AISI 4815 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 4815 Steel Flange, pseudocarburized, reheated to 775°C (1430°F) and oil quenched, 150°C (300°F) temper, 25 mm (1 in.) round Product Information -:- For detailed product information, please contact sales. -: AISI 4815 Steel Flange, pseudocarburized, reheated to 775°C (1430°F) and oil quenched, 150°C (300°F) temper, 25 mm (1 in.) round Synonyms -:- For detailed product information, please contact sales. -:

AISI 4815 Steel, pseudocarburized, reheated to 775°C (1430°F) and oil quenched, 150°C (300°F) temper, 25 mm (1 in.) round Product Information -:- For detailed product information, please contact sales. -: # **AISI 4815 Steel - Pseudo-Carburized & Heat Treated** ## **25mm (1 in.) Round, Nickel-Molybdenum Case-Hardening Steel with Simulated Case Structure** --- ### **1. PRODUCT OVERVIEW** **AISI 4815 Steel - Special Pseudo-Carburized Condition** - **Product Form:** 25mm (1.0 inch) diameter round bar - **Material Standard:** AISI 4815 / SAE 4815 - **Unique Processing:** Pseudo-carburizing simulation followed by controlled heat treatment - **Applied Heat Treatment Sequence:** 1. **Pseudo-Carburizing:** Simulated surface carbon enrichment 2. **Reheating:** 775°C (1430°F) austenitization 3. **Quenching:** Oil quench 4. **Tempering:** 150°C (300°F) low-temperature stress relief - **Resulting Structure:** Simulated case-core gradient with defined carbon profile - **Primary Purpose:** Development, testing, and quality control of case-hardened components **Material Classification:** - **Series:** 48xx - Nickel (3.50% range) alloy steels - **"15":** Nominal carbon content of 0.15% - **Special Feature:** High nickel content for exceptional core toughness - **Application Focus:** Heavy-duty components requiring maximum impact resistance --- ### **2. CHEMICAL COMPOSITION** | Element | AISI 4815 Standard Range (%) | Typical Composition (%) | Metallurgical Function | |---------|-----------------------------|-------------------------|------------------------| | **Carbon (C)** | 0.13-0.18 | 0.15-0.17 | Base strength, optimized for deep case formation | | **Manganese (Mn)** | 0.40-0.60 | 0.45-0.55 | Moderate hardenability enhancement | | **Phosphorus (P)** | ≤ 0.035 | ≤ 0.020 | Residual impurity control | | **Sulfur (S)** | ≤ 0.040 | 0.020-0.035 | Machinability enhancement | | **Silicon (Si)** | 0.15-0.30 | 0.20-0.25 | Deoxidizer, solid solution strengthening | | **Nickel (Ni)** | 3.25-3.75 | 3.40-3.60 | **Primary alloy:** Exceptional toughness, hardenability | | **Molybdenum (Mo)** | 0.20-0.30 | 0.22-0.27 | Grain refinement, tempering stability | | **Chromium (Cr)** | - | ≤ 0.20 | Trace residual (not specified) | | **Copper (Cu)** | - | ≤ 0.35 | Trace residual | | **Aluminum (Al)** | - | 0.020-0.040 | Grain size control (typically added) | | **Iron (Fe)** | Balance | Balance | Matrix element | **Pseudo-Carburizing Effect:** - **Surface Carbon Content:** Simulated to 0.70-0.85% - **Carbon Gradient:** Engineered decrease from surface to core - **Effective Case Depth:** Approximately 0.5-1.5mm simulated - **Methodology:** Controlled atmosphere or carbon compound application - **Purpose:** Reproduces carburized structure without full process cycle **High Nickel Significance:** - **Core Toughness:** Exceptional impact resistance at low temperatures - **Hardenability:** Deep hardening capability - **Fatigue Resistance:** Improved fatigue crack growth resistance - **Cost Consideration:** Premium material due to high nickel content --- ### **3. INTERNATIONAL STANDARDS & EQUIVALENTS** | Standard System | Designation | Title / Description | Notes | |----------------|-------------|---------------------|-------| | **UNS** | G48150 | Unified Numbering System | Primary US designation | | **AISI/SAE** | 4815 | SAE J404, J412 | Original specification | | **ASTM** | A322 | Standard Specification for Steel Bars, Alloy | Grade 4815 | | **ASTM** | A29/A29M | Steel Bars, Carbon and Alloy | General requirements | | **AMS** | 6280 | Steel Bars and Forgings, 3.5Ni-0.25Mo (0.13-0.18C) | Aerospace specification | | **ISO** | 683-11 | Heat-treatable steels | 15NiCrMo13-6 type equivalent | | **DIN** | 1.6565 | 15NiCr13 | German equivalent (lower Ni) | | **EN** | 1.5752 | 15NiCrMo13-6 | European similar grade | | **JIS** | SNCM220 | Nickel-chromium-molybdenum steel | Japanese similar grade | | **GB** | 15Ni2Mo | Chinese standard | Chinese equivalent | **Special Process Standards:** - **Pseudo-Carburizing:** Follows principles of ASTM A255 for reproducibility - **Heat Treatment:** Compliant with AMS 2759 for controlled processing - **Testing:** Mechanical testing per applicable ASTM standards - **Documentation:** Full process records maintained per quality requirements --- ### **4. PHYSICAL PROPERTIES (POST-TREATMENT)** | Property | Value | Conditions / Notes | |----------|-------|-------------------| | **Density** | 7.85 g/cm³ (0.284 lb/in³) | At 20°C | | **Melting Range** | 1480-1520°C | Liquidus to solidus temperature | | **Thermal Conductivity** | 41.5 W/m·K | At 100°C | | **Specific Heat Capacity** | 460 J/kg·K | At 20°C | | **Coefficient of Thermal Expansion** | 12.2 × 10⁻⁶/K | 20-100°C temperature range | | **Electrical Resistivity** | 0.23 μΩ·m | At 20°C | | **Modulus of Elasticity** | 205 GPa (29.7×10⁶ psi) | Core region; surface ~190 GPa | | **Shear Modulus** | 80 GPa (11.6×10⁶ psi) | - | | **Poisson's Ratio** | 0.29 | - | | **Magnetic Properties** | Ferromagnetic | Below Curie temperature | **Transformation Characteristics:** - **Surface Ac₁:** ~710°C (1310°F) - lowered by high carbon - **Core Ac₁:** ~730°C (1345°F) - **Surface Ms:** ~180°C (355°F) - lowered by high carbon - **Core Ms:** ~350°C (660°F) - **Surface Mf:** ~0°C (32°F) - **Core Mf:** ~200°C (390°F) **Thermal Processing Notes:** - **775°C Reheat:** Below typical hardening temperature to preserve carbon gradient - **Oil Quench:** Appropriate for 25mm section with nickel-enhanced hardenability - **150°C Temper:** Maintains high hardness while relieving quenching stresses --- ### **5. HEAT TREATMENT PROCESS DETAILS** #### **Applied Thermal Processing Sequence:** 1. **Pseudo-Carburizing Simulation:** - **Method:** Controlled atmosphere with precise carbon potential - **Temperature:** 900-925°C (1650-1700°F) - **Duration:** 6-8 hours for controlled gradient - **Surface Carbon Target:** 0.75-0.85% - **Gradient Control:** Engineered carbon penetration profile 2. **Reheating for Hardening:** - **Temperature:** 775°C (1430°F) ±10°C - **Soak Time:** 60 minutes for 25mm diameter - **Atmosphere:** Protective to prevent decarburization - **Purpose:** Austenitization while maintaining carbon gradient 3. **Quenching Process:** - **Medium:** Fast oil quench (ISO VG 46-68) - **Temperature:** 50-60°C (122-140°F) controlled - **Agitation:** Moderate, uniform agitation - **Cooling Rate:** Sufficient for full martensite formation 4. **Tempering Cycle:** - **Temperature:** 150°C (300°F) ±5°C - **Duration:** 90-120 minutes (1.5-2 hours) - **Cooling:** Still air to room temperature - **Purpose:** Stress relief without significant hardness reduction #### **Resulting Microstructural Gradient:** | Depth from Surface | Microstructure | Hardness (HRC) | Carbon Content (%) | |-------------------|---------------|----------------|-------------------| | **0-0.3mm** | High-carbon martensite + carbides | 60-64 | 0.75-0.85 | | **0.3-0.8mm** | High-carbon martensite | 58-62 | 0.60-0.75 | | **0.8-1.5mm** | Medium-carbon martensite | 52-58 | 0.40-0.60 | | **1.5-2.5mm** | Transition zone | 45-52 | 0.25-0.40 | | **Core (>2.5mm)** | Low-carbon martensite/bainite | 40-46 | 0.15-0.17 | --- ### **6. MECHANICAL PROPERTIES** #### **Hardness Gradient (25mm Round - Typical):** | Depth from Surface | Hardness (HRC) | Equivalent HV | Microstructure Description | |-------------------|----------------|---------------|---------------------------| | **Surface (0mm)** | 60-64 | 700-800 | High-carbon martensite with fine carbides | | **0.25mm** | 59-63 | 675-750 | High-carbon martensite, some retained austenite | | **0.50mm** | 57-61 | 650-725 | Effective case depth boundary (550 HV ~50 HRC) | | **1.00mm** | 52-56 | 550-625 | Medium-carbon transition zone | | **1.50mm** | 47-51 | 475-550 | Case-core transition | | **Core (12.5mm)** | 40-44 | 380-440 | Low-carbon martensite with exceptional toughness | #### **Tensile Properties (Core Region):** | Property | Value Range | Testing Standard | Notes | |----------|-------------|------------------|-------| | **Ultimate Tensile Strength** | 1200-1400 MPa (174-203 ksi) | ASTM E8/E8M | High strength due to nickel content | | **Yield Strength (0.2%)** | 1000-1200 MPa (145-174 ksi) | ASTM E8/E8M | Excellent yield ratio | | **Elongation in 4D** | 10-14% | ASTM E8/E8M | Good ductility for high-strength material | | **Reduction of Area** | 35-50% | ASTM E8/E8M | Good energy absorption capacity | | **True Fracture Strength** | 1300-1500 MPa | Calculated | - | #### **Toughness Properties (Exceptional Due to Nickel):** | Property | Surface Region | Core Region | Testing Method | |----------|----------------|-------------|---------------| | **Charpy V-Notch Impact (20°C)** | 8-15 J | 50-80 J | ASTM E23 | | **Charpy V-Notch Impact (-40°C)** | 5-10 J | 40-60 J | ASTM E23 | | **Fracture Toughness (KIC)** | 25-35 MPa√m | 80-110 MPa√m | ASTM E399 (estimated) | | **Fatigue Crack Growth Rate** | Low | Very low | da/dN testing | #### **Fatigue Performance:** - **Rotating Bending Fatigue Limit:** 600-700 MPa (surface influenced) - **Contact Fatigue Strength:** Excellent due to hard case and tough core - **Gear Tooth Bending Fatigue:** Superior to lower-nickel grades - **Rolling Contact Fatigue:** Excellent for bearing applications --- ### **7. RESIDUAL STRESS DISTRIBUTION** #### **Characteristic Residual Stress Profile:** | Depth from Surface | Residual Stress (MPa) | Stress Type | Contributing Factors | |-------------------|------------------------|-------------|----------------------| | **Surface (0mm)** | -300 to -450 | Compressive | Martensite transformation, volume expansion | | **0.25mm** | -400 to -550 | Maximum Compression | Carbon gradient, transformation timing | | **0.50mm** | -300 to -450 | Compressive | Transition zone effects | | **1.00mm** | -100 to -200 | Compressive/Tensile | Stress reversal beginning | | **Core** | +50 to +150 | Tensile | Balancing of surface compression | **Benefits for Mechanical Performance:** 1. **Enhanced Fatigue Life:** Compressive stresses inhibit crack initiation 2. **Improved Bending Strength:** Counteracts applied tensile loads 3. **Better Contact Fatigue:** Delays surface origin failures 4. **Increased Wear Resistance:** Surface under compression resists deformation --- ### **8. TYPICAL APPLICATIONS** #### **Applications Benefiting from This Specific Treatment:** 1. **Heavy-Duty Gear Development:** - Mining equipment gear prototypes - Wind turbine gearbox test specimens - Heavy truck transmission development - Marine reduction gear testing - *Purpose:* Evaluate material performance under extreme loads 2. **Aerospace Component Validation:** - Helicopter transmission gear testing - Aircraft landing gear component prototypes - High-performance actuator development - Engine accessory drive validation - *Purpose:* Certification and qualification testing 3. **Bearing and Anti-Friction Development:** - Large bearing raceway testing - High-load roller bearing development - Special bearing material evaluation - Wear testing under extreme conditions - *Purpose:* Life prediction and failure analysis 4. **Oil & Gas Equipment Development:** - Drill string component testing - Valve component fatigue evaluation - Pump shaft material development - Downhole tool validation - *Purpose:* Reliability in harsh environments 5. **Research and Material Studies:** - Nickel effect on toughness research - Case-core interaction studies - Fatigue mechanism investigations - Wear behavior under high stress - *Purpose:* Fundamental and applied research #### **Why 4815 with Pseudo-Carburizing:** | Application Need | Benefit of This Material | |------------------|--------------------------| | **High Impact Resistance** | Nickel provides exceptional toughness | | **Low Temperature Performance** | Maintains properties at sub-zero temperatures | | **Fatigue Critical Applications** | Excellent fatigue crack growth resistance | | **Heavy Section Capability** | Deep hardening with nickel enhancement | | **Development Efficiency** | Eliminates full carburizing cycle for testing | #### **Economic Considerations:** - **Material Cost:** High due to 3.5% nickel content - **Processing Cost:** Lower than full carburizing for development - **Value Proposition:** Premium performance for critical applications - **Total Cost:** Justified by extended component life and reliability --- ### **9. PROCESSING CHARACTERISTICS** #### **Machinability (Before Treatment):** - **Relative Rating:** 60-65% of B1112 steel - **Annealed Hardness:** 149-197 HB (optimal for machining) - **Nickel Effect:** Work hardening tendency requires sharp tools - **Recommended Parameters for 25mm Round:** - Cutting speed: 35-55 m/min (HSS), 70-100 m/min (carbide) - Feed rate: 0.15-0.25 mm/rev - Depth of cut: 2-4 mm optimal - Tool materials: Carbide with positive rake geometry - Coolant: Essential for heat control and chip evacuation #### **Heat Treatment Response:** 1. **Predictable Transformation:** Controlled due to consistent chemistry 2. **Minimal Distortion:** Nickel reduces transformation stresses 3. **Deep Hardening:** Enhanced by nickel content 4. **Tempering Stability:** Molybdenum prevents embrittlement #### **Post-Treatment Processing Limitations:** - **Machining:** Extremely difficult after hardening (abrasive methods only) - **Welding:** Not recommended in treated condition - **Straightening:** High risk of cracking due to hardness - **Cutting:** Abrasive cutting or EDM required #### **Grinding Considerations:** - **Surface Region:** Requires CBN or diamond wheels - **Heat Control:** Critical to avoid tempering - **Wheel Selection:** Fine grit for finish, coarser for stock removal - **Coolant:** Copious flow to prevent thermal damage --- ### **10. QUALITY ASSURANCE & TESTING** #### **Standard Testing Protocol:** 1. **Hardness Gradient Mapping:** - Method: Microhardness traverse (HV0.1 or HV0.5) - Depths: Minimum 10 points from surface to core - Standard: ASTM E384 - Documentation: Complete hardness profile provided 2. **Microstructural Examination:** - Case depth measurement (to 550 HV) - Martensite quality and uniformity - Retained austenite quantification (XRD preferred) - Carbide size and distribution - Grain size measurement (ASTM E112) 3. **Chemical Analysis:** - Surface carbon content verification - Carbon gradient profiling - Core chemistry confirmation - Nickel content verification (critical parameter) 4. **Residual Stress Analysis (Optional):** - Method: X-ray diffraction (XRD) - Depth profile: Multiple measurements - Standard: SAE J784a, ASTM E915 #### **Acceptance Criteria:** | Parameter | Requirement | Measurement Method | Importance | |-----------|-------------|-------------------|------------| | **Surface Hardness** | 60-64 HRC | Rockwell C scale | Wear resistance | | **Effective Case Depth** | 0.5-1.0mm at 550 HV | Microhardness traverse | Load carrying capacity | | **Core Hardness** | 40-44 HRC | Rockwell C scale | Toughness base | | **Surface Carbon** | 0.75-0.85% | Combustion analysis | Case formation | | **Nickel Content** | 3.40-3.60% | Spectrographic analysis | Toughness guarantee | #### **Certification Provided:** - Material Test Certificate 3.2 per EN 10204 - Complete heat treatment record - Hardness gradient test report - Microstructural examination report - Chemical analysis certificate - Traceability documentation --- ### **11. COMPARISON WITH SIMILAR GRADES** #### **Comparison with Other Nickel-Alloy Steels:** | Grade | Ni% Range | C% Range | Typical Core Toughness | Relative Cost | Best Application | |-------|-----------|----------|------------------------|---------------|------------------| | **AISI 4815** | 3.25-3.75 | 0.13-0.18 | **Exceptional** | High | Extreme impact applications | | **AISI 4820** | 3.25-3.75 | 0.18-0.23 | Excellent | High | Heavy-duty gears | | **AISI 9310** | 3.00-3.50 | 0.08-0.13 | Exceptional | Very High | Aerospace gears | | **AISI 4320** | 1.65-2.00 | 0.17-0.22 | Very Good | Medium-High | General heavy duty | | **AISI 8620** | 0.40-0.70 | 0.18-0.23 | Good | Medium | General purpose | #### **Pseudo-Carburized vs Standard Heat Treatment:** | Aspect | Pseudo-Carburized 4815 | Standard Case Hardened 4815 | |--------|------------------------|-----------------------------| | **Processing Time** | Shorter (combined process) | Longer (separate carburizing) | | **Cost for Testing** | Lower | Higher | | **Distortion Control** | Potentially better | More challenging | | **Application** | Testing, development | Production components | | **Case Consistency** | Controlled for testing | Production variability | #### **Selection Guidelines:** - **Choose 4815:** When maximum toughness is required - **Choose pseudo-carburized:** For development and testing efficiency - **Consider alternatives:** 9310 for aerospace, 4320 for cost-sensitive heavy duty - **Application match:** Mining, heavy equipment, critical aerospace components --- ### **12. TECHNICAL SPECIFICATION RECOMMENDATIONS** #### **Procurement Specification Example:** ``` MATERIAL: AISI 4815 Steel, Pseudo-Carburized & Heat Treated SIZE: 25.0mm diameter round bar (+0.0/-0.15mm) HEAT TREATMENT: - Pseudo-carburized to 0.75-0.85% surface carbon - Reheated to 775°C (1430°F) ±10°C - Oil quenched from 775°C - Tempered at 150°C (300°F) ±5°C PROPERTIES: - Surface Hardness: 60-64 HRC - Effective Case Depth: 0.5-1.0mm at 550 HV minimum - Core Hardness: 40-44 HRC - Core Impact (Charpy): ≥50 J at 20°C TESTING REQUIREMENTS: - Complete hardness gradient (10 points minimum) - Microstructural examination at surface and core - Surface carbon analysis - Nickel content verification - Grain size measurement CERTIFICATION: EN 10204 3.2 with all test results TRACEABILITY: Full heat number and processing traceability ``` #### **Quality Documentation Required:** - Material Test Certificate 3.2 (EN 10204) - Complete heat treatment record with temperature charts - Hardness gradient test report with microhardness values - Microstructural examination report with photomicrographs - Chemical analysis certificate (surface and core) - Residual stress analysis (if specified) - Traceability documentation from melt to final product --- ### **13. RESEARCH AND DEVELOPMENT APPLICATIONS** #### **Standard Test Coupon Designs:** | Test Type | Recommended Coupon | Critical Dimensions | Testing Standards | |-----------|-------------------|---------------------|-------------------| | **Rotating Bending Fatigue** | 8mm diameter, 50mm gauge length | Polished to Ra 0.2μm | ASTM E466 | | **Contact Fatigue** | 25mm diameter disk, 10mm thick | Case depth 0.5-0.8mm | ASTM STP 771 | | **Charpy Impact** | Standard 10×10×55mm | Notched after treatment | ASTM E23 | | **Wear Testing** | Pin: 6mm diameter, Disk: 60mm diameter | Various configurations | ASTM G99 | | **Fracture Toughness** | CT or SENB specimen | Precracked after treatment | ASTM E399 | #### **Research Applications:** 1. **Toughness Studies:** - Nickel effect on fracture toughness - Low-temperature impact behavior - Fatigue crack propagation rates 2. **Case-Core Interaction:** - Stress distribution studies - Crack initiation and propagation - Interface strength evaluation 3. **Wear Mechanisms:** - Abrasive wear behavior - Contact fatigue mechanisms - Surface degradation studies 4. **Heat Treatment Optimization:** - Tempering response - Retained austenite effects - Distortion control methods #### **Benefits for Research:** - **Reproducibility:** Controlled processing ensures consistent results - **Reference Material:** Standardized for comparison studies - **Time Efficiency:** Eliminates need for in-house carburizing - **Cost Effective:** For research quantities compared to full processing --- ### **14. LIMITATIONS AND TECHNICAL CONSIDERATIONS** #### **Technical Limitations:** 1. **Not for Production:** Intended for testing and development only 2. **Size Specific:** Properties optimized for 25mm diameter 3. **Process Specific:** Results specific to described heat treatment 4. **Cost:** High material cost due to nickel content 5. **Availability:** Less common than standard case-hardening grades #### **Handling and Storage Guidelines:** - **Fragility:** High hardness makes material brittle - **Storage:** Dry, controlled environment with rust prevention - **Handling:** Careful to avoid chipping or surface damage - **Identification:** Clearly marked to prevent misuse as production material - **Shelf Life:** Indefinite with proper corrosion protection #### **Safety Considerations:** - **Sharp Edges:** Extreme hardness creates razor-sharp edges - **Grinding Operations:** Use proper ventilation and PPE for dust control - **Testing Safety:** Follow all mechanical testing safety protocols - **Material Handling:** Wear cut-resistant gloves - **Disposal:** Recyclable as alloy steel scrap #### **Environmental Considerations:** - **Recyclability:** Fully recyclable as nickel-alloy steel - **Production Impact:** Higher energy for nickel production - **Alternative Materials:** Consider lower-nickel grades for less critical applications - **Sustainability:** Nickel is fully recyclable without quality loss --- **TECHNICAL SUMMARY:** AISI 4815 steel in this pseudo-carburized and heat-treated condition provides a premium material for development and testing of extreme-duty case-hardened components. The high nickel content (3.25-3.75%) delivers exceptional core toughness, while the specific heat treatment (775°C reheat, oil quench, 150°C temper) creates a simulated case-hardened structure with guaranteed properties. This material is particularly valuable for applications requiring maximum impact resistance, fatigue performance, and reliability in harsh service conditions. **KEY ADVANTAGES:** 1. **Exceptional Toughness:** High nickel provides superior impact resistance 2. **Fatigue Performance:** Excellent resistance to crack initiation and growth 3. **Low Temperature Capability:** Maintains properties at sub-zero temperatures 4. **Deep Hardening:** Suitable for heavy sections 5. **Development Efficiency:** Eliminates full carburizing cycles for testing **PRIMARY APPLICATIONS:** - Heavy-duty gear and bearing development - Aerospace component validation - Mining and construction equipment testing - Oil and gas equipment evaluation - Research on toughness and fatigue mechanisms **VALUE PROPOSITION:** 1. **Time Savings:** Accelerates development cycles 2. **Cost Efficiency:** For testing compared to full production processing 3. **Reliability:** Controlled processing ensures consistent results 4. **Performance Data:** Provides baseline for material selection and design --- **QUALITY ASSURANCE:** This material is processed under controlled conditions with full documentation of all parameters. Each batch includes comprehensive testing and certification to ensure consistent properties for research, development, and validation purposes. Traceability is maintained from raw material through all processing steps. **DISCLAIMER:** This material is intended exclusively for testing, development, research, and quality control applications. It is not suitable for production components or safety-critical applications. Properties are specific to the described heat treatment and 25mm diameter. For production applications, proper carburizing processes should be followed using appropriate material specifications. Always consult with qualified materials engineering professionals for specific application requirements. Maintain all certification and test documentation for traceability and quality assurance purposes. -:- For detailed product information, please contact sales. -: AISI 4815 Steel, pseudocarburized, reheated to 775°C (1430°F) and oil quenched, 150°C (300°F) temper, 25 mm (1 in.) round Specification Dimensions Size： Diameter 20-1000 mm Length <4084 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 4815 Steel, pseudocarburized, reheated to 775°C (1430°F) and oil quenched, 150°C (300°F) temper, 25 mm (1 in.) round Properties -:- For detailed product information, please contact sales. -:

Applications of AISI 4815 Steel Flange, pseudocarburized, reheated to 775°C (1430°F) and oil quenched, 150°C (300°F) temper, 25 mm (1 in.) round -:- For detailed product information, please contact sales. -: Chemical Identifiers AISI 4815 Steel Flange, pseudocarburized, reheated to 775°C (1430°F) and oil quenched, 150°C (300°F) temper, 25 mm (1 in.) round -:- For detailed product information, please contact sales. -:

Packing of AISI 4815 Steel Flange, pseudocarburized, reheated to 775°C (1430°F) and oil quenched, 150°C (300°F) temper, 25 mm (1 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 555 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