A l t r a I n d u s t r i a l M o t i o n

Warner Electric

Boston Gear

TB Wood’s
High Performance
Formsprag Clutch Non-Lubricated Coupling
Wichita Clutch Service Life and
Marland Clutch Failure Modes
Industrial Clutch

Bauer Gear Motor

Nuttall Gear

Warner Linear

Delroyd Worm Gear

Stieber Clutch

Svendborg Brakes

Ameridrives Couplings

Inertia Dynamics

Matrix International

Huco Dynatork

Bibby Turboflex

Twiflex Limited

Kilian Manufacturing

Lamiflex Couplings

Ameridrives Power
Transmission
High Performance Non-Lubricated Coupling
Service Life and Failure Modes
James H. Paluh, Manager-Engineering High Performance Products
Ameridrives International, December 1997

Metallic disc and diaphragm couplings are the two principle

types of non-lubricated couplings used in high performance
turbomachinery. Both transmit torque and accommodate
misalignment between turbo-machinery equipment shafts. These
types of couplings rely on the flexure of metallic membranes to
accept angular and axial misalignment. In disc couplings, torque is
transmitted by the driving bolts pulling the driven bolts with the
disc material at a constant bolt circle (Figure 1). The disc elements
generally consist of many thin, metallic, identically shaped rings
stacked directly on top of one another. The ring shape will vary by
design, from circular discs, hex discs, or scalloped discs. The discs
are clamped together with washers by bolts that are attached
alternately to the driving and driven flanges.
In diaphragm couplings the torque is transmitted radially from
Figure 1 the outside diameter of a drive flange through one or more metallic
plates to an attachment at the inside diameter. The diaphragms may
have either a constant or tapered thickness and may be flat,
convoluted, or spoked. The diaphragm outside diameter is usually
clamped by bolts while the inside diameter is unitized by electron
beam welds, splines, or bolts (Figure 2).
While disc couplings have multiple membranes, the individual
discs are typically not separated. When flexing of the disc occurs
under misalignment, each disc contacting surface rubs the adjoining
disc surface causing some degree of fretting and wear. This fretting
can allow corrosion to attack the disc material. When corrosion is
combined with fatigue, known as corrosion fatigue, it reduces the
endurance limit and may initiate a fatigue failure. The corrosion
products can act as a wedge, opening a crack in the fretted area of
the disc. Since there is direct contact with the adjoining discs, the
crack could propagate quickly. By properly designing the shape
(such as scalloping) and the thickness of the discs, fretting
corrosion can be reduced, but not eliminated.
Some manufacturers apply coatings to each disc to increase the
finite coupling life. However, studies have shown that most coatings
have a negative impact on the endurance strength of the base
material.
Stress corrosion cracking is defined as the combined action of
static stress and corrosion leading to the cracking or embrittlement
of metal and must be considered in metallic membrane material
selection. Standard disc materials are austenitic stainless steels such
as 301 full hard stainless steel. In corrosive environments such as
atmospheric sodium chloride, austenitic stainless steels exhibit a
Figure 2
high susceptibility to stress corrosion cracking when the
temperature exceeds 150° F. Most disc coupling
manufacturers offer alternate materials such as inconel which
are highly resistant to stress corrosion.
The design and proper installation of the disc coupling
bolts is also critical since the inherent design of disc
couplings require the bolts to transfer torque through shear
and bending. The highest bolt stresses are in bending (Figure
3). This is in contrast to a typical flange to flange connection
of a diaphragm coupling where torque subjects the bolts
predominately to shear stresses. The proper tension of the disc
coupling bolts not only decreases the bolt bending stress to
acceptable levels, but affects the fretting and corrosion fatigue
characteristics of the disc surface at the washer interface.
Although disc couplings may be extremely long life
couplings, they are not infinite life couplings. The life of
identical disc coupling designs in the same application at
different sites can vary due to the actual misalignment of the
equipment, the preload in the individual bolts, and the specific
environmental conditions encountered at each location. Figure 3

Adhering to the manufacturer's recommended bolt tightening

torque and minimizing the misalignment will assure the
longest service life. Experience with the specific hardened to H1025 is highly resistant to stress corrosion
turbomachinery equipment must be considered when cracking, even at sustained stress levels much greater
establishing maintenance and inspection intervals. than Ameriflex diaphragm stresses. In addition, all
The analysis of the disc life is complicated by the fretting Ameriflex diaphragms are individually shot peened. Shot
of the discs caused by coupling misalignment. Disc coupling peening provides a surface layer of compressive stress on
manufacturers typically calculate safety factors using the both sides of every diaphragm. Stress corrosion cracking
classical fatigue failure theories such as the modified can not occur in an area of compressive stress.
Goodman Diagram, but do not use a reduction in the disc raw The flex area is separated at the inside and outside
material endurance limit caused by corrosion fatigue, wear, or diameters (Figure 2) and then rigidly clamped. This
application of coatings. Published raw material endurance separation prevents fretting corrosion from angular and
limits are not intended to consider wear with fatigue or the axial misalignment usually associated with the rubbing
effects of coating. Users should exercise caution when of the flexing areas of multiple membrane couplings.
reviewing such data and consider the manufacturer's Since there is no fretting, the designer can legitimately
experience and disc life history for similar applications. Either use classical infinite life engineering fatigue analysis for
a reduction of endurance properties or higher safety or service the diaphragm design utilizing the raw material
factors may be required. Some manufacturers may require a properties. No reduction in the diaphragm material
minimum service or application factor. A fatigue analysis of endurance limit or decreased reliability is caused by
the bolts should be performed in high torque applications due fretting corrosion or wear of the flex area. In fact, no
to the high bending stresses. This will assure that the fatigue credit is taken for the added benefit of each diaphragm
analysis is performed on the coupling's component with the being individually shot peened. Using the appropriate
lowest safety factor. Following these guidelines will help stresses confirmed by finite element analysis and strain
assure long disc coupling service life in typical high gage testing. Ameridrives can accurately calculate safety
performance turbomachinery. factors using any of the fatigue failure theories such as
The Ameriflex diaphragm coupling incorporates life and Goodman, modified Goodman, or Constant Life. The
safety factors that are not present in disc coupling designs. Ameriflex coupling is a true infinite life design with
The Ameriflex metallic membranes consist of thin, multiple, diaphragm packs operating in excess of twenty years. In
convoluted and separated diaphragms. Each of these operation this translates into predictable equipment
properties provide a benefit to the overall coupling design. maintenance and inspection intervals regardless of the
The diaphragm life is not dependent on the operating angle angular and axial misalignment within the coupling's
within its design rating. design rating, environmental conditions and the length of
The standard Ameriflex diaphragm material is 15-5 PH in service.
condition H1025. Testing has shown that 15-5 PH age In the event of failure, a disc coupling and a
 Figure 4 Figure 5

diaphragm coupling affect the system differently. If a failure ultimate failure, the diaphragm inside diameter will
was to occur in a disc coupling either in fatigue by fretting shear from the spacer or spool preventing the transfer
corrosion or ultimate failure due to a peak torque overload, of power from the driving to driven equipment (Figure
the driving flange bolts will continue to load the driven 4).
flange bolts and drive the equipment. The flailing and high The instantaneous loss of load will result in standard
bending loads that occur in this condition may cause turbomachinery overspeed trip. After shear failure, the
significant damage to the adjoining equipment and high Ameriflex coupling's anti-flail guards contain the center
vibrations. Adequate vibration monitoring, plus typical section for safety and protect the adjoining equipment
overspeed trip devices are critical to prevent further damage (Figure 5).
to the connected equipment. In summary, a disc coupling's service life is finite
Conversely, if an Ameriflex diaphragm coupling was and significantly effected by the equipment's
subjected to excessive misalignment which was to initiate a misalignment, disc configuration, disc coatings, bolt
fatigue failure, the crack will propagate gradually due to the preload and environmental conditions. These factors
separation of the diaphragm flex areas. Eventually, as each should be considered in the coupling selection. If a
diaphragm fails, the remaining diaphragms will shear at failure was to occur in a disc coupling, more damage
their inside diameter due to excessive torque. Most may occur to the driven equipment since the bolts will
importantly, regardless of the cause of failure, by fatigue or continue to drive the equipment.
The Ameridrives Ameriflex diaphragm is a true
infinite life design where the high strength precipitation
hardened stainless steel, multiple, convoluted
diaphragm flex areas are separated to prevent corrosion
fatigue or fretting corrosion. No reduction or change in
life occurs up to the maximum ratings of the coupling.
The diaphragm material properties such as endurance
strength are not compromised by wear, fretting
corrosion or coatings. The Ameriflex diaphragms have
a built in fail-safe feature of redundancy with separated
US (Customer Service) diaphragms. If a failure occurs, power is no longer
814-480-5000 supplied to the driven equipment since the diaphragms
www.ameridrivescouplings.com will completely shear at their inner diameter. This
results in an overspeed trip. Finally, the anti-flail
Asia Pacific capability contains the center section which decreases
For a list of our AP sales offices: potential damage to adjoining equipment. These
www.AltraMotion.com/ContactUs Ameriflex features combined provide a level of
reliability and safety unique to other metallic
membrane couplings.
P-7491-AC 2/14 Printed in USA