1) The application of the chain
Many chains work well with light loads, but as loads get heavier the difference in manufacturing quality will become more noticeable. The chains are very specific to each application. Most chains can only handle a specific load range. It doesn't matter if the loads are pallets, racks or industrial containers. Once this range is exceeded, the rate of chain breakage increases more rapidly over time.
2) Premature chain failure
One of the main causes of chain breakage is the environment in which the chain is located. To increase the service life of the chain, first increase the strength and wear resistance. Some manufacturers have managed to modify the mechanical properties of their chains. As a result, it is important to note the number of applications the chain has run and how long it has been running. By being aware of how much the chain is used, it will be easier to predict when the chain needs to be replaced to avoid unplanned downtime.
3) Heat treatment
Chain wear is directly influenced by the hardness of the components subject to wear. The harder the parts, the longer the service life. End users are generally aware of this and apply this mindset to predict the lifespan of their chains. However, end users sometimes sacrifice component hardness or strength rather than overload current when using lower rated currents in higher load applications. This way the current will emit more heat.
As more heat is emitted, the material the chain is made of will play a greater role. Low carbon barrel steel will not respond to heat treatment even if it is placed in a furnace for heat treatment. Welded chains made of medium carbon steel respond better to heat treatment; providing twice the heat resistance.
However, even with greater heat resistance, a process is often overlooked; find the pipe welds. Due to heat, the integrity of the components decreases, causing the chain to wear out more quickly. It is also important to note that poor fusion of the weld between the cylinder and cylinder head side bar can lead to premature failure. Even if the chain has adequate load weight, the barrel's reduced resistance to bending will result in increased contact with the sprocket. This contact can cause brittle fractures in the heat-affected areas of the sidebar, which can lead to failure.
4) Print adaptations and the importance of interference
Welded steel chains offer superior fatigue resistance. To maintain this level of resistance, chains typically have well-controlled adjustments between the pin and hole in the chain's side bar. It is this beneficial residual stress in the sidebar that creates longer fatigue life. Some chains have a “stepped” pin to facilitate assembly and protect the integrity of the interference fit. Also note that poorly controlled interference fittings have lower fatigue resistance and are more susceptible to chain failure after multiple uses.
