Common Gear Material Inspection Methods

December 31, 2024

PRESENTER:   Sarah Tedesco, President, Ashford Consulting


Any quality engineer, manufacturing engineer, and customer liaison (sales or engineering) who would benefit from knowing and understanding the kinds of analysis involved in assuring the quality of their product.


Gear quality is of utmost importance to a manufacturer.  Presented in this webinar are several commonly used gear inspection methods to ensure the quality of a gear from the raw material through to the final manufactured form.  Discussed are methods of assuring the quality of: raw material (cast or billet), heat treatment (whether forged, quench and tempered, carburized induction hardened or nitrided) and final net shape formation (welding, machining and fine finishing).  Students will be able to assess the accuracy of the current methods used or possibly find newer, less expensive methods for assessing the quality of their gears. 


Following this webinar, attendees will be able to:

  • Evaluate their current quality control plan’s sufficiency
  • Assess what kinds of tests are necessary to ensure high quality gear manufacture
  • Understand the benefits and limitations of various forms of analysis 


  1. Brief introduction to gear manufacture
    1. Explanation of raw material manufacture:
      1. Steel- billet, round bar and cast
      2. Cast iron- gray, ductile and ADI
      3. Forging
  2. Explanation of various forms of heat treatment:
    1. Quench and temper
    2. Carburizing
    3. Nitriding (and FNC)
    4. Induction and flame hardening
  3. Explanation of various processes for final net shape formation
    1. Welding
    2. Machining
  4. Methods of analysis, including an overview of how they work and the kind of information that is yielded:
    1. Methods used for raw material evaluation:
      1. Tensile testing, C/S combustion analysis, optical emission spectroscopy, metallography, magnetic particle inspection, ultrasonic testing
    2. Methods used in heat treatment evaluation:
      1. Visual inspection, metrology, liquid dye penetrant, magnetic particle inspection, metallography
    3. Methods used in final net shape evaluation:
      1. Metrology, surface profilometry, grind burn evaluation techniques
  5. Costs of the various methods will be compared, their accuracy discussed, the quality of information (whether quantitative, qualitative or pass/fail) and whether the method is destructive will all be discussed.

You will have 30 days to view the archived webinar.