Abstract
Premature failure of conjunction gear in vehicle was reported frequently. The fractured of tooth of the conjunction gear in a vehicle was detected. Marco and micro analysis, chemical composition and mechanical test were employed to determine the causes of the failure of the conjunction gear. The analysis results showed that the lower hardening depth layer was formed in the tooth of conjunction gear due to the inappropriate heat treatment. And the micro cracks were formed on the surface of tooth of the conjunction gear on the action of the impact load. In addition, the upper bainit of material was formed based on the unqualified heat treatment, which reduced the impact toughness of material and accelerated the growth of cracks. The element segregation caused the brittleness of material was increased and the resisting propagation ability of micro crack was reduced. Finally, the tooth of the conjunction gear was fractured. The improvement scheme was proposed to prevent the similar failure based on the results of the study.
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