outlet ports of equipment to facilitate connections between two devices—for instance, the flange on a speed reducer. A "flange connection" or "flanged joint" refers to a detachable joint assembly comprising three interconnected elements—a flange, a gasket, and bolts—that together form a sealed structural unit. In the context of piping systems, a "pipe flange" specifically denotes a flange used for plumbing within the installation; when applied to equipment, it refers to the inlet or outlet flange of that specific device. Flanges feature a series of holes through which bolts are inserted to securely fasten the two flanges together, while a gasket placed between the flanges ensures a leak-proof seal. Flanges are broadly categorized into three types: threaded (screw-in) flanges, welded flanges, and clamp-type flanges. Flanges are invariably used in pairs; threaded flanges are suitable for low-pressure piping applications, whereas welded flanges are required for systems operating at pressures exceeding 4 kilograms per square centimeter. A sealing gasket is inserted between the two flange plates, which are then firmly secured using bolts. The thickness of a flange—as well as the specifications of the bolts used to fasten it—vary depending on the specific pressure rating required for the application. When connecting equipment such as water pumps or valves to piping systems, the corresponding connection points on these devices are often manufactured in the shape of a matching flange; this method of attachment is also referred to as a "flange connection." Generally, any connecting component that utilizes bolts to join and seal the perimeters of two flat surfaces—such as the joints in ventilation ducts—is termed a "flange"; such components may collectively be classified as "flange-type parts." However, since such a connection often constitutes merely a *portion* of a larger device—for instance, the interface between a flange and a water pump—it would be inappropriate to classify the entire water pump itself as a "flange-type part." Conversely, smaller components—such as valves—that feature such flanged interfaces may indeed be appropriately categorized as "flange-type parts." -:- For detailed product information, please contact sales. -: AISI 1040 Steel Flange, water quenched from 845°C (1550°F), 650°C (1200°F) temper, 100 mm (4 in.) round Product Information -:- For detailed product information, please contact sales. -: AISI 1040 Steel Flange, water quenched from 845°C (1550°F), 650°C (1200°F) temper, 100 mm (4 in.) round Synonyms -:- For detailed product information, please contact sales. -:

AISI 1040 Steel, water quenched from 845°C (1550°F), 650°C (1200°F) temper, 100 mm (4 in.) round Product Information -:- For detailed product information, please contact sales. -: # **Technical Datasheet: AISI 1040 Steel - Water Quenched & Tempered (845°C / 650°C), 100 mm (4 in.) Round** --- ## **1. Product Overview** AISI 1040 steel subjected to water quenching from 845°C (1550°F) followed by tempering at 650°C (1200°F) represents a specific through-hardening heat treatment condition designed to achieve a balanced combination of strength and toughness in large cross-sections. This treatment transforms the steel's microstructure to tempered martensite, providing enhanced mechanical properties throughout the 100 mm (4 in.) diameter. The water quench provides maximum hardenability for this medium-carbon grade, while the high tempering temperature optimizes ductility and toughness for demanding structural applications. --- ## **2. Key Characteristics** - **Through-Hardened Structure**: Achieves uniform properties across 100 mm diameter section - **Balanced Strength-Toughness**: High tempering temperature prioritizes ductility and impact resistance - **Water Quench Severity**: Provides maximum possible hardness for AISI 1040 composition - **Large Section Capability**: Specifically processed for heavy-duty components - **Reduced Residual Stresses**: High tempering temperature minimizes quench stresses - **Good Wear Resistance**: Tempered martensite structure provides moderate abrasion resistance --- ## **3. Chemical Composition** | Element | Composition Range (%) | Standard Reference | |---------|----------------------|-------------------| | **Carbon (C)** | 0.37 - 0.44 | SAE J403 / ASTM A29 | | **Manganese (Mn)** | 0.60 - 0.90 | SAE J403 / ASTM A29 | | **Phosphorus (P)** | ≤ 0.040 | SAE J403 / ASTM A29 | | **Sulfur (S)** | ≤ 0.050 | SAE J403 / ASTM A29 | | **Silicon (Si)** | 0.15 - 0.35 | SAE J403 / ASTM A29 | | **Iron (Fe)** | Balance | - | *Note: For 100 mm sections, the upper end of the manganese range (0.80-0.90%) is preferred for adequate hardenability.* --- ## **4. Heat Treatment Process Details** ### **Step 1: Austenitizing** - **Temperature**: 845°C (1550°F) ± 10°C - **Soaking Time**: 2.5-3.0 hours (30-45 minutes per inch of diameter) - **Atmosphere**: Protective or neutral to prevent decarburization - **Purpose**: Complete transformation to austenite, carbon dissolution ### **Step 2: Quenching** - **Medium**: Water at 20-30°C (68-86°F) - **Agitation**: Vigorous circulation to maximize cooling rate - **Quench Severity (H-value)**: Approximately 1.0 (water quench) - **Resulting Structure**: Martensite with possible minor bainite at core ### **Step 3: Tempering** - **Temperature**: 650°C (1200°F) ± 10°C - **Time**: 4-5 hours (1 hour per inch minimum) - **Cooling**: Air cool from tempering temperature - **Purpose**: Stress relief, martensite tempering, toughness development --- ## **5. Microstructural Characteristics** ### **Surface to Core Variation (100 mm diameter)** | Location from Surface | Microstructure | Prior Austenite Grain Size | |----------------------|----------------|----------------------------| | **Surface (0-10 mm)** | Tempered martensite | ASTM 7-8 | | **Mid-radius (25 mm)** | Tempered martensite | ASTM 7-8 | | **Core (50 mm)** | Tempered martensite + possible bainite | ASTM 7-8 | ### **Phase Distribution** - **Martensite Content**: >90% throughout cross-section - **Retained Austenite**: <2% (minimal due to high tempering temperature) - **Carbide Precipitation**: Fine cementite particles in ferrite matrix - **Decarburization**: ≤0.25 mm (0.010 in) maximum if unprotected --- ## **6. Mechanical Properties** ### **Tensile Properties (Typical)** | Property | Surface | Mid-radius | Core | Test Standard | |----------|---------|------------|------|---------------| | **Tensile Strength** | 850-950 MPa | 820-920 MPa | 800-900 MPa | ASTM A370 | | **Yield Strength (0.2%)** | 700-800 MPa | 680-780 MPa | 660-760 MPa | ASTM A370 | | **Elongation (50 mm)** | 18-22% | 19-23% | 20-24% | ASTM A370 | | **Reduction of Area** | 55-65% | 58-68% | 60-70% | ASTM A370 | ### **Hardness Profile (Typical)** | Distance from Surface (mm) | Hardness (HB) | Hardness (HRC) | |----------------------------|---------------|----------------| | **0 (Surface)** | 285-325 | 30-34 | | **25** | 275-315 | 28-32 | | **50 (Center)** | 265-305 | 26-30 | ### **Impact Properties** | Temperature | Charpy V-Notch Impact Energy | Test Standard | |-------------|-------------------------------|---------------| | **20°C (68°F)** | 40-60 J (30-44 ft-lb) | ASTM A370 | | **0°C (32°F)** | 35-55 J (26-41 ft-lb) | ASTM A370 | | **-20°C (-4°F)** | 25-45 J (18-33 ft-lb) | ASTM A370 | ### **Additional Mechanical Properties** | Property | Value | Test Standard | |----------|-------|---------------| | **Modulus of Elasticity** | 200 GPa (29,000 ksi) | ASTM E111 | | **Shear Modulus** | 80 GPa (11,600 ksi) | ASTM E143 | | **Poisson's Ratio** | 0.29 | ASTM E132 | | **Fatigue Strength (10⁷ cycles)** | 350-420 MPa | Rotating bending | | **Fracture Toughness (KIC)** | 70-90 MPa√m | ASTM E1820 | --- ## **7. Physical Properties** | Property | Value | |----------|-------| | **Density** | 7.87 g/cm³ (0.284 lb/in³) | | **Thermal Conductivity** | 51.9 W/m·K (36.0 BTU·in/hr·ft²·°F) | | **Specific Heat Capacity** | 486 J/kg·K (0.116 BTU/lb·°F) | | **Coefficient of Thermal Expansion** | 11.3 µm/m·°C (6.3 µin/in·°F) 20-100°C | | **Electrical Resistivity** | 0.160 µΩ·m | | **Magnetic Properties** | Ferromagnetic | --- ## **8. International Standard Equivalents** | Standard System | Designation | Heat Treatment Equivalent | |----------------|-------------|---------------------------| | **UNS** | G10400 | Grade 1040, Q&T condition | | **SAE/AISI** | 1040 | Water quenched & tempered | | **ASTM** | Grade 1040 | ASTM A29, specified HT | | **EN (Europe)** | 1.1186 (C40E) | EN 10083-2, QT condition | | **ISO** | C40E | ISO 683-18, Type QT | | **JIS (Japan)** | S40C | JIS G4051, heat treated | | **GB (China)** | 40# (40钢) | GB/T 699,调质处理 | --- ## **9. Hardenability Analysis (Jominy Test Reference)** ### **Theoretical Jominy Curve for AISI 1040** | Distance from Quenched End | Hardness (HRC) | |----------------------------|----------------| | **1.5 mm (1/16")** | 55-60 | | **3.0 mm (1/8")** | 50-55 | | **5.0 mm (3/16")** | 45-50 | | **10.0 mm (3/8")** | 35-40 | | **15.0 mm (5/8")** | 30-35 | | **20.0 mm (3/4")** | 25-30 | ### **Equivalent Round Diameter Analysis** - **50% Martensite at Center**: Approximately 75 mm (3 in.) diameter in water - **90% Martensite at Center**: Approximately 50 mm (2 in.) diameter in water - **100 mm Diameter**: Center hardness indicates mixed structure --- ## **10. Primary Applications** ### **Heavy Equipment Components** - Mining shovel dipper teeth and adapters - Excavator bucket pins and bushings - Crane hook blocks and sheaves - Heavy-duty axle shafts for off-road vehicles - Large gear blanks for industrial machinery ### **Power Transmission Components** - Large diameter drive shafts - Heavy-duty coupling components - Industrial clutch plates and components - Turbine and generator shafting - Large sprockets and chain wheels ### **Industrial Machinery** - Press frame components - Rolling mill rolls (backup rolls) - Large bearing races and rings - Hydraulic cylinder rods for heavy presses - Machine tool structural components ### **Marine & Offshore Applications** - Ship propulsion shafting - Offshore platform components - Deck machinery components - Anchor windlass components ### **Construction Equipment** - Pile driver components - Concrete mixer drum shafts - Crane boom sections - Heavy-duty fastener stock --- ## **11. Fabrication Considerations** ### **Machining Operations (Post-Heat Treatment)** - **Tooling**: Carbide or ceramic tools required - **Cutting Speeds**: 15-30 m/min (50-100 ft/min) - **Feeds**: 0.1-0.2 mm/rev (0.004-0.008 in/rev) - **Coolant**: High-pressure coolant essential - **Difficulty**: Challenging due to hardness; grinding often preferred - **Best Practice**: Machine before final heat treatment when possible ### **Welding (Not Recommended)** - **Pre-heating**: 300-350°C (570-660°F) if absolutely necessary - **Post-Weld Heat Treatment**: Full re-austenitize and quench required - **Alternative Joining**: Mechanical fastening preferred - **Risk**: High probability of cracking in HAZ ### **Grinding & Finishing** - **Grinding Wheels**: Aluminum oxide (A) or CBN wheels - **Parameters**: Light cuts, frequent dressing - **Surface Finish**: Capable of <0.8 µm Ra with proper technique - **Stress Relief**: May require additional tempering after heavy grinding ### **Non-Destructive Testing** - **Ultrasonic Testing**: Essential for large forgings - **Magnetic Particle**: Surface crack detection - **Hardness Survey**: Multiple points across diameter - **Microstructure Check**: Surface and core verification --- ## **12. Quality Assurance Requirements** ### **Mandatory Testing (Per Heat/Lot)** | Test | Frequency | Standard | Acceptance Criteria | |------|-----------|----------|-------------------| | **Chemical Analysis** | Per heat | ASTM E415 | Within specified ranges | | **Tensile Test** | Per lot (2 samples) | ASTM A370 | Meet minimum values | | **Hardness Survey** | Per piece (3 locations) | ASTM E10 | Within 30 HB range | | **Impact Test** | Per heat | ASTM A370 | Min 40 J at 20°C | | **Macroetch** | Per heat | ASTM E381 | Sound center, no defects | ### **Optional Testing** - **Jominy Hardenability**: For hardenability verification - **Microcleanliness**: ASTM E45 inclusion rating - **Grain Size**: ASTM E112 method - **Residual Stress**: X-ray diffraction measurement - **Fracture Toughness**: For critical applications ### **Certification Requirements** - Complete heat treatment records (time-temperature charts) - Quench bath temperature records - Mechanical property test reports - NDT reports (UT, MT) - Full material traceability --- ## **13. Comparison with Alternative Treatments** ### **Water Quench vs. Oil Quench (100 mm diameter)** | Property | Water Quench (845°C/650°C) | Oil Quench (845°C/550°C) | |----------|-----------------------------|--------------------------| | **Surface Hardness** | 30-34 HRC | 35-40 HRC | | **Core Hardness** | 26-30 HRC | 22-26 HRC | | **Tensile Strength** | 850-950 MPa | 950-1050 MPa | | **Impact Toughness** | 40-60 J | 25-40 J | | **Distortion Risk** | High | Moderate | | **Cracking Risk** | High | Low | ### **Effect of Tempering Temperature** | Tempering Temperature | Strength | Toughness | Primary Application | |----------------------|----------|-----------|---------------------| | **550°C (1020°F)** | 950-1050 MPa | 25-40 J | High strength gears | | **650°C (1200°F)** | 850-950 MPa | 40-60 J | Structural components | | **700°C (1290°F)** | 750-850 MPa | 60-80 J | High impact applications | --- ## **14. Design Considerations** ### **Section Size Effects** - **Diameter Capability**: Maximum ~125 mm (5 in.) for through-hardening - **Property Gradient**: Hardness variation ≤60 HB across diameter - **Residual Stresses**: High surface compression, moderate tension at core - **Fatigue Performance**: Best in bending, good in torsion ### **Stress Analysis Guidelines** - **Allowable Bending Stress**: 400-500 MPa - **Allowable Shear Stress**: 250-300 MPa - **Fatigue Endurance Limit**: 350-420 MPa - **Stress Concentration Factors**: Use Kt ≥ 2.0 for notches ### **Safety Factors Recommended** | Loading Type | Safety Factor | Application | |--------------|---------------|-------------| | **Static** | 2.0-2.5 | General machinery | | **Fatigue** | 3.0-4.0 | Rotating components | | **Impact** | 4.0-5.0 | Hammer components | | **Critical** | 6.0+ | Safety components | --- ## **15. Storage & Handling** ### **Special Considerations** - **Stress Corrosion**: Susceptible in certain environments; protect surfaces - **Dimensional Stability**: Minimal growth/shrinkage after processing - **Surface Protection**: Oil or rust preventive coating recommended - **Handling**: Use proper slings to avoid surface damage ### **Inspection Requirements** - **Periodic Checks**: Every 6 months for corrosion - **Hardness Verification**: Before critical use if long-term stored - **NDT**: Recommended after extended storage for critical applications --- ## **16. Limitations & Special Notes** ### **Technical Limitations** 1. **Not for Welded Construction**: Re-heat treatment required after welding 2. **Temperature Limitations**: Maximum service temperature 400°C (750°F) 3. **Size Limitations**: Ineffective for diameters >125 mm (5 in.) 4. **Corrosion Resistance**: Moderate; requires protection in aggressive environments ### **Processing Warnings** - **Quench Cracks**: High risk with water quenching; inspection critical - **Distortion**: Significant; requires straightening or machining allowance - **Decarburization**: Must be removed by machining if present - **Retained Austenite**: Minimal due to high tempering temperature --- ## **17. Cost & Economic Considerations** ### **Cost Factors** - **Material Cost**: Moderate (standard carbon steel) - **Heat Treatment Cost**: High (specialized water quench facility required) - **Machining Cost**: High (difficult to machine after hardening) - **Testing Cost**: Significant (multiple tests required) ### **Value Proposition** - **Performance**: Excellent strength-toughness balance for large sections - **Reliability**: Consistent properties with proper processing - **Life Cycle**: Long service life in appropriate applications - **Alternative Comparison**: More economical than alloy steels for many applications --- **Disclaimer**: This technical data sheet provides detailed information about AISI 1040 steel in a specific heat-treated condition. Actual properties may vary based on exact chemical composition, heat treatment parameters, and section size. Water quenching of large sections carries significant risk of distortion and cracking. For critical applications, consult with qualified metallurgical engineers, conduct thorough testing, and consider alternative materials or treatments. Always follow appropriate safety procedures when handling and processing heat-treated steel components. --- **Revision**: 1.0 **Date**: November 2023 **Status**: Current Specification **Note**: Water quenching of 100 mm rounds requires specialized equipment and expertise. Consider oil quenching for reduced risk with slightly lower properties. -:- For detailed product information, please contact sales. -: AISI 1040 Steel, water quenched from 845°C (1550°F), 650°C (1200°F) temper, 100 mm (4 in.) round Specification Dimensions Size： Diameter 20-1000 mm Length <4822 mm Size:We can customized as required Standard： Per your request or drawing We can customized as required Properties（Theoretical） Chemical Composition -:- For detailed product information, please contact sales. -: AISI 1040 Steel, water quenched from 845°C (1550°F), 650°C (1200°F) temper, 100 mm (4 in.) round Properties -:- For detailed product information, please contact sales. -:

Applications of AISI 1040 Steel Flange, water quenched from 845°C (1550°F), 650°C (1200°F) temper, 100 mm (4 in.) round -:- For detailed product information, please contact sales. -: Chemical Identifiers AISI 1040 Steel Flange, water quenched from 845°C (1550°F), 650°C (1200°F) temper, 100 mm (4 in.) round -:- For detailed product information, please contact sales. -:

Packing of AISI 1040 Steel Flange, water quenched from 845°C (1550°F), 650°C (1200°F) temper, 100 mm (4 in.) round -:- For detailed product information, please contact sales. -: Standard Packing: -:- For detailed product information, please contact sales. -: Typical bulk packaging includes palletized plastic 5 gallon/25 kg. pails, fiber and Steel Flange drums to 1 ton super sacks in full container (FCL) or truck load (T/L) quantities. Research and sample quantities and hygroscopic, oxidizing or other air sensitive materials may be packaged under argon or vacuum. Solutions are packaged in polypropylene, plastic or glass jars up to palletized 1293 gallon liquid totes Special package is available on request. E FORUs’ is carefully handled to minimize damage during storage and transportation and to preserve the quality of our products in their original condition