Академический Документы
Профессиональный Документы
Культура Документы
Construction Engineering
Research Laboratory
January 2002
Final report
Approved for public release; distribution is unlimited.
Prepared for
Under
ERDC/CERL TR-02-7
(TR HPMS-02-1)
January 2002
ERDC/CERL TR-02-7
Preface
The study described in this report was authorized by Headquarters, U.S. Army
Corps of Engineers (HQUSACE), as part of the High-Performance Materials and
Systems (HPM&S) Research Program. The work was performed under Work
Unit 33238, Civil Works Advanced Materials Selection Guide, for which
Dr. Ashok Kumar, U.S. Army Engineer Research and Development Center
(ERDC), Construction Engineering Research Laboratory (CERL), was the Principal Investigator.
Dr. Tony Liu was the HPM&S Coordinator at the Directorate of Research and
Development; Research Area Manager was Mr. Roy Braden; and Program Monitor was Mr. Andy Wu, HQUSACE. Dr. Mary Ellen Hynes, ERDC Geotechnical
and Structures Laboratory (GSL), was the ERDC Lead Technical Director for
Infrastructure Engineering and Management. Mr. James E. McDonald, ERDC
GSL, was the HPM&S Program Manager.
The work was performed by the Materials and Structures Branch (CF-M) of the
Facilities Division (CF), CERL.
The report was prepared by Dr. L.D.
Stephenson, CERL; and Mr. Paul Willis, Portland District (retired). Mr. Martin
J. Savoie was Chief, CF-M, and Mr. L. Michael Golish was Chief, CF. Dr. Paul
A. Howdyshell was the Technical Director for this work unit, and Dr. Alan W.
Moore was Director of CERL.
At the time of preparation of this report, COL John W. Morris III, EN, was the
Commander and Executive Director of the ERDC, and Dr. James R. Houston
was the Director.
DISCLAIMER: The contents of this report are not to be used for advertising, publication, or promotional purposes. Citation of trade names does not constitute an official endorsement or approval of the use of such
commercial products. All product names and trademarks cited are the property of their respective owners.
The findings of this report are not to be construed as an official Department of the Army position unless so
designated by other authorized documents.
DESTROY THIS REPORT WHEN IT IS NO LONGER NEEDED. DO NOT RETURN IT TO THE ORIGINATOR.
ERDC/CERL TR-02-7
Contents
Preface................................................................................................................................................ 2
List of Tables ..................................................................................................................................... 4
1
Introduction ................................................................................................................................ 5
Background......................................................................................................................... 5
Objectives ........................................................................................................................... 7
Approach ............................................................................................................................ 7
Mode of Technology Transfer ............................................................................................. 8
Units of Weight and Measure ............................................................................................. 8
Lubrication Requirements................................................................................................. 14
Problems With Loss of Lubrication .............................................................................................. 14
Use of Self-Lubricating Bushings Versus Greased Bushings ...................................................... 15
References....................................................................................................................................... 56
Appendix A:
SF 298
ERDC/CERL TR-02-7
List of Tables
1. Materials selection guidance for bulkhead and tainter gate components. ................. 20
2. Materials selection guidance for miter gate components. .......................................... 24
3. Materials selection guidance for miter gate machinery. ............................................. 28
4. Materials selection guidance for tainter valve components........................................ 32
5. Materials selection guidance for emergency gate machinery..................................... 34
6. Materials selection guidance for segmental valve machinery. ................................... 36
7. Materials selection guidance for emergency dam (wicket type) components. ........... 37
8. Materials selection guidance for gears. ...................................................................... 38
9. Materials selection guidance for shafts. ..................................................................... 39
10. Materials selection guidance for pins. ...................................................................... 40
11. Materials selection guidance for steel reinforcements for concrete.......................... 40
12. Materials selection guidance for hydroelectric plant components............................ 41
13. Materials selection guidance for piping. ................................................................... 44
14. Materials selection guidance for fisheries. ............................................................... 48
15. Materials selection guidance for traveling fish screens. ........................................... 49
16. Materials selection guidance for miscellaneous components. ................................. 50
ERDC/CERL TR-02-7
1 Introduction
Background
Army Corps of Engineers Civil Works projects can often benefit from the application of new generations of advanced engineering materials that are continuously
being brought to market. Two of the more important materials in this regard are
stainless steels and self-lubricating bushing materials. The Corps of Engineers
has previously published technical information about stainless steel performance
in Civil Works applications (Kumar et al. 1989), but self-lubricating materials
were not addressed. This technical report updates available Corps guidance on
selecting high-performance materials, including self-lubricating bushing materials, for locks, dams, and components of hydroelectric plants.
Carbon steels and low-alloy steels have been the primary source for materials
used to construct locks, dams, and hydroelectric plants. To a much lesser extent,
components for such facilities have been fabricated from 400-series martensitic
stainless steels (e.g., Types 410 and 416) and 300-series austenitic stainless
steels (e.g., Types 302, 303, 304, 308, and 316). Although the 300-series stainless
steels normally have excellent corrosion resistance in most freshwater environments (see Appendix Table A-1 in Kamp and Schmitt 1966), their yield strengths
(about 35,000 psi in the annealed condition) are somewhat low for many applications. Furthermore, a number of locks and dams use bolts and nuts fabricated
from the same 300-series stainless steels, and these have a tendency to pit in
waters containing more than about 1000 parts per million (ppm) chloride (including Type 316, which is formulated with a small amount of molybdenum to resist
pitting). They are also subject to oxygen-differential concentration-cell corrosion
under deposits and in crevices. An advantage of the austenitic grades of
stainless steel, however, is that they do not experience chloride-induced, stresscorrosion cracking at temperatures lower than about 150 F (Pecknar and Bernstein 1977). They also exhibit excellent resistance to freshwater erosion corrosion.
The yield strength limitations of the 300-series stainless steels for Civil Works
projects were originally overcome by using heat-treatable, 400-series stainless
steels. Unfortunately, these alloys often do not exhibit the desired corrosion
ERDC/CERL TR-02-7
ERDC/CERL TR-02-7
Objectives
The objectives of this work are to
1. present stainless steel mechanical and material property data, provide an overview of corrosion behavior, and provide general guidelines on using the various
types of stainless steels for locks, dams, and hydroelectric plant applications
2. discuss selected types of self-lubricating bushing materials, including presentation of laboratory data on friction coefficients and wear rates obtained from two
laboratory tests.
Approach
Researchers selected 17 stainless steels that may reduce maintenance costs and
are becoming more available for Civil Works applications. These may be categorized as follows:
ERDC/CERL TR-02-7
2.54 cm
1 ft
0.305 m
1 sq in.
6.452 cm2
1 lb
0.453 kg
1 psi
6.89 kPa
(C x 1.8) + 32
ERDC/CERL TR-02-7
10
ERDC/CERL TR-02-7
* PTFE: polytetrafluoroethylene.
ERDC/CERL TR-02-7
11
12
ERDC/CERL TR-02-7
ERDC/CERL TR-02-7
13
14
ERDC/CERL TR-02-7
the chemistry or metallurgical condition of the stainless steel involved. The corrosion current densities for the ASTM A 36 steel vary between 1.4 2.5 x 10-5
ampere/cm2.
Cavitation
Tests conducted in accordance with ASTM G 32 have allowed stainless steels
and a low-alloy carbon steel to be ranked according to their cavitation resistance
(Table A-7, Segan et al. 1982). Not unexpectedly, NITRONIC 60 had the best
cavitation resistance of the materials evaluated. Similar cavitation-resistance
results have been obtained for stainless steels exposed to jet-impingement by
river water. The relative cavitation depth damages for NITRONIC 60, 17-4PH,
Type 316, and CA_6NM were reported as being 1.0, 1.9, 3.7, and 6.6, respectively
(Schumacher 1986). These data clearly indicate that cast NITRONIC 60 could
be a viable alternative for CA-6NM where cavitation is a concern.
Galling
When two metal surfaces are rubbed together under heavy pressure, and without lubrication, it is expected that galling (or even seizing) may result. The button and block galling test has been used to evaluate the adhesive wear resistance of various stainless steels under nonlubricated conditions (Schumacher
1977). Specimens were considered galled if deep scoring and heavy surface damage were evident during examination of the surfaces at 10X magnification. The
lightest load that caused galling was used to calculate the threshold galling
stress. Threshold galling stresses for selected stainless steel combinations are
included in Table A-8 (Schumacher 1977). The data in Table 8 establish that
many contacting stainless steel combinations are highly susceptible to galling.
More important, the data show that NITRONIC 60 can be used in contact with
many stainless steels without concern for galling. Galling problems associated
with the use of Type 304 nuts and bolts could very well be eliminated by fabricating one of the components from NITRONIC 60.
Lubrication Requirements
Problems With Loss of Lubrication
Loss of lubrication results in direct contact between two moving metal surfaces.
The resulting friction is the main cause of wear in these parts. This results in
ERDC/CERL TR-02-7
material loss and damage that can cause equipment failure. High friction is also
responsible for excessive heat generation and a loss of efficiency.
Lubrication can be divided into three broad categories:
1. hydrodynamic
2. elastohyrodynamic
3. boundary layer.
Hydrodynamic lubrication occurs when a wedge of oil forms between the sliding metal surfaces, reducing friction to very low levels. Hydrodynamic lubrication requires high sliding speeds to create internal pressure to support the load
on the bearing.
Elastohydrodynamic lubrication is used to describe the action of rolling bodies
such as ball bearings. Similar to hydrodynamic lubrication, elastohydrodynamic
lubrication creates high pressure to maintain a thin film of oil between the metal
surfaces. Elastohydrodynamic lubrication also requires fairly high sliding
speeds to maintain the oil film.
When a bearing does not reach high sliding speeds or is subject to frequent starts
and stops, the oil film will not fully develop, resulting in contact between the
metal surfaces. This is called boundary layer lubrication and it is the most
common means of lubrication in lock, dam, and hydropower applications.
Use of Self-Lubricating Bushings Versus Greased Bushings
A greaseless self-lubricating bushing uses a solid lubricant coating on the inner
surface for protection from friction and wear. Solid lubricants are ideal for intermittent loading conditions, as when equipment is idle for long periods of time,
They are also useful for inaccessible locations where monitoring of liquid lubricants would be difficult, and in environmental conditions where contamination
by oils or greases would be a problem, such as submerged in water (EM 1110-21424).
The characteristics of solid lubricants allow self-lubricating bushings to be effective at high loads and low speeds, resistant to deterioration in storage, and stable in corrosive environments where oils or grease may break down. Also, selflubricating bushings do not require lubrication distribution systems. However,
for best performance, it is recommended that self-lubricating bushings be in-
15
16
ERDC/CERL TR-02-7
stalled with seals wherever they may be exposed to water or other contaminants
(Jones et al. 1999).
Self-lubricating bushings do have several disadvantages compared to conventional oils and greases. First, they have poor self-healing properties. A breach
in the solid lubricant film will not heal itself as oils and greases do. Second, the
solid lubricants used in greaseless bushings have poor heat dissipation characteristics because they tend to be insulators with low thermal conductivities. Finally, greaseless bushings tend to have a higher coefficient of friction than hydrodynamically lubricated bushings (EM 1110-2-1424). This last disadvantage is
probably not a significant problem in low-speed applications such as locks and
dams, however, because the lubrication mechanism in greaseless bushings is
likely to be designed as boundary layer lubrication rather than hydrodynamic
lubrication.
In order to ensure that self-lubricating bushings work properly, they must be
mated either to a heated-treated steel shaft or a hard-chrome-plated medium- to
high-strength steel shaft material such as 17-4 PH.
ERDC/CERL TR-02-7
Disadvantages to using ductile iron include the need for higher-purity raw
materials and a lower mold yield. A high-purity melt must be maintained in
ductile iron casting to ensure the growth of the graphite in a spherical shape. A
lower mold yield than gray iron is caused by the need for risers during ductile
iron casting. Overall, greater control and testing are required to produce highquality ductile iron. Therefore, the production cost for ductile iron components
tends to be greater than components produced from gray iron (Metals Handbook
1998).
17
18
ERDC/CERL TR-02-7
2.
3.
4. tainter-valve components
5. emergency-gate machinery
6. segmental valve machinery
7. emergency dam (wicket type) components
ERDC/CERL TR-02-7
8. gears
9. shafts
10. pins
11. steel reinforcements for concrete
12. hydroelectric plant components
13. piping materials and components
14. fisheries
15. traveling fish screens
16. miscellaneous components.
In the materials selection tables, all stainless steel selection recommendations
are identified with a pound sign (#).
19
20
ERDC/CERL TR-02-7
Table 1. Materials selection guidance for bulkhead and tainter gate components.
Skin Plate
Diagonals
Horizontal Girders
Trunnion Pins
Trunnion Bushings
Trunnion Housings
J-Seals
Natural Rubber*
Neoprene*
* Preferably with fluorocarbon inserts for
rubbing-contact areas
ERDC/CERL TR-02-7
Trunnion Girders
21
Trunnion Yokes
Bottom/Embedded Seals
Babbitt, ASTM B 23
Wire Ropes
Rope-to-Gate Connections
Rope Sockets
J-Seal Heaters
Trunnion-Hub Pins
22
ERDC/CERL TR-02-7
Gate Arms
Side/Embedded Seal
Bulkhead
Bulkhead roller
Bulkhead Collar
Bulkhead Bolts
Bulkhead Bushings
Bulkhead Axle
Hoist Bolts
Hoist Nuts
# Stainless Steel, ASTM A 194, Grade Symbol 8S (UNS S21800) (Armco NITRONIC 60
Flanged-Spiral Segment
Safety Grating
Hoist Frame
ERDC/CERL TR-02-7
Hoist-Chain Bars
23
Hoist-Chain Pins
Link Chain
Pocketwheel
Bolts
Nuts
Shear Pins
Shims
Pinions
Pinion/Hoist
24
ERDC/CERL TR-02-7
Diagonals
Intercostals
Diaphragms
Horizontal Girders
Gudgeon Pins
Gudgeon Bushings
Gudgeon-Pin Hoods
Gudgeon Rings
Gudgeon-Pin Barrels
Link Pins
Anchor Bars
Embedded Anchorages
ERDC/CERL TR-02-7
Pintles
25
Pintle Shoes
Pintle Base
Pintle Bushings
26
ERDC/CERL TR-02-7
Reaction Bar
Gate Seals/J-Seals
Neoprene+
Natural Rubber+
+ Preferably with fluorocarbon inserts for
rubbing-contact areas.
Sill Plates/Nosings
Miscellaneous Bushings
Miscellaneous Bearings
Aluminum Bronze
ERDC/CERL TR-02-7
Miscellaneous Bolts/Nuts
27
28
ERDC/CERL TR-02-7
Angles
Base
Stud Bolts
Turned Bolts
Rack Bumper
Piston-Rod Bushing
Snubbing Bushing
Sector Arm
Cap Screws
Sector Base
Cross Pins
ERDC/CERL TR-02-7
29
Cylinder Heads
Hydraulic Cylinder
Fitted Bolts
Flanged Spacers
Strut Follower
Pistons
Wedge Nuts
30
ERDC/CERL TR-02-7
Spacer (Ring)
Springs
Pinion Shafts
Spring Cartridge
Spring Rod
Strut Pins
Stud Bolts
ERDC/CERL TR-02-7
31
Ring-Spring Mandrell
Sector Gear
Selsyn Drive
32
ERDC/CERL TR-02-7
Structural Members
Trunnion Pins
Trunnion-Pin Bushings
Anchorage Beams
Seal Bolts
Seal Nuts
J-Seals
Neoprene*
Natural Rubber*
* Preferably with fluorocarbon inserts for
rubbing-contact areas
Trunnion Housings
Neoprene
Natural Rubber
Bell Crank
ERDC/CERL TR-02-7
Hydraulic Cylinder
33
Piston Rods
Anchorages
Bushings
34
ERDC/CERL TR-02-7
Angles
Axle
Bearing Pedestal
Bearing Stance
Shear Bolt
Bull Gear
Sheave Bushing
Carriage Wheel
Drum Plates
Machinery Base
Spacer/Spool
ERDC/CERL TR-02-7
Sheave
35
Cartridge Wheel
Rope Separator
Separator Pins
Drum Shaft
Reducer Shaft
Sleeve Shaft
Intermediate Gear
36
ERDC/CERL TR-02-7
Angles
Base
Bearing Bracket
Bushing
Forgings
Turned Bolts
Bushings
Cylinder Bracket
Trunnion Bushing
Hydraulic Cylinder
Cylinder Heads
ERDC/CERL TR-02-7
37
Hinged Bearing
Selsyn Keys
Spindle Nut
Stop Plates
Strut Spindle
Pistons
Piston Rod
Table 7. Materials selection guidance for emergency dam (wicket type) components.
Structural Steel
Link Chain
Ductile Iron
Dogging Device
38
ERDC/CERL TR-02-7
Countershaft
Drum Pinion
Bull (Rim)
Phosphorus Bronze
ERDC/CERL TR-02-7
39
Countershaft
Reducer Shaft
40
ERDC/CERL TR-02-7
Table 11. Materials selection guidance for steel reinforcements for concrete.
Rods
Post-Tension Cables
ERDC/CERL TR-02-7
41
Wicket Gates
Body
Sleeves
Wear Plates
42
ERDC/CERL TR-02-7
Scroll Case
Intake Gates
Hoist Cylinder Piston Rods
Guide Track
Roller Chains
ERDC/CERL TR-02-7
43
Bearing Tracks
Seal Bolts
Seal Nuts
Structure
Trashracks
Dielectric Unions
44
System
Max
press
kPa
Pipe
Fittings
Generator cooling(10)
865
Schedule or thickness:
see Note 7
Turbine glands
Cast iron:
flanged ASTM A 126
Potable water
865
Same as Group A
Same as Group A
1040
ERDC/CERL TR-02-7
System
Max
press
kPa
Pipe
Fittings
125
Same as Group A
ERDC/CERL TR-02-7
Group
Exposed:
Exposed:
None
None
None
Pressure sewage
700
Piezometer
865
1040
See Note 9
Transformer oil
Transfer systems
45
System
Max
press
kPa
Pipe
Fittings
Service air
865
Same as group b
Same as Group A
Brake air
t3.20.14
46
Group
Governer air
4140
Nitrogen
Governer air
Hypochlorite solution
Floatwells
7590
Globe valve:
PVC
None
See Note 2
Sleeves
ERDC/CERL TR-02-7
ERDC/CERL TR-02-7
47
48
ERDC/CERL TR-01-DRAFT
Directional Jets
Exit Screens
ERDC/CERL TR-02-7
49
Bushings
Chain Pins
Cotter Pins
Sprockets
Chair Tracks
Structural Steel
Wire Rope
Bolts
Nuts
Screen
50
ERDC/CERL TR-01-DRAFT
Heating/Ventilating Louvers
Handrailings
Body of Bitts
ERDC/CERL TR-02-7
51
Roller Axles
Roller Bushings*
Floating Bulkheads
52
ERDC/CERL TR-01-DRAFT
Drain Line
Waterstops
Natural Rubber
Polyvinyl Chloride
Axles
ERDC/CERL TR-02-7
53
Wheels
Nuts
54
ERDC/CERL TR-01-DRAFT
Sewage Pumps
Impellers
Bronze
Fasteners
Water Pumps
Casings
Steel
Shafts
I ntermediate Shafts
Impellers
Bronze
Steel
Bowls
Steel
Suction Bell
Steel
Column
Bolts
Sluice Gates
ERDC/CERL TR-02-7
55
56
ERDC/CERL TR-01-DRAFT
References
Armco 17-4 PH Precipitation-Hardening Stainless Steel Wire and Bar. 1983. Armco, Inc.
Armco NITRONIC 60 Stainless Steel. 1984(a). Armco, Inc.
Armco Precipitation-Hardening Stainless Steels. 1984(b). Armco, Inc.
ASM Handbook, v.20: Materials Selection and Design. 1998. ASM International.
Carpenter Custom 450. 1971. Carpenter Technology Corporation.
Carpenter Stainless Steels. 1999. Carpenter Specialty Alloys.
Department of the Army, Office of the Chief of Engineers. 1966 (August). Design of Spillway
Tainter Gates, Engineer Manual 110-2-2702. Washington, DC.
Jones, J. A., R. A. Palylyk, P. Willis, and R. A. Weber. 1999 (December). Greaseless Bushings for
Hydropower Applications: Program, Testing, and Results, U.S. Army Construction
Engineering Research Laboratory Technical Report 99/104.
Kamp, M. E., and R. J. Schmitt. 1966. Selection and Application of Stainless Steels for Corrosive
Environments, reprint of paper presented at the First University of Florida Symposium
on Methods of Materials Selection, Gainesville, Florida.
Kumar, A, Ali A. Odeh, and James R. Myers. 1989 (December). Mechanical Properties and
Corrosion Behavior of Stainless Steels for Locks, Dams, and Hydroelectric Plant
Applications, U.S. Army Construction Engineering Research Laboratory Technical Report
EM-6.
Lubricants and Hydraulic Fluids. 1999 (February). U.S. Army Corps of Engineers. Engineer
Manual No. 1110-2-1424.
ERDC/CERL TR-02-7
Return on Investment Case Study: Material Selection and Corrosion Analysis. 1980. U.S. Army
Corps of Engineers Information Exchange Bulletin, vol R3, no. 2.
Schultz, R.W. 1997 (August). Olmsted Prototype: Hydraulically Operated Navigable Pass Wicket
Dam, U.S. Army Corps of Engineers, Louisville District.
Schumacher, W.J. 1986. A New Stainless Alloy for the Hydroelectric Industry, paper presented
at the ASME International Symposium on Hydropower Fluid Machinery, Anaheim,
California.
Schumacher, W.J. 1977. Wear and Galling Can Knock Out Equipment, Chemical Engineering,
Reprint, May 9, 1977.
Segan, E.G., J. Bukowski, H. Uyeda, and A. Kumar. 1982 (March). Wrought Stainless Steel
Fasteners for Civil Works Applications, U.S. Army Construction Engineering Research
Laboratory Technical Report M-306.
57
58
ERDC/CERL TR-01-DRAFT
Table A-2. Nominal compositions of stainless steels for lock, dam, and hydroelectric plant applications.*
Alloy
302
303
304
308
316
NITRONIC 60
410
416
431
Alloy
17-4PH
Custom 450
Mn
Si
Fe
Other
0.15
2.00
1.00
0.045
0.030
Bal.
0.15
2.00
1.00
0.20
0.15
Bal.
0.6 Mo (optional)
0.08
2.00
1.00
0.045
0.030
Bal.
0.08
2.00
1.00
0.045
0.030
Bal.
0.08
2.00
1.00
0.045
0.030
Bal.
2.00-3.00 Mo
8.00-9.00
0.10
7.009.00
3.504.50
Bal.
0.08-0.18 N
0.15
1.00
1.00
0.040
0.030
Bal.
0.15
1.25
1.00
0.060
0.15
Bal.
0.60 Mo (optional)
1.25-2.50
0.20
1.00
1.00
0.040
0.030
Bal.
Other
3.00-5.00
0.15-0.45 Nb + Ta
0.50-1.00 Cu
1.25-1.75 Cu
8xC (min) Nb
Cr
17.0019.00
17.0019.00
18.0020.00
19.0021.00
16.0018.00
16.0018.00
11.5013.50
12.0014.00
15.0017.00
Cr
15.0017.50
Ni
8.0010.00
8.0010.00
8.0010.50
10.0012.00
10.0014.00
14.0016.00
Ni
Mn
3.00-5.00
0.07
1.00
5.0010.00
0.05
16.006.50-7.75
0.09
18.00
11.50CA-6NM
3.50-4.50
0.06
14.00
18.008.00CF-8
0.08
21.00
11.00
15.00Gall-Tough
4.00-6.00
18.00
0.15
Carpenter
16.500.50-2.50
0.15
18-2-12
19.00
11.0010.75Custom 465
0.02
12.50
11.25
* Values expressed in weight percent
Maximum value except where otherwise noted
Minimum
17-7PH
Si
Fe
1.00
0.040
0.030
Bal.
1.00
1.00
0.030
0.030
Bal.
1.00
1.00
0.040
0.030
Bal.
0.75-1.50 Al
1.00
1.00
0.040
0.030
Bal.
0.40-1.00 Mo
1.50
2.00
0.040
0.040
Bal.
4.006.00
11.014.00
3.004.00
0.040
0.040
Bal.
Nitrogen 0.08-0.20
1.00
0.060
0.030
Bal.
Nitrogen 0.20-0.45
0.25
0.25
0.015
0.010
Bal.
Ti 1.50-1.80
Mb 0.75-1.25
ERDC/CERL TR-02-7
59
60
ERDC/CERL TR-01-DRAFT
Stainless
Steel
Condition*
Passivation
Potential,
Volt vs. SCE**
Critical current
density for
passivation,
amp/cm2
Transpassive
Potential,
Volt vs. SCE
Type 304
Annealed +
10% CW
-0.347
4.28 x 10-4
3.27 x 10-6
+0.89
Type 410
Annealed
-0.376
1.49 x 10-2
5.27 x 10-6
+0.81
-0.256
3.68 x 10
-5
1.92 x 10
-6
+0.92
-5
2.00 x 10
-6
+0.87
Custom 450
SA
o
Custom 450
Aged at 1150
-0.277
2.63 x 10
17-4PH
Condition Ao
-0.269
1.60 x 10-4
2.02 x 10-6
+0.89
-0.312
-5
-6
+0.88
17-4PH
H1150
8.75 x 10
2.53 x 10
-4
-6
NITRONIC 60
Annealed
-0.346
3.63 x 10
1.58 x 10
+0.92
*See Table A-3 for condition abbreviations. All samples are deaerated in sulfuric acid at ambient temperature.
**
Saturated calomel electrode.
Table A-5. Galvanic series for selected alloys.
Alloy
Condition*
NITRONIC 60
Annealed
-0.327
0.247
Type 304
Annealed + 10%
CW
-0.328
0.246
Custom 450
SA
-0.330
0.244
-0.362
0.212
Custom 450
Aged at 1150 F
17-4PH
H1150
-0.384
0.190
17-4PH
Condition A
-0.396
0.178
Type 410
Annealed
-0.488
0.086
ASTM A 36
Normalized
-0.574
0.000
* See Table A-3 for condition abbreviations. All samples are 0.5 M sodium chloride solution at ambient temperature.
** Saturated calomel electrode.
Table A-6. Galvanic corrosion current densities for ASTM A 36 steel when coupled to
an equal area of stainless steel.
Stainless Steel
Condition
NITRONIC 60
Annealed
1.4 x 10-5
Type 304
Annealed + 10% CW
2.1 x 10-5
Custom 450
SA
2.0 x 10-5
Custom 450
Aged at 1150oF
1.6 x 10-5
17-4PH
H1150
1.9 x 10-5
17-4PH
Condition A
2.2 x 10-5
Type 410
Annealed
2.5 x 10-5
* See Table A-3 for condition abbreviations. All samples exposed to aerated 0.5M sodium
chloride solution at ambient temperatures.
ERDC/CERL TR-02-7
61
Stainless Steel
Condition**
NITRONIC 60
Annealed
17-4PH
H1150
201
0.4
388
1.2
Custom 450
Aged at 1150 F
320
1.3
17-4PH
Condition A
321
1.6
Type 304
Annealed +10%
CW
197
1.7
Custom 450
SA
270
1.9
Normalized
286
2.5
8
Type 410
Annealed
223
* Based on cavitation resistance according to ASTM G 32 testing.
** See Table A-3 for condition abbreviations.
3.8
Type
416
Type
303
Type
304
Type
316
174PH
NITRONIC 60
Type 4102
50+
Type 416
13
24
42
50+
Type 303
50+
Type 304
24
50+
Type 316
42
38
17-4PH
50+
NITRONIC 60
50+
50+
50+
50+
38
50+
50+
Note: Gall-Tough Stainless has shown excellent wear resistance when it is self-mated. In testing it has
not shown visible galling damage at 15 ksi (following ASTM G 83), but has not been tested at higher
stresses (Carpenter Stainless Steels, 1999).
62
ERDC/CERL TR-01-DRAFT
Static
Dynamic
Wear
COF*
COF*
Rate (mils/100hrs)**
Devatex I (edge)
0.049
0.038
0.113
Devatex I (Wet)
0.113
0.094
1.214
Devatex I (Dry)
0.061
0.047
0.017
0.073
0.062
0.216
0.081
0.075
0.047
0.066
0.053
0.552
Fiberglide (edge)
0.064
0.051
-0.156#
Fiberglide (Wet)
0.048
0.039
0.186
Fiberglide (Dry)
0.0089
0.068
-0.161#
Lubron TF (edge)
0.058
0.046
0.146
Lubron TF (wet)
0.059
0.049
0.232
Lubron TF (dry)
0.072
0.059
0.087
Karon V (edge)
0.045
0.034
0.101
Karon V (wet)
0.068
0.06
0.268
Karon V (dry)
0.046
0.036
0.075
0.076
0.058
0.592
0.068
0.06
0.504
0.088
0.061
0.199
Karon V (edge)
0.046
0.040
0.202
Karon V (wet)
0.046
0.042
0.587
Karon V (dry)
0.032
0.026
0.001
Karon F (edge)
0.221
0.052
0.043
Karon F (wet)
0.053
0.049
0.325
Karon F (dry)
0.061
0.053
1.169
0.081
0.054
0.319
0.061
0.038
0.023
0.401
0.038
0.334
0.276
0.228
0.098
0.273
0.214
16.562
ERDC/CERL TR-02-7
63
Static
Dynamic
Wear
COF*
COF*
Rate (mils/100hrs)**
0.058
0.047
0.412
0.076
0.057
0.564
0.092
0.073
0.013
0.131
0.107
0.197
0.168
0.103
0.426
0.302
0.241
11.167
0.256
0.212
44.475
0.131
0.107
0.197
0.113
0.078
0.826
0.168
0.103
0.426
Devatex II (edge)
0.057
0.048
0.189
Devatex II (wet)
0.053
0.047
0.221
Devatex II (dry)
0.067
0.05
0.146
0.223
0.19
0.595
0.185
0.098
0.097
0.16
0.127
0.983
0.161
0.129
1.458
0.142
0.69
-For reference-
Coefficient of friction calculated from the average of the peak values measured during the 80th-120th
hours of the wear test
**
Slope of the least squares curve fit of test data measured during the 80th-120th hours of the wear
test.
The test setup consisted of a stainless steel sleeve upon which a radial static load
of 3300 psi and a variable superimposed load of 1000 psi were applied by hydraulic cylinders. The radial load was applied with continuous minor oscillations of
+1 degree at 2 cycles/second interrupted by a major oscillation (+15 degrees at
0.1 cycles/second) every 15 minutes. Two seconds before ending the major oscillation, the variable load was removed and conditions were recorded. Two seconds after the major oscillation, the recorder was again placed on standby.
Therefore, the data was recorded in 4-second intervals. Midway through the 15minute minor oscillation period, the recorder was activated for five seconds to
record the effect of the superimposed variable load. This test was performed in
64
ERDC/CERL TR-01-DRAFT
air, submerged in distilled water, and edge loaded. The edge pressure test was
run in the same manner as the wet and dry tests except a double taper was
ground into the center of the test sleeve to simulate a misaligned shaft.
Table A-10. Properties of self-lubricating bushings in the presence of foreign debris.1
Type
Dry Test
COF2
COF2
TENMAT T814
0.05
0.048
0.0023
KARON V
0.05
0.025
0.0052
THORDON SXL
0.0163
Debris made up of 100 gm river sand passed through a 425 u mesh and 25 gm iron oxide.
The dry test applied a radial load of 3,300 psi with a superimposed dynamic load
of 1000 psi to a shaft rotated +1 degree continuously at 2 Hz. Every 15 minutes
the radial dynamic load was paused and the shaft rotated +15 degrees at 0.1 Hz
with only the static radial load applied. The measurements of the static load,
dynamic load to rotate shaft, and wear were recorded during the major swing.
Halfway through the test, the wet slurry was added, and measurements were
carried out in the same fashion as the dry tests. Grooves cut in the bushings allowed the slurry to enter into the friction zone. The tests were run for a minimum of 120 hours.
Table A-11. Typical composition ranges for unalloyed cast irons.
Type
Composition, %
TC*
Mn
Si
Cr
Ni
Mo
Cu
Ce
Mg
Gray iron
3.253.50
0.500.90
1.802.30
0.050.45
0.050.20
0.050.10
0.150.40
0.12
max
0.15
max
Malleable
0.252.55
0.350.55
1.401.50
0.040.07
0.050.30
0.030.10
0.030.40
0.03
max
0.050.07
iron
Ductile
iron
3.603.80
0.151.00
1.802.80
0.030.07
0.050.20
0.010.10
0.151.00
0.03
max
0.002
max
0.0050.20**
0.030.06
ERDC/CERL TR-02-7
65
Grade or Class
Hardness
(min), HB
Tensile Strength
(min), MPa
Elongation in
50mm (min), %
ASTM A 48
40
235
293
**
50
262
362
**
60-40-18
414
18*
120-90-02
827
2*
Gray iron
ASTM A 48
Gray iron
ASTM A 536
Ductile iron
ASTM A 536
Ductile iron
*
Determined using a standard specimen taken from a separately cast test block, as set forth in the
applicable specification.
** Elongation at fracture is on the order of 0.6%.
[Compiled from Metals Handbook, 2nd Edition]
Form Approved
OMB No. 0704-0188
Public reporting burden for this collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering and maintaining the
data needed, and completing and reviewing this collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information, including suggestions for reducing
this burden to Department of Defense, Washington Headquarters Services, Directorate for Information Operations and Reports (0704-0188), 1215 Jefferson Davis Highway, Suite 1204, Arlington, VA 222024302. Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to any penalty for failing to comply with a collection of information if it does not display a currently
valid OMB control number. PLEASE DO NOT RETURN YOUR FORM TO THE ABOVE ADDRESS.
2. REPORT TYPE
01-2002
Final
Advanced Materials Selection Guide for Lock, Dam, and Hydroelectric Plant Components
5b. GRANT NUMBER
5c. PROGRAM ELEMENT NUMBER
6. AUTHOR(S)
CW
5e. TASK NUMBER
5f. WORK UNIT NUMBER
33238
7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES)
U.S. Army Engineer Research and Development Center (ERDC), Construction Engineering
Research Laboratory (CERL), P.O. Box 9005, Champaign, IL 61826-9005
ERDC/CERL TR-02-7
U.S. Army Engineer District, Portland, P.O. Box 2870, Portland, OR 97208-2870
HQUSACE
ATTN: CECW-EI
7701 Telegraph Road
Alexandria, VA 22315
TR HPMS-02-1
Copies are available from the National Technical Information Service, 5285 Port Royal Road, Springfield, VA 22161.
14. ABSTRACT
Army Corps of Engineers Civil Works projects can often benefit from the application of new generations of advanced engineering materials that are continuously being brought to market. However, in order for the Corps to realize the maximum life-cycle cost benefits
while ensuring project reliability and safety, project-level engineering and operations personnel need specialized technical guidance on
application-specific material selection. This document provides technical information and application guidance for two key types of
materials used in Civil Works projects stainless steels and bushing materials.
Typical mechanical property data are presented for 17 stainless steels that are becoming more available for Civil Works applications,
and general material selection guidelines for specific components of locks, dams, and hydroelectric plants are provided. Also presented are properties data and related technical information on applications in which self-lubricated bushings may successfully be used.
Regardless of the application, it is recommended that self-lubricating bushings be (1) sealed from the environment when conditions require it, as is any conventional greased bushing, and (2) installed with a hard chrome-plated shaft material of heated-treated steel, or
medium- to high-strength steel such as 17-4 PH.
15. SUBJECT TERMS
Unclassified
b. ABSTRACT
Unclassified
17. LIMITATION
OF ABSTRACT
18. NUMBER
OF PAGES
c. THIS PAGE
Unclassified
SAR
67
Ashok Kumar
19b. TELEPHONE NUMBER (include area code)