Update: I've been quenching my leaf springs wrong for years
I was making a set of kitchen knives from old truck springs and kept getting hairline cracks along the edge. A guy at the local guild meet in Springfield watched me quench one and just said, 'You're putting it in the oil too hot, you can see the steam flash.' I never let the steel cool enough after forging before the quench. Has anyone else had this happen with 5160? What's your soak time before the oil bath?
Yeah that steam flash is a dead giveaway. I had the same problem with 5160 until I started letting it cool to black heat, like you can't see any glow at all. My soak time is usually just a couple minutes once it hits critical, but getting the temp right before the quench is way more important.
That steam flash is the worst. Letting it go to black heat is the only thing that worked for me too. A cheap infrared thermometer helps a ton for checking the actual temp before the quench. Getting that wrong just ruins the whole piece.