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Old 07-06-2020, 03:45 PM   #2
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Join Date: Jun 2010
Location: 34.22 N 118.36 W
Posts: 490
Default Re: O/T What material would you use for new axle shafts?

IMHO, I would stay away from the x6 tool steels as typically too brittle and cost prohibitive. I have used S7 for cams, broke one, heat treatment more than likely not uniform. (anneal after hardening)
4140 is probably good, another might be 1144, this is a "stress Proof steel" used very much in large calendar rolls and large shafting.
I would also stay away from anything with lead to assist machining such as 41L40.

Not being familiar with design of the axle, remember large radius fillets and avoid peak stress risers. (such as end of spline section)
As Carroll Smith wrote; All Failures are Human in Origin.
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