Transcript
AAR Manual of Standards and Recommended Practices
11/1/04
Wheels and Axles
M-101
AXLES, CARBON STEEL, HEAT-TREATED HEAT-TREATED Specification M-101 Adopted: Adopted: 1914; Revised: Revised: 1996, 2004, 2004, 2005, 2007 1.0 SCOPE These specifications cover heat-treated axles of all sizes for passenger cars and freight cars to designs shown in Section G. These specifications also cover heat-treated locomotive axles. The grades of carbon steel axles are as follows:
Grade F—Double normalized and tempered. (All freight axles over 6 1/2 in. nominal diameter at center shall be Grade F.) Grade G—Quenched and tempered. Grade H—Normalized, quenched, and tempered. Grades F, F, G, and H—Axles are used in heavy duty service on locomotives, cars, and other equipment. 2.0 QUALIFI QUALIFICATI CATION ON AS MANUFAC MANUFACTURE TURER R Qualification as a manufacturer of axles for use in AAR interchange service must be in accordance with Appendix with Appendix C of C of this specification. Qualification is effective until revoked for cause by the Committee. Failure Failure to maintain reasonable quality standards in manufacturing is an example of cause. Axle manufacturers must meet the requirements of the AAR Manual of Standards and Recommended Practices , Section J, Specification M-1003, “Specification for Quality Assurance.” 3.0 3.0 MANU MANUFA FACT CTUR URE E 3.1 Process The steel shall be made by any of the following processes: open hearth, electric furnace, or basic oxygen. 3.2 Discard A sufficient discard shall be made from each ingot to ensure freedom from piping and undue segresegregation. 3.3 3.3 Redu Reduct ctio ion n Pract Practic ice e The axles may be made directly from the ingot or from blooms. The total reduction from ingot or strand-cast bloom to forging or extrusion shall be not less than 3 to 1, unless otherwise specified.
blooms shall be designed to ensure freedom from Note: The process for manufacturing strand-cast blooms center porosity and undue segregation. 4.0 4.0 COOL COOLIN ING G AND AND HEAT HEATIN ING G 4.1 After axle blooms are produced, they shall be slow-cooled in closed containers, hoods, or furnaces. 4.2 Blooms shall be reheated for working in a manner that will prevent internal bursts and overheating. 4.3 After reduction, axles shall be slow-cooled in closed containers, covered conveyors, or in hoods. If axles (Grades F, G, and H) are heat-treated directly from reduction, they shall be slow-cooled following the final heat treatment. 4.4 Axles (Grades F, G, and H) that are heat-treated directly from reduction 1) shall be cooled below the transformation temperature temperature or to approximately 1,000 °F before any reheating opera11/1/04
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tion; and 2) must not be permitted to cool below below 500 °F without slow-cooling as as defined in paragr paragraph aph 4.3 4.3.. °F, a supplemental heat Note: As the temperature of the axles approaches the minimum of 500 °F, source may be necessary to ensure an effective slow-cooling cycle. 4.5 When properly vacuum-degassed steel is used, the slow-cooling requirements of paragraphs 4.1,, 4.3 4.1 4.3,, and item 2 of paragr paragraph aph 4.4 4.4 may may be omitted, but axle blooms must then be pile cooled.
4.1,, 4.3 4.3,, and item 2 of paragr paragraph aph 4.4 4.4 may be 4.6 The slow-cooling requirements of paragraphs 4.1 accomplished by piling and covering the piled blooms or axles with insulating materials in lieu of using closed containers, hoods, furnaces, and covered conveyors. Covered piles must be capable of providing effective cooling rates in accordance with the manufacturer’s procedure or specification. 5.0 5.0 HEAT HEAT TRE TREAT ATME MENT NT
reheated gradually and uniformly to a suitable suitable temperature temperature 5.1 Axles for heat treatment shall be reheated to refine the grain structure. 5.2 5.2 Norm Normal aliz izin ing g After being heated to a suitable temperature, the axles shall be withdrawn from the furnace and allowed to cool uniformly in air. A furnace charge thus treated is termed a normalizing charge. Cooling may be accelerated by increased air circulation, which must be controlled to provide reasonably uniform cooling. 5.3 5.3 Doub Double le Norm Normal aliz izin ing g The procedure shall consist of two separate normalizing treatments. The second treatment shall be performed at a lower temperature than the first treatment. A furnace charge thus treated is termed a double normalizing charge. Cooling may be accelerated by increased air circulation, which must be controlled to provide reasonably uniform cooling.
normalizing treatment shall be permitted permitted when all other requirements requirements for Grade Grade F Note: A single normalizing can be met. 5.4 Quenchi ching After being heated to a suitable temperature, the axles shall be quenched in a suitable medium under reasonably uniform conditions. A furnace charge thus treated is termed a quenching charge. 5.5 Temperin ring Axles shall be reheated gradually to, and held at, a suitable temperature below the critical range and shall then be allowed to cool under suitable conditions. A furnace charge thus treated is termed a tempering charge. 5.6 Heat treatment may be performed in either batch-type furnaces or continuous furnaces. 6.0 6.0 STRA STRAIG IGHT HTEN ENIN ING G Straightening shall be done before machining and preferably at a temperature not lower than 950 °F. °F. Straightening Straightening performed at temperatures lower than 950 °F shall be followed by stress relieving or an applicable heat treatment.
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7.0 CHEMICAL COMPOSITION The steel shall conform to the requirements for chemical composition shown in Table 7.1. Table 7.1 Chemical composition Grade F
Grades G and H Heat-Treated
Min.
Max.
Min.
Max
Carbon, percentage
0.45
0.59
—
—
Manganese, percentage
0.60
0.90
0.60
0.90
Phosphorus, percentage
—
0.045
—
0.045
Sulphur, percentage
—
0.050
—
0.050
Silicon, percentage
0.15
—
0.15
—
8.0 LADLE ANALYSIS 8.1 An analysis of each heat of steel shall be made by the manufacturer to determine the percentage of carbon, manganese, phosphorus, sulfur, and silicon. The chemical composition thus determined shall be reported to the purchaser or purchaser’s representative and shall conform to the requirements of paragraph 7.0. 8.2 Identification of Heats in Consecutive Strand Castings If more than one heat is consecutively strand cast at one time, ladle analyses shall be obtained of each heat. If the ladle analysis of one heat does not meet the requirements of the specification, the bloom or blooms that comprise a mix of the two consecutive heats shall be deemed to be outside the requirements of the specification unless additional chemical analyses prove compliance. If both ladle analyses are in compliance with the specification, the heat number assigned to the cast product shall remain unchanged until all of the steel in the bloom is from the following heat. Alternatively, when all of the mixed portion of two consecutive heats is in one bloom, that bloom may be given the heat number that comprises the larger portion of the bloom on either side of the mixed portion. 9.0 CHECK ANALYSIS Analysis may be made by the purchaser from one axle representing each heat. The chemical composition thus determined shall conform to the requirements of paragraph 7.0, subject to tolerances included in Table 9.1. The sample for these analyses shall be taken from one end of the test axle or full-size prolongation at a point midway between the center and surface. If drillings are taken, they shall be obtained using a 5/8-in.-diameter drill, or turnings may be taken from a tensile test specimen. Table 9.1 Permissible variations for check analysis Permissible Variations, Over the Maximum Limit or Under the Minimum Limit Elements
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Percentage
Manganese
0.030
Phosphorus
0.008
Sulphur
0.008
Silicon
0.020
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10.0 TENSION TESTS 10.1 Grades F, G, and H axles shall conform to the requirements in Table 10.1. Table 10.1 Tensile requirements for carbon steel heat-treated axles Size (Solid Diameter or Thickness) (in.)
Tensile Strength (psi)
Yield Strength (psi)
Elongation in 2 in. (percentage)
Reduction of Area (percentage)
Grade
Over
Not Over
Min.
Min.
Min.
Min.
F (Double Normalized and Tempered)
—
8
88,000
50,000
22
37
—
4
90,000
55,000
20
39
(Quenched
4
7
85,000
50,000
20
39
and Tempered)
7
10
85,000
50,000
19
37
(Normalized,
—
7
115,000
75,000
16
35
Quenched,
7
10
105,000
65,000
18
35
G
H
and Tempered) 10.2 The size classification shall be determined by the finished diameter of the journal. 10.3 The diameter of the test prolongation shall be at least equal to the as-formed diameter of the journal. 10.4 The tensile properties for all grades listed in Table 10.1 shall be determined by the procedure described in ASTM A 370, “Standard Methods and Definitions for Mechanical Testing of Steel Products.” The yield strength shall be determined using the 0.2% offset technique. A Class B2 or more accurate extensometer shall be used. 10.5 The use of automated devices that determine the offset yield strength without the need for plotting a stress-strain curve are acceptable. 10.6 Tests shall be made only after final heat treatment of Grades F, G, and H axles. 11.0 TENSION TEST SPECIMENS 11.1 Tension test specimens shall be taken from the test prolongation or an axle in accordance with the provisions of paragraph 12.0. 11.2 Unless otherwise specified, the axis of the specimen shall be located at any point midway between the center and surface of the axle or full-sized prolongation and shall be parallel to the axis of the axle. 11.3 Tension test specimens shall conform to dimensions shown in Fig. C.1. 11.4 Tension tests from the prolongations shall have minimum tensile strength and yield point values 5% greater than shown in Table 10.1. For example, Grade F tension tests from axle prolongations shall have 92,500 psi minimum tensile strength and 52, 500 psi minimum yield point. 11.5 Tension test specimens from axles shall be taken from the journal of the axle at the mid-radius, halfway between the surface and center, with the gauge dimension parallel to the axis of the axle. For tensile specimens removed from the prolongation, samples shall be taken from the mid-radius, halfway between the surface and center, with the gauge dimension parallel to the axis of the axle.
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12.0 PROLONGATION FOR TEST 12.1 For test purposes, prolongations shall be attached to at least 5% of the axles in each size classification of each heat in each heat-treating lot. 12.2 If axles with prolongations have been expended, then axles may be used for test procurement. 12.3 Test reports shall state prolongation sizing prior to test or the use of axles for test. 13.0 MICROSCOPIC TEST FOR HEAT-TREATED AXLES (GRADES F, G, AND H) 13.1 A specimen, representing each size classification of each heat in each heat-treatment lot, shall be taken for microscopic test from the tension test s pecimen. This section for microscopic test shall be cut from the large undistorted portion of the tension test specimen in such a way as will give a face transverse to the axis of the axle. 13.2 The face shall be polished practically free from scratches and shall be etched to define the microstructure. The specimen shall be examined under a magnification of 100 diameters. 13.3 The entire specimen shall show a uniform, fine-grained structure, and shall have a grain size of 5 or finer as measured in accordance with ASTM Standard Method E112, latest version. 14.0 NUMBER OF TESTS 14.1 Unless otherwise specified by the purchaser, mechanical tests for grades and sizes shown in Table 10.1 shall be made from heat-treated axles as covered in paragraph 14.2 14.2 One test per grade, per heat, per size classification is required, but each test shall represent no more than 70 axles, including the test axle. The axles represented by this test shall be called a heat-treatment lot . Each heat-treatment lot of axles shall be heat-treated together, whether in batch-type or continuous furnaces. In the event that the mechanical properties of a test do not conform to the requirements specified, all of the axles from the heat-treatment lot are to be retreated in accordance with paragraph 15.2 of this specification. 14.3 If any test specimen fails because of mechanical condition of the testing apparatus, it may be discarded and another specimen taken. 15.0 RETEST 15.1 If the results of the mechanical tests of any lot do not conform to the requirements specified because a flaw developed in the test specimen during testing, a retest shall be allowed if the defect is not caused by ruptures, cracks, or flakes in the steel. 15.2 If the result of the mechanical test of any lot of Grade F, G, or H axles does not conform to the requirements specified, the axles may be retreated, but not more than three additional times, and retests shall be made in accordance with paragraph 10.0. 16.0 ULTRASONIC TESTING 16.1 Ultrasonic testing is required for all heat-treated axles. 16.2 Time of Inspection Inspection shall be made after axle ends are machined and centered, but prior to drilling the cap screw holes.
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17.0 TEST EQUIPMENT AND INSPECTION PERSONNEL REQUIREMENTS 17.1 Test Equipment The instrument or ultrasonic flaw detector shall be a pulse-echo-type, broadband pass amplifier with the capability of operating transducers in the range of .4 MHz to 10 MHz. 17.1.1 The ultrasonic transducer shall be operated at a 2 1/4 MHz frequency for both penetrability and discontinuity detection for heat-treated axles or equivalent such as ISO 9712 or other national standards that have similar testing and certification requirements and have been reviewed and deemed acceptable by the AAR. When “equivalent” processes are used, applicants will forward their specifications to the AAR with their application under the provision of Appendix C. 17.1.2 The instrument may use various transducers or piezoelectric elements ranging in size from 3/4-in. to 1-in. diameter or 1-in. square. The transducer type is at the option of the axle manufacturer. Other transducers of similar response capability as those described may be used. 17.1.3 Single or multiple transducers may be used for scanning. However, the signal for each transducer in a multiple set shall be individually monitored. 17.1.4 Ultrasonic test instrumentation shall be calibrated and certified annually or whenever repairs are made or parts replaced that may affect the performance of the instrument. 17.1.5 A suitable couplant shall be used between the test surface of the axle and the transducer. The transducer face, test surface of the axle, and couplant shall be free of contaminants that would affect the quality of sound transmission. 17.2 Personnel Requirements for Ultrasonic Inspection 17.2.1 All personnel engaged in ultrasonic operations will be qualified to NDT (nondestructive testing) Level I according to the qualification requirements as defined by the American Society for Nondestructive Testing, Recommended Practice SNT-TC-1A, latest edition. 17.2.2 All personnel conducting inspection setups and machinery setups will be trained and qualified to meet the criteria for NDT Level II for ultrasonic testing as defined by the American Society for Nondestructive Testing, Recommended Practice SNT-TC-1A, latest edition. 17.2.3 Each manufacturer will employ the services of an individual who will be trained and qualified to meet the criteria for NDT Level III for ultrasonic testing as defined by the American Society for Nondestructive Testing, Recommended Practice SNT-TC-1A, latest edition. 17.3 Records Each facility shall maintain the following:
• A procedure specification for each of its qualified ultrasonic testing procedures • A copy of each of its qualified ultrasonic testing procedures posted in the ultrasonic testing area • Records of test results • Certification records, based on the requirements in paragraphs 17.0 through 17.2.3, for all qualified personnel engaged in ultrasonic inspection testing. These records shall be attested by a responsible official of the facility and shall be accessible to the AAR representative.
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18.0 INSTRUMENT SENSITIVITY, SCANNING, AND DISTANCE AMPLITUDE CORRECTION 18.1 Instrument Sensitivity 18.1.1 Prior to testing the instrument, sensitivity shall be adjusted to produce an indication of the amplitude specified in Table 18.1 below from a reference test block 16 in. long, manufactured from a Grade F axle forging having a 1/8-in.-diameter, 1-in.-deep, flat-bottom hole drilled perpendicular to and at a distance of 15 in. from the test end face of the axle section. Table 18.1 Instrument sensitivity setting Indication Amplitude [% Full Screen Height (FSH)] Heat-treated axles
20
18.1.2 Reference blocks shall be kept free of dirt, rust, grit, or defacement and shall be inspected semiannually for compliance with a surface finish of 80 µin. to 125 µin. Inspection certification records shall be maintained and shall indicate inspector, inspection date, and surface finish. 18.1.3 At the sensitivity established in paragraph 18.1.1, the instrument shall detect in heat-treated reference axles a flat-bottom hole of the size and distance specified in Table 18.2. Table 18.2 Required size (flat-bottom holes) detectable at various distances from end faces Test Distance up to 15 in. Heat-treated axles
1/8 in. Test Distance 15 in.–30 in.
Heat-treated axles
1/4 in. Test Distance Over 30 in. to Mid-Length
Heat-treated axles
3/8 in.
18.2 Scanning 18.2.1 Scanning shall be performed from both end faces, which shall have a surface finish not exceeding 125 µin. finish. The scanning shall include the maximum end face area obtainable by manual or automated inspection techniques. 18.2.2 The end faces of the axles and the surface of the transducer shall be free of dirt or grit during testing. Periodic tests shall be made during production testing against the reference block described in paragraph 18.1.1 and adjustments shall be made to instrument controls to ensure compliance with the specifications. 18.2.3 During scanning, the amplitude of the indication from the end face opposite the transducer shall be monitored. The amplitudes of all discontinuity indications shall be evaluated not only with respect to the distance from the test surface (see paragraph 18.3), but also with respect to the effect on the back reflection amplitude (see paragraph 19.1). During the discontinuity inspection test, an additional 6 dB minimum shall be added to the reference or sensitivity level for scanning purposes. All discontinuity evaluation shall be performed at the original recorded sensitivity level prior to final disposition. 18.2.4 Results of scanning of each axle shall be recorded by axle serial number. Records of results shall be maintained for at least 5 years. 18.3 Distance Amplitude Correction The amplitude of an ultrasonic indication must be considered in relation to its distance from the testing surface to evaluate its significance. This can be accomplished by an electronic device or by distance-amplitude curves (DAC) that are described in Appendix B, paragraph 2.0. 11/1/04
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19.0 REJECTION 19.1 Longitudinal Penetration Axles that do not produce a 40% minimum full screen height (FSH) back reflection from the end face opposite the search unit shall be rejected or made acceptable by heat treatment. 19.2 Discontinuity Test The axle shall be rejected if the amplitude of any discontinuity indication exceeds the indication levels obtained from the flat-bottom holes listed in Table 18.2, considering the distance amplitude correction as described in paragraph 18.3 20.0 RECALIBRATION Check the calibration of the instrument using the calibration block and technique previously established when any of the following occur: 20.1 Every 4 hours of continuous use 20.2 Change in operators 20.3 Change in transducers, cables, and other accessories 20.4 Loss of power or equipment malfunction 21.0 DIMENSIONS AND TOLERANCES 21.1 For other than the standard freight and passenger car axles referenced in this specification, standard tolerances and allowances will apply, if not specified in axle drawings provided by the purchaser. 21.2 Axle centers shall conform to Fig. C.5. 21.3 For all axles ordered for finished end facing by the purchaser, the overall length shall range from 1/8 in. to 1/4 in. over the specified minimum length. 21.4 Rough machined journals and wheel seats shall be 1/8 in. to 1/4 in. over the finished diameters and longitudinally 1/8 in. to 1/4 in. of metal shall be allowed at each change of cross section for finish machining. 21.5 The smooth machined body shall be to the specified size, with no more than 1/8 in. over on the diameters and shall have no more than 1/8 in. allowance longitudinally at each change of cross section, unless specified otherwise in Fig. C.3. 22.0 WEIGHT The approximate weights of the passenger and freight car axles covered by this specification are shown in M-101. 23.0 WORKMANSHIP AND FINISH 23.1 Axles shall be machined to a smooth machined finish between the wheel seats. The wheel seats and journals shall be rough machined; the rough machining shall be free from objectionable ridges and chatter marks. Journals, dust guard seats, and wheel seats of axles supplied in finished form will comply with applicable provisions of the AAR Manual of Standards and Recommended Practices, Section G, Part II, “Wheel and Axle Manual.” 23.2 Finish The axles shall be free from injurious defects. The machining shall be done in a workmanlike manner. 23.3 The interpretation of injurious defects in axles shall comply with Appendix A , “Interpretation of Defects Considered Injurious in Axles.”
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24.0 MARKING Axles shall be legibly cold stamped with characters not less than 1/4 in. high in accordance with the AAR standard marking requirements shown in Fig. C.2. 25.0 INSPECTION 25.1 The inspector representing the purchaser shall have free entry, at all times while the work on the contract of the purchaser is being performed, to all parts of the manufacturer’s works that concern the manufacture of the material ordered. The manufacturer shall afford the inspector, free of charge, all reasonable facilities and necessary assistance to satisfy the inspector that the material is being furnished in accordance with these specifications. Tests and inspection for acceptance shall be made at the place of manufacture. 25.2 The purchaser may make tests to cover the acceptance or rejection of the material in purchaser’s own laboratory or elsewhere. Such tests shall be made at the expense of the purchaser. 25.3 The inspector shall examine each axle in each heat for workmanship, defects, and conformity to the dimensions given on the order or drawing. If in this inspection defects are found that the manufacturer can remedy, manufacturer may correct such defects. 26.0 REJECTION 26.1 Any axle that fails to meet the requirements of these specifications will be rejected. 26.2 Axles that show injurious defects subsequent to their original inspection and acceptance at the manufacturer’s works or elsewhere will be rejected and the manufacturer shall be notified. 27.0 REHEARING Samples of axles tested in accordance with these specifications that represent rejected material shall be held for 14 days from date of the test report. In case of dissatisfaction with the results of the tests, the manufacturer may request a hearing within that time. 28.0 CERTIFICATION Upon request of the purchaser in the contract or order, a manufacturer’s certification that the material was manufactured and tested in accordance with this specification, together with a report of the test results, shall be furnished at the time of shipment. 29.0 The following supplementary requirements shall apply only when specified by the purchaser. Details shall be agreed upon by the manufacturer and the purchaser. 29.1 Microscopic Tests The prolongation from the largest axle in each heat shall be sawed normal to the axis of the axle and shall then be split longitudinally. The transverse and the longitudinal face shall be etched for microscopic examination. Reference shall be made to Specification ASTM E381, “Standard Method of Macroetch Testing Steel Bars, Billets, Blooms, and Forgings.” 29.2 The purchaser may specify axle wheel seat diameters 1/8 in. larger than those shown under dimension “I” in Fig. C.3. 30.0 This specification includes Appendices A , B, C, Figs. C.1 through C.5, and M-101.
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APPENDIX A
M-101
APPENDIX A INTERPRETATION OF DEFECTS CONSIDERED INJURIOUS IN AXLES 1.0 The conditions that have been most difficult for inspectors to evaluate are light lines visible to the normal unaided eye, variously described as actual seams, hairlines, stringers, shadow seams, ghost lines, etc., that appear after the axles have been finish-machined and burnished or ground. It is therefore advisable to describe these conditions in more detail. 2.0 The interpretation of injurious defects as enumerated below is not to be considered as precluding other unforeseen or objectionable conditions not specifically listed. The right of the purchaser is reserved to reject temporarily such axles and make final settlement on the basis of further negotiations between representatives of the manufacturer and the purchaser who are especially qualified to decide such questions. 3.0 Any transverse or circumferential seams, cracks, or laps of indeterminate depth on the axle surfaces other than the discolorations listed in paragraph 4.0, regardless of their location, are considered to be injurious and are cause for rejection without further machining. 4.0 Ghost lines, shadow marks, or other similar discolorations, visible to the normal unaided eye that are not actual separations in the metal are not considered injurious, regardless of location. 5.0 Any longitudinal discontinuity, variously termed hairline, stringer, or fine seam, in machined fillets is considered to be injurious and is cause for rejection without further conditioning. 6.0 JOURNALS AND DUST GUARDS 6.1 Roller Bearing Axles Fine longitudinal discontinuities on the finished (burnished or ground) surfaces variously termed hairlines, stringers, or fine seams are not considered injurious if they meet the following conditions: 6.1.1 Must not extend into fillets. 6.1.2 Must not be over 3/4 in. long individually in the journal or 1/2 in. long individually in the dust guard seat. 6.1.3 Total length of such imperfections over 1/4 in. long must not exceed 2 in. in any one end of axle. 7.0 WHEEL AND GEAR SEATS 7.1 Freight Car Axles (Roller Bearing) Longitudinal seams in wheel seats of freight car axles are not considered injurious if they meet the following conditions: 7.1.1 Must not extend into the dust guard or body fillets. 7.1.2 Must not be over 2 in. long individually. 7.1.3 Total length of such imperfections, 1/4 in. to 2 in. long, must not exceed 4 in. in any one end of axle. 7.2 All Other Axles Longitudinal discontinuities on the finished machined surface of wheel and gear seats, variously termed hairlines, stringers, fine seams, tight seams, surface imperfections, etc., are not considered injurious if they meet the following conditions: 7.2.1 Must not extend within 1 1/2 in. of either end of wheel or gear seat. 7.2.2 Must not be over 1/2 in. long individually.
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APPENDIX A
7.2.3 Total length of such imperfections, 1/4 in. to 1/2 in. long, must not exceed 3 in. in any one end of axle. 8.0 AREAS BETWEEN WHEEL (AND GEAR) SEATS (BODY) 8.1 Machined Bodies Longitudinal discontinuities on the finished surfaces, variously termed hairlines, stringers, or fine seams, are not considered injurious if they meet the following conditions: 8.1.1 Must not extend into fillets adjacent to wheel or gear seat. 8.1.2 Must not be over 1/2 in. long individually. 8.1.3 Total length of such imperfections, 1/4 in. to 1/2 in. long, must not exceed 1 1/2 in. in any 12 in. of body length. 8.1.4 Axles containing longitudinal discontinuities in the body in excess of those described in paragraphs 8.1.2 and 8.1.3 above may be reconditioned by grinding or machining, provided the diameter is not reduced below the specified limit.
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APPENDIX B
M-101
APPENDIX B DISTANCE AMPLITUDE CORRECTION 1.0 ALTERNATE REFERENCE STANDARDS Alternate references may be used to establish the test sensitivity if they are cross-referenced with the reference test block described in paragraph 18.1.1. For example, the following are alternate references for heat-treated axles that give equivalent sensitivity: 1) a 1-in. indication from a #1 series “A” Alcoa block; and 2) a 1 1/2-in. indication from an ASTM E-127 block #1-0300. 2.0 DISTANCE-AMPLITUDE CORRECTION The amplitude of an ultrasonic indication from a given discontinuity size varies with its distance from the test surface. To compensate for this effect, a distance-amplitude relationship is employed. The relationship can be established by an electronic device or by curves. Because the distance-amplitude relationship is influenced primarily by the ultrasonic transducer and instrument, it is necessary to relate this factor to the specific equipment used. Appropriate distance-amplitude curves shall be developed. A typical example is shown in Fig. B.2 as related to the axle in Fig. B.1. 3.0 SPURIOUS ULTRASONIC INDICATIONS FROM CONTOUR VARIATIONS Because an axle varies in cross-section, it is possible to produce spurious indications, particularly at changes of cross-section. These must be recognized and are not reason for rejection. It is not practical to define these indications in the specification, but the competent operator or technician will recognize these spurious indications as responses from axle contours. 4.0 NEAR-FIELD RESOLUTION It should be recognized that detection of discontinuities near the test surface is limited by the ultrasonic test frequency. In the case of heat-treated axles, this is approximately 1 in. from the test surface.
Fig. B.1 Showing location of reference holes in axles
Fig. B.2 Typical distance-amplitude curve for heat-treated axle (as determined with a Sperry reflectoscope, Type UM using a 1 1/8-in.-diameter, 2.25 MHz quartz transducer)
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APPENDIX C
APPENDIX C QUALIFICATION OF MANUFACTURER’S PLANT AS A PRODUCER OF AXLES FOR AAR INTERCHANGE SERVICE 1.0 Applications for approval are to be submitted to the AAR. AAR prefers electronic submissions. However, if an electronic copy is not provided, then applicant should provide 15 copies of the printed documentation. Applicants should provide brochures and information that will provide a general description of the plant and the equipment to be used in the production of axles. In the event it is desired to deliver mounted wheel sets, information indicating that equipment is available to comply with the wheel mounting requirements of the AAR Manual of Standards and Recommended Practices, Section G, Part II, “Wheel and Axle Manual,” should be included. 2.0 After satisfactory review of the data submitted with the application, the Committee will authorize the applicant to contact the AAR for information concerning product testing. This will consist of the applicant furnishing three axles, at applicant’s expense, for testing by the AAR. All costs are to be paid by the applicant upon notification of the testing charges. 3.0 Subsequent to the satisfactory completion of the tests and approval by the Committee of test results, the AAR will inspect for proper equipment the plant where the axles are to be produced per S-649. If mounted wheels are to be provided, an AAR inspection will be arranged for the wheel shop. These inspections will require that all costs be paid by the applicant. Upon the granting of AAR approval, company marks to be stamped on the axle end face will be assigned. 4.0 All plants desiring to maintain their status as an AAR-approved manufacturer of axles for use in AAR interchange service must be inspected as described in S-649. The costs of inspection are to be borne by the axle producer. In the event that a facility fails to satisfy inspection or testing expense obligation, the AAR, in conjunction with the Committee, reserves the right to withhold or withdraw approval. 5.0 In the event that a facility ceases production for less than a year and has not received its scheduled annual inspection, an inspection of the facility is required prior to the delivery of any items for use in interchange service. In the event a plant ceases production of axles for AAR interchange service for more than 60 days and less than 1 year, the AAR must be notified no later than 2 weeks prior to reopening. 6.0 In the event a plant does not receive its annual inspection or ceases production of axles for AAR interchange service for more than 1 year, requalification will be required prior to delivery of any items for use in AAR interchange service. 7.0 In addition to the foregoing, axle manufacturers must meet the requirements of the AAR Manual of Standards and Recommended Practices , Section J, Specification M-1003, “Specification for Quality Assurance.” 8.0 All plants desiring to maintain their status as an AAR-approved manufacturer of axles for use in AAR interchange service must also have their steel suppliers and heat-treating subcontractors inspected if they do not use their own facility. These inspections will be made in conjunction with the facility inspection, and the cost will be borne by the applicant.
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APPENDIX C
M-101
NOTE: THE GAUGELENGTH, PARALLEL SECTION, AND FILLETS SHALL BE AS SHOWN, BUT THE ENDS MAY BE OF ANY SHAPE TO FIT THE HOLDERS OF THE TESTING MACHINE IN SUCH A WAY THAT THE LOAD SHALL BE AXIAL.
Fig. C.1 Standard round tension test specimen with 2-in. gauge length Paragraph 11.3
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M-101
APPENDIX C
AAR STANDARD AXLEMARKINGS NOTES: 1. LABORATORY ACCEPTANCE STAMP—FOR USE BY PURCHASER TO SIGNIFY ACCEPTANCE OF AXLES SO MARKED PRIOR TO SHIPMENT BY PRODUCER 2. SERIAL NUMBER. 3. MANUFACTURER’S NAME OR BRAND BF
Bumar-Fablock S.A.
Chrzanow. Poland
SSD
Standard Steel LLC.
BSa/ CAF
Bethlehem Steel Corporation Construcciones y Auxiliar de Ferrocarriles (CAF)
Johnstown, PA Beasain, Spain
Burnham, Pennsylvania
SW
SWASAP Works
CBa/
Cobrasma
Brazil
Germiston, South Africa
CF CHB
Valdunes (formerly Creusot-Loire) Baotou
Ta/
British Steel
Trafford Park Works, England
THM or TZ
Taiyuan Heavy Machinery (Group) Co. LTD.
Taiyuan, Shanxi Province, P.R.C
TW plus a/ UF
Hawker Siddeley Ural Forge
Trenton Canada Chebarkul, Russia
USS-Fa/
United States Steel Corp.
Fairfield Works
USS-Ga/ USS-Ha/
United States Steel Corp. United States Steel Corp.
Gary Works Homestead Works
V
Valdunes (formerly Creusot-Loire)
Valenciennes, France
WAP
Rail Wheel Factory Indian Railways (Formerly Wheel and Axle Plant)
Yelahanka, Bagalore, India
ZB
Bonatrans a.s. (Formerly ZAD)
Bohumin, Czech Republic
CHT DDAP DSS
Dunkerque, France Baotou Inner Mongolia PRC Jinxi AxleCompany LTD. (Formerly NorincoJinxi) Taiyuan, Shanxi Province, P.R.C
DDAP/RAX JSC Dneprospetsstal, Zaporozhye (DSS)
Dneprderzhinsk, Ukraine Zaporozhye, Ukraine
HM
Huta Gliwice-Osie Sp. zo.o
Gliwice, Poland
JAW
Standard Forged Products
Johnstown, PA
KWa/ L
Klockner Lucchini Siderugica Spa (Formerly Temi)
West Germany Lovere, Italy
LCKZ
LugCentroKuZ
Lugansk, Ukraine
LP MKa/
Huta L. W. (Formerly Lucchini Poland) Makrotek
Warsaw, Poland Mexico
MRF
Standard Forged Products
McKees Rocks, Pennsylvania
MW
MWL Rodas & Eixos LTDA (Formerly Mafersa)
Cacapavz, Sao Paulo, Brazil
RW
S. C. SMR S.A.
Bals, Romania
SCOTa/
Scot Forge
Clinton, Wisconsin
SFC or Sa/ SMI
Standard Forgings Sumitomo Metal Industries LTD.
Osaka, Japan
SPTa/
British Steel
a/ No Longer in Production 4. MONTHAND YEAR MADE 5. GRADE OF AXLE F =Double Normalized and Tempered G=Quenched and Tempered H=Normalized, Quenched and Tempered 6. HEAT IDENTIFICATION NUMBER
Templebourough Works, England
General Notes: Refer to the latest mechanical division circular letter listing of AAR-approved axle manufacturers for current approval status. All marks will be deeply and legibly stamped with characters not less than 1/4 in. high. All marks for freight car roller bearing axles must be located adjacent to the periphery of the centering hole. Manufacturers must finish one end of the axle for stamping. The above are the minimum marking requirements, but the locations on individual items may vary from that illustrated.
Fig. C.2 AAR standard marking requirements Paragraph 24.0 11/1/04
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APPENDIX C
M-101
Fig. 5.8
NOTES: 1. “I” DIMENSION TOLERANCE IS +0.015 –0.015. 2. MAXIMUM ALLOWABLE RUNOUT BETWEEN “G” AND “H” IS .006" TOTAL DIAL INDICATOR. 3. MAXIMUM ALLOWABLE RUNOUT BETWEEN “G” AND “I” IS .008" TOTAL DIAL INDICATOR. 4. FOR7" × 12" JOURNALS, END CHAMFER IS 4° 15' 5/8" ±1/8". 5. REQUIRED FOR PRESS FIT OF ROLLER BEARING BACKING RING WHERE THE “H” DIAMETER IS TOLERANCED. FINISH TO 125 µIN. MAXIMUM WHEN TOLERANCED. 6. THE"W"DIMENSIONCANNOTEXCEEDTHETOLERANCELIMITSOFTHEGAUGESHOWNIN MSRP SECTION G-II, FIG. 5.26. 7. RUNOUT ONJOURNAL SURFACE “G”, WHEN ROTATEDON CENTERS, MUST NOT EXCEED .015" TOTAL DIAL INDICATOR. 8. DIMENSIONS “B” AND “N” ARE CONSIDERED ENGINEERING DATA FOR TRUCK DESIGN AND DO NOT NECESSARILY AGREE WITH AXLE MANUFACTURING TOLERANCES. 9. JOURNAL FINISH MUST NOT EXCEED 63 µIN., IF GROUND OR TURNED ONLY. IF TURNED AND ROLLED, THE TURNED FINISH MUST NOT EXCEED 125 µIN., AND THE ROLLED FINISH MUST NOT EXCEED 16 µIN.
Fig. C.3 Axle for freight car roller bearing—raised wheel seat (page 1 of 2) Standard 1963; Revised 1984, 1998; Effective March 1, 1985 Paragraph 21.5 and Paragraph 29.2
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M-101
APPENDIX C
" Y 8 ° 2
S N O I S N E M I D
" 8 ° 2
" 8 ° 2
" 5 1 ° 4
° 0 1
—
—
4 " / 4 " / 4 / " 0 8 " " / 1 1 4 1 2 / / . — — - 4 - 4 - 8 1 0 X / / 5 / / 1 / 1 1 0 5 2 0 0 0 . ± 1 + 1 + 1 + ± " " " " " " " 6 6 1 / 4 6 7 1 0 / / 1 / 0 3 0 1 3 W 0 5 1 2 9 0 1 1 1 . . . 8 8 9 1 1 0 1 1 " 8 " " 8 " 4 " 8 " " 8 V / 7 2 / 1 / 1 / 1 2 / 1 1 2 2 2 2 " " " " " " 4 6 0 8 8 8 " / / / 9 8 0 6 1 1 1 2 0 5 U 6 . . . 6 6 7 9 9 6 6 6 6 6 9 6 7 ) 7 7 9 8 7 – – – 8 – 2 f " – " " – " – 8 T " 4 o 8 / 8 / " / / 8 1 " / 1 1 1 1 1 2 7 1 1 1 1 e g " " " " " 6 " a 4 6 1 " 8 6 1 8 8 / / / 1 / / / p R 3 5 1 / 1 5 1 ( 5 1 1 1 1 2 2 2 1 2 t a e " " " " " s " 6 0 8 8 4 l / " / / 5 5 0 . 5 1 1 5 e O 1 8 . 5 . 8 9 9 7 6 e 8 8 8 8 8 7 8 h w " " " " " " " N 7 7 8 7 9 7 9 7 9 7 8 7 9 7 d e " s 2 " 2 " 2 " 2 " 2 " 2 " 2 i / / / / / / / 1 1 1 1 1 1 a M 1 r 2 6 2 6 2 6 2 6 2 6 2 6 2 6 — g " " " " " n 6 6 8 1 8 " / 8 / i / " K / 7 / 3 8 3 1 8 r a 5 7 7 7 6 7 6 e b " " " " " " " r 6 6 6 6 4 1 8 1 8 1 / / 1 e / J / l 3 / 7 / 7 / l 5 9 5 9 6 7 7 8 7 7 8 o r " r " " " " " " 6 a 4 4 2 4 4 2 1 / / / / / / I / 3 1 3 1 1 c 9 1 t 8 8 9 8 8 9 7 h g " i 0 2 0 2 0 2 0 2 0 2 0 8 2 3 3 3 3 0 0 3 3 3 3 3 3 / e H 3 0 0 5 5 0 0 5 5 0 0 5 5 r . 7 . 7 . 7 . 8 . 8 . 7 . 7 . 7 . 7 . 7 . 7 . f 6 7
r
o 5 5 5 5 5 5 5 5 5 5 0 0 4 3 f 1 4 1 0 1 0 1 0 1 0 0 3 0 0 9 9 9 9 9 9 9 0 0 9 9 9 e 0 0 1 . 1 . 7 . 1 . 6 . 6 . 1 . 1 . 7 . 1 . 6 . 6 . 5 . 5 . l G 5 x 5 5 5 6 6 6 6 5 5 6 6 . x . . . . . . x n x n x n x n a i n x n x n A a i a i a i a i a i a i m m m m m m m m m m m m m m 3 . " E 3 " 3 " 3 " 3 " 3 " 3 " 3 C . g " " " " " " " i 8 8 8 8 8 8 8 D / 5 / 5 / 5 / 5 / 5 / 5 / 5 F 7 7 7 7 7 7 7 " " " " 3 0 " 6 6 4 1 1 6 9 0 / / 1 7 9 / C 3 3 / 2 5 3 3 . . . 1 1 1 1 1 5 2 3 3 3 " " " " 7 0 " 6 2 6 1 6 1 3 5 5 / 1 / 5 / B / 4 7 1 5 8 . . 7 5 . 1 4 4 5 1 4 5 6 5 0 2 F L A 1 1 1 2 9 O N × 1 × 1 × 8 9 × × E R / 2 × / 2 × 2 / Z I U 6 7 1 6 1 7 1 S O 6 J 5 6
- E I F I N L O S I X S T A D A A F L C C O
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F
G
K
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APPENDIX C
M-101
Freight Car Axles Class
Size (in.)
A (in.)
B (in.)
C
D (in.)
E
D
5 1/2 × 10
3.5000
6 3/16
5.195
2 3/8
.740
E
6 × 11
3.8750
6 11/16
5.695
2 5/8
.850
F
6 1/2 × 12
4.2500
7 3/16
6.195
2 7/8
.955
G
7 × 12
4.6250
8
7.008
3 1/2
1.080
K
6 1/2 × 9
4.2500
7 3/16
6.195
2 7/8
.955
L
6×8
3.8750
6 11/16
5.695
2 5/8
.850
M
7×9
4.625
7 3/16
6.508
2 7/8
0.955
Amtrak Passenger Car Axles D
5 1/2 × 10
3.0000
6 1/2
5.507
1 7/8
.636
E
6 × 11
3.5000
7
6.007
2 3/8
.749
F
6 1/2 × 12
3.8750
7 1/2
6.507
2 5/8
.749
MATERIAL: ASTM A-576, GRADE 1045 OR EQUIVALENT. PARTS TO BE HARDENED AND SURFACES MARKED “G” ARE TO BE GROUND. BREAK SHARP CORNERS. TOLERANCE ON ALL DIMENSIONS TO BE 1/64 IN. UNLESS OTHERWISE SPECIFIED.
Fig. C.4 Pin-type gauge for cap screw holes in ends of roller bearing axles Standard 1979; Revised 1982, 1998
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APPENDIX C
NOTE: DEPTH OF COUNTERBORE IN ROUGH AXLE SHALL BE INCREASED FROM THAT SHOWN TO COMPENSATE FOR STOCK ALLOWED TO FACE AXLE. WHEN SECONDHAND AXLES ARE RECENTERED, DIAMETER AND DEPTH MAY BE INCREASED SUFFICIENTLY TO PRODUCE AN ACCURATE 60º CENTER.
Fig. C.5 Axle centering and gauge for axle center and lathe center Adopted 1944; Revised 1966, 1979 Paragraph 21.2
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RP-622
WEIGHTS OF MACHINED-FINISH, RAISED WHEEL SEAT AXLES Recommended Practice RP-622 Adopted: 1966; Revised: 2007 Nominal Weight (lb) Classification of Axles
Roller Bearing
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Size of Journal (in.)
Rough-Turned Journal and Wheel Seats Freight Car
Passenger Car
D
5 1/2 × 10
810
840
E
6 × 11
975
1005
F
6 1/2 × 12
1175
1220
G
7 × 12
1415
—
K
6 1/2 × 9
1168
—
L
6×8
900
—
M
7×9
1325
—
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