246499607-AAR-M-101.pdf

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Association of American

Association of American Railroads

Railroads

MANUAL OF STANDARDS

AND AND

RECOMMENDED PRACTICES

SECTION G

SAFETY AND OPERATIONS SAFETY AND OPERATIONS

WHEELS AND AXLES

Published by Published by

The Association of American Railroads The Association of American Railroads 425 Third Street, SW., Washington, D.C. 20024 425 Third Street, SW., Washington, D.C. 20024

Printed in U.S.A. Printed in U.S.A. Effective March 2011 Effective March 2011

Compiled under the direction of the Committees responsible for the subjects shown herein. Compiled under the direction of the Committees responsible for the subjects shown herein.

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Safety and Operations 425 Third Street SW. 425 Third Street SW. Washington, D.C. 20024 Washington, D.C. 20024

All rights reserved, including the right to reproduce this book in any form. It is the AAR’s intention that this All rights reserved, including the right to reproduce this book in any form. It is the AAR’s intention that this publica-tion be used to promote the objectives of the AAR and its members for the safe, efficient, and uniform interchange of tion be used to promote the objectives of the AAR and its members for the safe, efficient, and uniform interchange of rail equipment in North America. To this end, only excerpts of a rule or specification may be reproduced by the rail equipment in North America. To this end, only excerpts of a rule or specification may be reproduced by the pur-chaser for their own use in promoting this objective. No portion of this publication may be displayed or otherwise chaser for their own use in promoting this objective. No portion of this publication may be displayed or otherwise made available to multiple users through any electronic distribution media including but not limited to a local area made available to multiple users through any electronic distribution media including but not limited to a local area net-work or the Internet. No portion may be sold or used for advertisement or gain by any entity other than the AAR and work or the Internet. No portion may be sold or used for advertisement or gain by any entity other than the AAR and its authorized distributor(s) without written permission from the AAR.

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Wheels and Axles Wheels and Axles

ORDERING INFORMATION

Copies of the various sections of this manual can be obtained as follows: Copies of the various sections of this manual can be obtained as follows: ORDERS FOR ORDERS FOR PUBLICATIONS PUBLICATIONS Publications Department Publications Department

Transportation Technology Center, Inc. Transportation Technology Center, Inc. P.O. Box 11130 P.O. Box 11130 55500 DOT Road 55500 DOT Road Pueblo, CO 81001 Pueblo, CO 81001 Email:

Email: pubs@[email protected]

Phone: Toll-free 877-999-8824, Direct 719-584-0538 Phone: Toll-free 877-999-8824, Direct 719-584-0538 Fax: 719-584-7157

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Online ordering:

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CIRCULAR CIRCULAR LETTER LETTER SUBSCRIPTIONS SUBSCRIPTIONS

Subscriptions to Circular Letters of the AAR Safety and

Subscriptions to Circular Letters of the AAR Safety and Operations’ TOperations’ Technical Services are available inechnical Services are available in hardcopy or electronic format (online access

hardcopy or electronic format (online access via AAR’s Web page atvia AAR’s Web page at www.aarcirculars.aar.orgwww.aarcirculars.aar.org). Circulars). Circulars are issued at least monthly and include industry letter ballots and results, arbitration decisions, notification are issued at least monthly and include industry letter ballots and results, arbitration decisions, notification of rules and standards revisions, industry early

of rules and standards revisions, industry early warning and maintenance advisories, and otherwarning and maintenance advisories, and other information related to mechanical rules and standards. Subscriptions are valid for

information related to mechanical rules and standards. Subscriptions are valid for one year.one year. For ordering information, contact the following:

For ordering information, contact the following: Phone: Toll-free 877-999-8824, Direct 719-584-0538 Phone: Toll-free 877-999-8824, Direct 719-584-0538 Fax: 719-584-7157

Fax: 719-584-7157 Email:

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MSRP-A1 MSRP-A1 INDEX INDEX

The MSRP-A1 Tab

The MSRP-A1 Table of Contents is le of Contents is an inclusive index an inclusive index of all MSRP specifications, of all MSRP specifications, standards, andstandards, and recommended practices. It is available online at

recommended practices. It is available online at http://wwwhttp://www.aar.com.aar.com/aar_standards-publications.ht/aar_standards-publications.htmm This This easy-to-access document is a convenient way to quickly identify in

easy-to-access document is a convenient way to quickly identify in which manual a specific documentwhich manual a specific document resides. The index is updated weekly, enabling the user to see in "real-time" which documents have been resides. The index is updated weekly, enabling the user to see in "real-time" which documents have been updated via Circular Letter.

updated via Circular Letter.

TECHNICAL TECHNICAL QUESTIONS QUESTIONS

For technical questions regarding this manual, contact the following: For technical questions regarding this manual, contact the following: Technical Committee Coordinator

Technical Committee Coordinator Transportation Technology Center, Inc. Transportation Technology Center, Inc. P.O. Box 11130 P.O. Box 11130 55500 DOT Road 55500 DOT Road Pueblo, CO 81001 Pueblo, CO 81001 Email:

Email: wabl@[email protected] Phone: 719-584-0670 Phone: 719-584-0670 Fax: 719-585-1895 Fax: 719-585-1895

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Wheels and Axles

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Wheels and Axles

TO THE USER

Section G—Wheels and Axles, Manual of Standards and Recommended Practices , covers three main components: the wrought (or forged) steel wheel, the cast steel wheel, and the steel axle. Be-cause of the critical functions of all these components, exhaustive details are given on design, met-allurgy, manufacture, inspection, acceptance, assembly, wear limits, reclamation, and machining for reuse. Wheels and axles are medium-range carbon steels containing a maximum of less than 1% manganese and minimal levels of phosphorus, sulfur, and silicon. Wheels subjected to severe service conditions have rims heat-treated and quenched to produce wear-resistant surfaces, followed by overall tempering and controlled cooling. Axles must always be normalized and, when used un-der high-capacity freight cars, passenger cars, and locomotives, are to be heat-treated, normalized, quenched, and tempered. A specification included in this volume treats electrochemical metal dep-osition for restoration of journal surfaces of roller bearing axles. There also are standards and rec-ommended practices for dimensions, marking, inspection, gauges, condemning limits, wheel mounting, and manufacturing tolerances.

USER’S GUIDE

Section G contains three specifications, twenty-one standards, and thirteen recommended practic-es. It consists of the following:

• Preface: A listing of the subjects covered in the 25 individual sections, the volumes mak-ing up this manual. This preface is part of each section.

• Table of Contents—Alphabetical: An alphabetical listing of the specifications (M pre-fix), standards (S prepre-fix), and recommended practices (RP prefix).

• Table of Contents—Numerical: A numerical listing of the specifications (M prefix), standards (S prefix), and recommended practices (RP prefix).

• Section G: A generalized subject listing that indicates applicable specifications, stan-dards, and recommended practices.

• Specifications, Standards, and Recommended Practices: The body of this volume.

RELATED SECTIONS

Section G—Wheels and Axles, should be used in conjunction with Section G, Part II—Wheel and Axle (shop) Manual. Other sections containing pertinent information are as follows:

• Section D—Trucks and Truck Details

• Section H—Journal Bearing and Lubrication • Section H, Part II—Roller Bearing (Shop) Manual • Section H, Part III—Lubrication Manual

• Section J—Specifications for Quality Assurance, M-1003

RESPONSIBILITY

The coverage of Section G—Wheels and Axles, is the responsibility of the AAR Wheels, Axles, Bear-ings, and Lubrication Committee.

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Wheels and Axles

PREFACE

The Manual of Standards and Recommended Practices of the Safety and Operations Depart-ment, Association of American Railroads, is issued by authority of the Management Committee of the Division and includes all regularly adopted specifications, standards, and recommended prac-tices of the Association of American Railroads.

The manual is composed of the following sections:

• Section AS—Administrative Supplement serves as a suplement to all MSRP sections (this is available as a free download at http://www.aar.com/aar_standards-publications.htm)

• Section A—Table of Contents, Alphabetical and Numerical Index of Sections B through S inclusive (this is available as a free download at http://www.aar.com/aar_standards-publications.htm) • Section B—Couplers and Freight Car Draft Components (100 Series)

• Section C—Car Construction—Fundamentals and Details (200 and 2000 Series) • Section C, Part II—Design, Fabrication, and Construction of Freight Cars, M-1001 • Section C, Part III—Specifications for Tank Cars, M-1002

• Section D—Trucks and Truck Details (300 and 3000 Series)

• Section E—Brakes and Brake Equipment (300, 400, and 4000 Series) • Section E, Part II—Electronically Controlled Brake Systems

• Section F—Sensors

• Section G—Wheels and Axles (600 Series)

• Section G, Part II—Wheel and Axle (Shop) Manual (600 Series) • Section H—Journal Bearings and Lubrication (700 Series) • Section H, Part II—Roller Bearing (Shop) Manual (700 Series) • Section H, Part III—Lubrication (Shop) Manual (700 Series) • Section I—Intermodal Equipment Manual

• Section J—Specification for Quality Assurance, M-1003 • Section K—Railway Electronics (5700 Series)

• Section K, Part II—Railway Electronics (5800 Series) • Section K, Part III—Railway Electronics (5900 Series) • Section L—Lettering and Marking of Cars (900 Series)

• Section M—Locomotives and Locomotive Interchange Equipment • Section N—Multi-Level Manual

• Section S—Casting Details

• Section S, Part II—Truck Details and Casting Codes • Section S, Part III—Coupler and Yoke Details

Specifications are designated with an “M” prefix (e.g., M-900). Standards are prefixed “S” (e.g., S-900). Recommended Practices carry the prefix “RP”( e.g., RP-900).

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Wheels and Axles

TABLE OF CONTENTS—ALPHABETICAL

Subject Standard Page

Axle for Passenger Cars (Amfleet) Inboard Roller Bearing— Raised Wheel Seat

S-658 G[S-658]101 Axle, Weight—Machined Finish, Raised Wheel Seat RP-622 G[RP-622]157 Axles, Carbon Steel, Heat-Treated M-101 G[M-101]1 Axles—Manufacturing Facility Inspection By Technical

Services

S-649 G[S-649]97 Circumference Measure (Tape) for 27-in. to 38-in. Steel

Wheels

S-612 G[S-612]73 Circumference Measure (Tape) for 38-in. to 52-in. Steel

Wheels

S-613 G[S-613]75 Electrochemical Metal Deposition for Repairing Roller

Bearing Axle Journals

M-967 G[M-967]61 Gauge, Axle—Master Gauge For Verifying Axle Journal and

Fillet Gauge S-614

RP-613 G[RP-609]145 Gauge, Axle—Reference Gauge For Verifying Axle Journal

and Fillet Gauge S-614

S-616 G[S-616]81 Gauge, Wheel—Application Drawing For AAR 1B Wheel

Gauges S-661 and S-665

RP-637 G[RP-637]165 Gauge, Wheel—Application Drawing For AAR 1B Wheel

RP-636 G[RP-636]163 Gauge, Wheel—Application Drawing For Reference Gauge To

Verify Wheel Gauges 661, 662, 663, 664, 665, S-666, S-667, and S-668

RP-638 G[RP-638]167

Gauge, Wheel—Application for Measuring Condemnable Overheated Wheels

RP-630 G[RP-630]161 Gauge, Wheel—Combination Gauge For Wheel

Measurements

S-627 G[S-627]87 Gauge, Wheel—Combination Gauge For Wheel

Measurements Including Locomotive Flange Limit Of 0.875 In.

S-628 G[S-628]89

Gauge, Wheel—for Measuring Condemnable Overheated Wheels

RP-629 G[RP-629]159 Gauge, Wheel—Former Standard 1976 S-618 G[S-618]85 Gauge, Wheel—Former Standard 1980 S-617 G[S-617]83 Gauge, Wheel—Master Gauge For Verifying Wheel Gauges

S-617 and S-618

RP-614 G[RP-614]151 Gauge, Wheel—Maximum Flange Thickness, Height, and

Throat Radii Gauge for AAR-1B Narrow-Flange Steel Wheel

S-661 G[S-661]109

Gauge, Wheel—Maximum Flange Thickness, Height, and Throat Radii Gauge for AAR-1B Wide-Flange Steel Wheels

S-665 G[S-665]117 Gauge, Wheel—Minimum Flange Thickness, Height, and

Throat Radii Gauge for AAR-1B Narrow-Flange Steel

S-662 G[S-662]111

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Wheels and Axles

Gauge, Wheel—Minimum Flange Thickness, Height, and Throat Radii Gauge for AAR-1B Wide-Flange Steel Wheels

S-667 G[S-667]121 Gauge, Wheel—Reference Gauge For Verifying Combination

Wheel Gauge S-627

S-629 G[S-629]91 Gauge, Wheel—Reference Limit Gauge For Verifying AAR 1B

Narrow Flange Wheel Gauge S-661

Narrow Flange Wheel Gauge S-662

Wide Flange Wheel Gauge S-665

S-668 G[S-668]123 Analytic Evaluation of Locomotive Wheel Designs S-669 G[S-669]125

Gauge, Wheel—Reference Master Disk For Verifying Wheel Circumference Gauges S-612 and S-613

RP-608 G[RP-608]143

Gauge, Wheel—Simplified RP-615 G[RP-615]153

Gauge, Wheel—Standard S-630 G[S-630]95

Inspection Stand for Use with Master Disks RP-609 G[RP-609]145 Mounting Pressures for Wrought and Cast Steel Wheels on

Gear-Driven and Idler Axles of Locomotives Other than Steam

RP-612 G[RP-612]147

Reference Groove for Multiple-Wear Diesel Wheels RP-619 G[RP-619]155 Wheel Defect—Worn Journal Collar and Journal Fillet Gauge S-614 G[S-614]77 Wheel Defect—Worn Journal Collar and Journal Fillet Gauge S-615 G[S-615]79 Wheel Designs, Locomotive and Freight Car—Analytic

Evaluation

S-660 G[S-660]103 Wheel, Passenger Car (Amfleet) S-657 G[S-657]99

Wheels, Carbon Steel M-107/M-208 G[M-107/M-208]21

Wheels—Manufacturing Facility Inspection By Technical Services

S-601 G[S-601]69 Wheels—Measuring Wheel Circumference (Tape) Using

Wheel Gauges S-612 and S-613

S-611 G[S-611]71

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Wheels and Axles

TABLE OF CONTENTS—NUMERICAL

Standard Subject Page

M-101 Axles, Carbon Steel, Heat-Treated G[M-101]1

M-107/M-208 Wheels, Carbon Steel G[M-107/M-208]21

M-967 Electrochemical Metal Deposition for Repairing Roller Bearing Axle Journals

G[M-967]61 S-601 Wheels—Manufacturing Facility Inspection By Technical

Services

G[S-601]69 S-611 Wheels—Measuring Wheel Circumference (Tape) Using

Wheel Gauges S-612 and S-613

G[S-611]71 S-612 Circumference Measure (Tape) for 27-in. to 38-in. Steel

Wheels

G[S-612]73 S-613 Circumference Measure (Tape) for 38-in. to 52-in. Steel

Wheels

G[S-613]75 S-614 Wheel Defect—Worn Journal Collar and Journal Fillet Gauge G[S-614]77 S-615 Wheel Defect—Worn Journal Collar and Journal Fillet Gauge G[S-615]79 S-616 Gauge, Axle—Reference Gauge For Verifying Axle Journal

and Fillet Gauge S-614

G[S-616]81 S-617 Gauge, Wheel—Former Standard 1980 G[S-617]83 S-618 Gauge, Wheel—Former Standard 1976 G[S-618]85 S-627 Gauge, Wheel—Combination Gauge For Wheel

Measurements

G[S-627]87 S-628 Gauge, Wheel—Combination Gauge For Wheel

Measurements Including Locomotive Flange Limit Of 0.875 In.

G[S-628]89

S-629 Gauge, Wheel—Reference Gauge For Verifying Combination Wheel Gauge S-627

G[S-629]91

S-630 Gauge, Wheel—Standard G[S-630]95

S-649 Axles—Manufacturing Facility Inspection By Technical Services

G[S-649]97 S-657 Wheel, Passenger Car (Amfleet) G[S-657]99 S-658 Axle for Passenger Cars (Amfleet) Inboard Roller Bearing—

Raised Wheel Seat

G[S-658]101 S-660 Wheel Designs, Locomotive and Freight Car—Analytic

Evaluation

G[S-660]103 S-661 Gauge, Wheel—Maximum Flange Thickness, Height, and

Throat Radii Gauge for AAR-1B Narrow-Flange Steel Wheel

G[S-661]109

S-662 Gauge, Wheel—Minimum Flange Thickness, Height, and Throat Radii Gauge for AAR-1B Narrow-Flange Steel Wheel

G[S-662]111

S-663 Gauge, Wheel—Reference Limit Gauge For Verifying AAR 1B Narrow Flange Wheel Gauge S-661

G[S-663]113 S-664 Gauge, Wheel—Reference Limit Gauge For Verifying AAR 1B G[S-664]115

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Wheels and Axles

S-665 Gauge, Wheel—Maximum Flange Thickness, Height, and Throat Radii Gauge for AAR-1B Wide-Flange Steel Wheels

G[S-665]117 S-666 Gauge, Wheel—Reference Limit Gauge For Verifying AAR 1B

G[S-666]119 S-667 Gauge, Wheel—Minimum Flange Thickness, Height, and

Throat Radii Gauge for AAR-1B Wide-Flange Steel Wheels

G[S-667]121 S-668 Gauge, Wheel—Reference Limit Gauge For Verifying AAR 1B

G[S-668]123 S-669 Analytic Evaluation of Locomotive Wheel Designs G[S-669]125 RP-608 Gauge, Wheel—Reference Master Disk For Verifying Wheel

Circumference Gauges S-612 and S-613

G[RP-608]143 RP-609 Inspection Stand for Use with Master Disks G[RP-609]145 RP-612 Mounting Pressures for Wrought and Cast Steel Wheels on

Gear-Driven and Idler Axles of Locomotives Other than Steam

G[RP-612]147

RP-613 Gauge, Axle—Master Gauge For Verifying Axle Journal and Fillet Gauge S-614

G[RP-609]145 RP-614 Gauge, Wheel—Master Gauge For Verifying Wheel Gauges

S-617 and S-618

G[RP-614]151

RP-615 Gauge, Wheel—Simplified G[RP-615]153

RP-619 Reference Groove for Multiple-Wear Diesel Wheels G[RP-619]155 RP-622 Axle, Weight—Machined Finish, Raised Wheel Seat G[RP-622]157 RP-629 Gauge, Wheel—for Measuring Condemnable Overheated

Wheels

G[RP-629]159 RP-630 Gauge, Wheel—Application for Measuring Condemnable

Overheated Wheels

G[RP-630]161 RP-636 Gauge, Wheel—Application Drawing For AAR 1B Wheel

G[RP-636]163 RP-637 Gauge, Wheel—Application Drawing For AAR 1B Wheel

G[RP-637]165 RP-638 Gauge, Wheel—Application Drawing For Reference Gauge To

Verify Wheel Gauges 661, 662, 663, 664, 665, S-666, S-667, and S-668

G[RP-638]167

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Wheels and Axles

REQUIREMENTS FOR WHEELS AND AXLES MANUFACTURED TO AAR

SPECIFICATIONS

The requirements of these standards, recommended practices, and specifications represent the minimum acceptable requirements. All manufacturers of wheels and/or axles are urged to exceed the intent of these requirements as much as possible. These specifications have been developed on the basis of extensive field experience and tests. Each specification contained herein should be read as including an additional requirement for satisfactory performance under a field test if such test is deemed appropriate after consideration by the Assistant Vice President of Technical Services and Chief of Technical Standards, working with the appropriate technical committee(s).

Normally, periodic inspections of manufacturers’ facilities will be conducted by AAR personnel proximately every year. These periodic inspections will include wheel mounting facilities, where ap-plicable.

When inspection of manufacturing processes or facilities of companies manufacturing wheels and/ or axles for use on cars in interchange service involve travel, the out-of-pocket expenses involved to conduct such required inspections will be paid by the company offering such products for this service. Expenses will be prorated when more than one facility is visited in the same geographic area.

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Wheels and Axles

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Wheels and Axles M-101

AXLES, CARBON STEEL, HEAT-TREATED

Specification

M-101

Adopted: 1914; Last Revised: 20

 

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:

2.0 QUALIFICATION AS MANUFACTURER

Qualification as a manufacturer of axles for use in AAR interchange service must be in accordance with Appendix C of this specification. Qualification is effective until revoked for cause by the Com-mittee. 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

Recom-mended Practices, Section J, Specification M-1003, “Specification for Quality Assurance.” 3.0 MANUFACTURE

3.1 Process

The steel shall be made by any of the following processes: open hearth, electric furnace, or basic oxygen. Proposed changes to material or manufacturing processes must be submitted to the AAR for consideration. Approval of a new material or process may include meeting the requirements stated in Appendix C.

3.2 Discard

A sufficient discard shall be made from each ingot to ensure freedom from piping and undue segre-gation.

3.3 Reduction Practice

The axles may be made directly from the ingot or from blooms. The total reduction from ingot or strand-cast bloom to forging or rolling shall be not less than 3 to 1, unless otherwise specified. Note: The process for manufacturing strand-cast blooms shall be designed to ensure freedom from center porosity and undue segregation.

4.0 COOLING AND HEATING

4.1 After axle blooms are produced, they shall be slow-cooled in closed containers, hoods, or fur-naces.

4.2 Blooms shall be reheated for working in a manner that will prevent internal bursts and over-heating.

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.

Grade F—Double normalized and tempered. (All freight axles over 6 1/2 in. nominal di-ameter at center shall be Grade F.)

Grade G—Quenched and tempered.

Grade H—Normalized, quenched, and tempered.

Grades F, G, and H—Axles are used in heavy duty service on locomotives, cars, and other equip-ment.

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Wheels and Axles

M-101

4.4 Axles (Grades F, G, and H) that are heat-treated directly from reduction 1) shall be cooled below the transformation temperature or to approximately 1,000 °F before any reheating opera-tion; and 2) must not be permitted to cool below 500 °F without slow-cooling as defined in paragraph 4.3.

Note: As the temperature of the axles approaches the minimum of 500 °F, a supplemental heat 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, and item 2 of paragraph 4.4 may be omitted, but axle blooms must then be pile cooled. 4.6 The slow-cooling requirements of paragraphs 4.1, 4.3, and item 2 of paragraph 4.4 may be 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 HEAT TREATMENT

5.1 Axles for heat treatment shall be reheated gradually and uniformly to a suitable temperature to refine the grain structure.

5.2 Normalizing

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 rea-sonably uniform cooling.

5.3 Double Normalizing

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.

Note: A single normalizing treatment shall be permitted when all other requirements for Grade F can be met.

5.4 Quenching

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 Tempering

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 STRAIGHTENING

Straightening shall be done before machining and preferably at a temperature not lower than 950 °F. Straightening performed at temperatures lower than 950 °F shall be followed by stress relieving or an applicable heat treatment.

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Wheels and Axles Wheels and Axles M-101

M-101

7.

7.00 CHCHEMEMICICAL AL COCOMPOMPOSISITITIONON

The steel shall conform to the requirements for chemical composition shown in

The steel shall conform to the requirements for chemical composition shown in TTablablee 7.17.1..

8.

8.00 LALADLDLE ANE ANALALYSYSIISS 8.1

8.1 An analysi An analysis of each s of each heat of steel heat of steel shall be mshall be made by tade by the manufacturer he manufacturer to determine to determine the percent-the percent-age of carbon, manganese, phosphorus, sulfur, and silicon. The chemical composition thus age of carbon, manganese, phosphorus, sulfur, and silicon. The chemical composition thus deter-mined shall be reported to the purchaser or purchaser’s representative and shall conform to the mined shall be reported to the purchaser or purchaser’s representative and shall conform to the requirements of

requirements of parparagragraphaph 7.07.0.. 8.2

8.2 IdentiIdentificatiofication of n of Heats Heats in Cin Consecutonsecutive ive Strand Strand CastiCastingsngs

If more than one heat is consecutively strand cast at one time, ladle analyses shall be obtained of 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 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 co

bloom or blooms that comprise a mix of the two consecutive heats shall be deemed to be outside thensecutive heats shall be deemed to be outside the requirements of the specification unless additional chemical analyses prove compliance. If both 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 ladle analyses are in compliance with the specification, the heat number assigned to the cast prod-uct shall remain unchanged until all of the steel in the bloom is from the following heat. uct shall remain unchanged until all of the steel in the bloom is from the following heat. Alterna-tively, when all of the mixed portion of two consecutive heats is in one bloom, that bloom may be tively, 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 given the heat number that comprises the larger portion of the bloom on either side of the mixed portion.

portion. 9.

9.00 CHCHECECK ANK ANALALYSYSISIS

Analysis may be made by the purchaser from one axle representing each heat. The chemical Analysis may be made by the purchaser from one axle representing each heat. The chemical

com-position thus determined shall conform to the requirements of

position thus determined shall conform to the requirements of parparagragraphaph 7.07.0, subject to tolerances, subject to tolerances included in

included in TTablablee 9.9.11. The sample for these . The sample for these analyses shall be taken from one end of analyses shall be taken from one end of the test axle orthe test axle or full-size prolongation at a point midway between the center and surface. If drillings are taken, 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 they shall be obtained using a 5/8-in.-diameter drill, or turnings may be taken from a tensile test specimen.

specimen.

T

Table 7.able 7.11 ChemChemical cical composiompositiontion G

Grraadde e FF GGrraaddees s G G aannd d HH Heat-Treated

Heat-Treated M

Miinn.. MMaaxx.. MMiinn.. MMaaxx C Caarrbboonn, , ppeerrcceennttaaggee 00..4455 00..5599 —— —— M Maannggaanneessee, , ppeerrcceennttaaggee 00..6600 00..9900 00..6600 00..9900 P Phhoosspphhoorruuss, , ppeerrcceennttaaggee —— 00..004455 —— 00..004455 S Suullpphhuurr, , ppeerrcceennttaaggee —— 00..005500 —— 00..005500 S Siilliiccoonn, , ppeerrcceennttaaggee 00..1155 —— 00..1155 —— Ta

Table 9.1ble 9.1 PermiPermissiblssible variatioe variations for check analysins for check analysiss

Permissible Variations, Over the Maximum Limit Permissible Variations, Over the Maximum Limit

or Under the Minimum Limit or Under the Minimum Limit E

Elleemmeennttss PPeerrcceennttaaggee M Maannggaanneessee 00..003300 P Phhoosspphhoorruuss 00..000088 S Suullpphhuurr 00..000088 S Siilliiccoonn 00..002200

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M-101 M-101

10

10.0.0 TTENENSISION TON TESESTSTS 10.1

10.1 Grades F, G, and H axles shall conform to the requirements inGrades F, G, and H axles shall conform to the requirements in TTablablee 10.10.11..

10.2

10.2 The size classification shall be determined by the finished diameter of the journal.The size classification shall be determined by the finished diameter of the journal. 10.3

10.3 The diameter of the test prolongation shall be at least equal The diameter of the test prolongation shall be at least equal to the as-formed diameter of theto the as-formed diameter of the journal.

journal. 10.4

10.4 The tensile properties for all grades listed inThe tensile properties for all grades listed in TTabablele 10.10.11 shall be determined by the shall be determined by the procedure described in ASTM A

procedure described in ASTM A 370, “Standard Methods and Definitions for Mechanical Testing of 370, “Standard Methods and Definitions for Mechanical Testing of Steel Products.” The yield strength shall be determined using the 0.2% offset technique. A Steel Products.” The yield strength shall be determined using the 0.2% offset technique. A Class

Class B2 or more B2 or more accurate extensomaccurate extensometer shall beter shall be used.e used. 10.5

10.5 The use of automated devices that determine the offset yield strength without the need forThe use of automated devices that determine the offset yield strength without the need for plotting a stress-strain curve are acceptable.

plotting a stress-strain curve are acceptable. 10.6

10.6 Tests shall be made only after final heat treatment of Grades F, G, and H axles.Tests shall be made only after final heat treatment of Grades F, G, and H axles. 11.

11.00 TTENSENSION ION TTEST EST SPESPECIMECIMENSNS 11.1

11.1 Tension test specimens shall be taken from the test prolongation or an axle in accordanceTension test specimens shall be taken from the test prolongation or an axle in accordance with the provisions of

with the provisions of paragparagraphraph 12.012.0.. 11.2

11.2 Unless otherwise specified, the axis of the specimen shall be located at any point midwayUnless 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 between the center and surface of the axle or full-sized prolongation and shall be parallel to the axis of the axle.

axis of the axle. 11.3

11.3 TensiTension test specimens on test specimens shall conform to dimensions shown shall conform to dimensions shown inin FiFig.g. CC.1.1.. 11.4

11.4 Tension tests from the prolongations shall have minimum tensile strength and yield pointTension tests from the prolongations shall have minimum tensile strength and yield point values 5% greater than shown in

values 5% greater than shown in TTablablee 10.10.11. For example, Grade F tension tests . For example, Grade F tension tests from axle prolon-from axle prolon-gations shall have 92,500 psi minimum tensile

gations shall have 92,500 psi minimum tensile strength and 52, 500 psi strength and 52, 500 psi minimum yield point.minimum yield point. 11.5

11.5 Tension test specimens from axles shall be taken from the journal of the axle at theTension test specimens from axles shall be taken from the journal of the axle at the mid-radius, halfw

mid-radius, halfway between the surface ay between the surface and centerand center, with the , with the gauge dimension parallel to the gauge dimension parallel to the axisaxis of the axle. For tensile specimens removed from the

of the axle. For tensile specimens removed from the prolongation, samples shall be taken from theprolongation, samples shall be taken from the mid-radius, halfw

mid-radius, halfway between the surface ay between the surface and centerand center, with the , with the gauge dimension parallel to the gauge dimension parallel to the axisaxis of the axle.

of the axle.

Table

Table 10.110.1 TensTensile requirements ile requirements for carbon steel for carbon steel heat-treated axlesheat-treated axles Size

Size

(Solid Diameter or Thickness) (Solid Diameter or Thickness)

(in.) (in.) Tensile Tensile Strength Strength (psi) (psi) Yield Yield Strength Strength (psi) (psi) Elongation Elongation in 2 in. in 2 in. (percentage) (percentage) Reduction Reduction of Area of Area (percentage) (percentage) G

Grraaddee OOvveerr NNoot t OOvveerr MiinMn.. MMiinn.. MMiinn.. MMiinn.. F F (Double Normalized (Double Normalized and Tempered) and Tempered) — — 88 8888,,000000 5500,,000000 2222 3377 G G —— 44 9900,,000000 5555,,000000 2200 3399 ((QQuueenncchheedd 44 77 8855,,000000 5500,,000000 2200 3399 aannd d TTeemmppeerreedd)) 77 1100 8855,,000000 5500,,000000 1199 3377

H H ((NNoorrmmaalliizzeedd,, —— 77 111155,,000000 7755,,000000 1166 3355 Q Quueenncchheedd,, 77 1100 110055,,000000 6655,,000000 1188 3355 and Tempered) and Tempered)

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Wheels and Axles Wheels and Axles M-101

M-101

12

12.0.0 PROPROLOLONGNGATIATION FON FOR TOR TESESTT 12.1

12.1 For test purposes, prolongations shall be attached to at least 5% of the axles in each sizeFor 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.

classification of each heat in each heat-treating lot. 12.2

12.2 If axles with prolongations have been expended, then axles may be used for test procure-If axles with prolongations have been expended, then axles may be used for test procure-ment.

ment. 12.3

12.3 Test reports shall state prolongatiTest reports shall state prolongation sizing prior to test or the on sizing prior to test or the use of axles for test.use of axles for test. 13.0

13.0 MICROSMICROSCOPIC TCOPIC TEST FEST FOR HEAT-OR HEAT-TREATED TREATED AXLES (GRAXLES (GRADES FADES F, G, AND H, G, AND H)) 13.1

13.1 A A specimen, specimen, representing representing each each size size classification of classification of each each heat heat in in each each heat-treatment lot,heat-treatment lot, shall be taken for microscopic test from the tension test s

shall be taken for microscopic test from the tension test specimen. This section for microscopic testpecimen. This section for microscopic test shall be cut from the large undistorted portion of the tension test specimen in such a way as will 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

give a face transverse to the axis of the axle.the axle. 13.2

13.2 The face shall be polished practically free from scratches and shall be etched to define theThe face shall be polished practically free from scratches and shall be etched to define the microstructure

microstructure. The specimen shall . The specimen shall be examined under a be examined under a magnification of 100 diameters.magnification of 100 diameters. 13.3

13.3 The entire specimen shall show a uniform, fine-grained structure, and shall have a grainThe entire specimen shall show a uniform, fine-grained structure, and shall have a grain size of 5 or finer

size of 5 or finer as measured in accordance with ASTM Standard Method E112, latest version.as measured in accordance with ASTM Standard Method E112, latest version. 14

14.0.0 NUNUMBMBER ER OF OF TTESESTSTS 14.1

14.1 Unless otherwise specified by the Unless otherwise specified by the purchaserpurchaser, mechanical tests for grades and sizes , mechanical tests for grades and sizes shown inshown in T

Tablablee 1010.1.1 shall be made from heat-treated axles as covered in shall be made from heat-treated axles as covered in paraparagraphgraph 14.214.2 14.2

14.2 One test per grade, per heat, per One test per grade, per heat, per size classification is required, but each test shall representsize 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 no more than 70 axles, including the test axle. The axles represented by this test shall be called a heat-treatment lot

heat-treatment lot. Each heat-treatment lot of axles shall be heat-treated together, whether in. 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 batch-type or continuous furnaces. In the event that the mechanical properties of a test do not con-form to the requirements specified, all of the axles from the heat-treatment lot are to be retreated in form to the requirements specified, all of the axles from the heat-treatment lot are to be retreated in accordance with

accordance with parparagragraphaph 15.15.22 of this specification. of this specification. 14.3

14.3 If any test specimen fails because of If any test specimen fails because of mechanical condition of the testing apparatusmechanical condition of the testing apparatus, it may be, it may be discarded and another specimen taken.

discarded and another specimen taken. 1

155..00 RREETTEESSTT 15.1

15.1 If the results of the mechanical tests of any lot do not If the results of the mechanical tests of any lot do not conform to the requirements specifiedconform to the requirements specified because a flaw developed in the test

because a flaw developed in the test specimen during testing, a retest shall be allowed if the defectspecimen during testing, a retest shall be allowed if the defect is not caused by ruptures, cracks, or flakes in the steel.

is not caused by ruptures, cracks, or flakes in the steel. 15.2

15.2 If the result of the mechanical test of any lot of Grade F, G, or H axles does not conform toIf 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, the requirements specified, the axles may be retreated, but not more than three additional times, and retests shall be made in accordance with

and retests shall be made in accordance with paraparagraphgraph 10.010.0..

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Wheels and Axles

M-101

16.0 ULTRASONIC TESTING (NEW AXLES ONLY—RADIAL AND AXIAL) 16.1 Scope

16.1.1 This paragraph becomes effective July 1, 2009. 16.1.2 This paragraph applies to all new axles.

16.2 Time of Inspection

16.2.1 Axial—anytime during production following axle end facing and center drilling, but before drilling cap screw holes.

16.2.2 Radial—anytime during production following initial rough turn (forged s urfaces cannot be effectively radial UT-tested).

16.3 Test Equipment

16.3.1 Axial Transducers

16.3.2 Radial Transducers

16.4 Personnel

16.4.1 All personnel performing ultrasonic inspection operations must be prequalified to non-destructive testing (NDT) Level 1, at a minimum, in accordance with American Society for Nondestructive Testing (ASNT), Recommended Practice SNT TC-1A, latest edition.

16.4.2 _{All personnel setting up ultrasonic inspection systems must be prequalified to NDT Level 2,}

at a minimum, in accordance with ASNT, Recommended Practice SNT TC-1A, latest edition.

16.4.3 _{Each manufacturer must employ the services of an individual who is prequalified to NDT}

Level 3, at a minimum, in accordance with ASNT, Recommended Practice SNT TC-1A, latest edition. 16.5 Records

Each facility must maintain the following records for the duration indicated. Records must be accessible within 4 hours upon request by any AAR representative.

• A procedural specification for each validated UT process (current revision)

• A posted controlled copy of each UT specification in each UT testing equipment area(s) (current revision)

• All individual axle test results in printable form, including individual heat, axle serial number, and date of inspection (10 years from date of manufacture)

Type Pulse-echo-type broadband pass amplifier

Quantity One or more. Multiple transducer arrays must be capable of monitoring individual transducers. Couplant A couplant must be used between the face of the transducer and the test surface. Same couplant

to be used for test and calibration.

Machine Calibration At least annually and each time the system receives maintenance that affects system performance.

Frequency 1.0– 2.25 MHz

Size/shape 0.75–1.00 in. diameter or 1.00 in.2

Frequency Range 1.0–5.0 MHz

Size/shape 0.50–1.00 in. diameter or 1.00 in.2

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16.5.1 Personnel certifications for UT testing must be, at a minimum, in accordance with ASNT, Recommended Practice SNT TC-1A, latest edition. Each certification must be endorsed by a responsible official of that facility and the verifying level III (10 years).

16.5.2 Reference block semiannual validation record, including the inspector’s name/ID, revalida-tion date, and measured surface finish of the reference block. (10 years)

16.6 Validation

Validation (system testing) must be performed using the same couplant used during axle testing. All contact surfaces must be smooth with a surface roughness better than 125 microinch for axial

test and 500 microinch for the radial test. It also should be free from dirt and grit. 16.6.1 Axial

16.6.1.1 Calibration and System Tests

The ultrasonic inspection system must be validated initially upon installation and at least once every year after initial installation.

16.6.1.1.1 Calibration—1/8-in. flat-bottom hole at 15-in. depth, set up at 20% full-screen height using 16-in.-long reference block manufactured from a Grade F axle forging.

16.6.1.1.2 Detection Capabilities

16.6.1.2 Alternate reference standards may be used to calibrate or test system sensitivity, provided the output from the alternate standard is cross-referenced with the reference block and axle

of paragraph 16.6.1.1.1.

Example: the following alternates provide equivalent sensitivity: • 1-in. indication from a #1 series “A” Alcoa block

• 1 1/2-in. indication from an ASTM E-127 block #1-0300

16.6.1.3 Reference standards must be inspected and certified semiannually for surface finish on the inspection face(s) of 80 microinch to 125 microinch.

16.6.1.4 Periodic

16.6.1.4.1 Periodic tests shall be made during production testing against the 16-in.-long refer-ence block described above, and adjustments shall be made to instrument controls to ensure com-pliance with the specifications.

16.6.1.4.2 Periodic tests must be made at least once every 4 hours of use. 16.6.1.5 Continuous

16.6.1.5.1 Unscheduled system tests shall be made during production testing against the 16-in.-long reference block described above, and adjustments shall be made to instrument controls to ensure compliance with the specifications.

16.6.1.5.1.1 Tests must be made every time there is a change of system operators.

16.6.1.5.1.2 Tests must be made every time there is a change of transducers, cables, or any other system hardware or accessories.

16.6.1.5.1.3 Tests must be made every time there is an equipment malfunction or upon powering on.

1/8-in. flat-bottom hole From 2 in. to 15 in. depth, detectable in reference axle 1/4-in. flat-bottom hole From 15 in. to 30 in. depth, detectable in reference axle 3/8-in. flat-bottom hole From 30 in. to 46 in. depth, detectable in reference axle

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Wheels and Axles

M-101

16.6.2 Radial

16.6.2.1 Calibration and System Tests

16.6.2.1.1 The ultrasonic inspection system must be validated initially upon installation and at least once every year after initial installation.

16.6.2.1.2 Calibration—The system must be calibrated to exhibit an 80% full-screen-height indi-cation from the backface reflection in the thickest part of the production axle section (wheel seat). 16.6.2.1.3 Tests must be made every time there is an equipment malfunction or upon powering on.

16.6.2.1.4 When a change to the equipment power source, transducer, operator, or coaxial cable occurs, the system set-up must be reverified.

16.7 Inspection 16.7.1 General

16.7.1.1 Inspection surfaces must be free of all dirt and grit prior to the start of testing. 16.7.1.2 The same couplant must be used for calibration and examination.

16.7.1.3 During the axial discontinuity inspection test and the radial loss of back face reflection test, an additional 6 dB shall be added to the reference or sensitivity level for scanning purposes. Discontinuity evaluation shall be performed at the original recorded sensitivity level prior to final disposition.

16.7.2 Axial

16.7.2.1 The amplitude of the 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 that are described in Appendix B, paragraph 2.0.

16.7.2.2 The variation in cross-section of the axle may produce spurious indications. These expected indications must be recognized and are not cause for rejection.

16.7.2.3 Both end faces of the axle must be scanned to the full extent of the surfaces (100% area coverage). The axle end faces must be prepared with a surface finish of 125 microinch or better. 16.7.2.3.1 If the amplitude of any indication exceeds the DAC curves as defined in Appendix B, the axle is rejected.

16.7.2.3.2 If any backface reflection does not exceed 40% of screen height, the axle is rejected. 16.7.3 Radial

16.7.3.1 The variation in cross-section of the axle may produce spurious indications. These expected indications must be recognized and are not cause for rejection.

16.7.3.2 Scan the entire length of the axle radially through the diameter along one line only. At a minimum, the axle surface must be rough-turned with a surface finish of 500 microinch or better. 16.7.3.3 The axle will be rejected for a location if a loss of back reflection of 80% or greater is experienced, unless the loss is attributed to geometry.

16.8 Marking

All axles that are to be tested radially must have the character “R” immediately following the axle grade marking. All axles failing the radial test must be immediately identified and segregated for scrapping.

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17.0 DIMENSIONS AND TOLERANCES

17.1 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.

17.2 Axle centers shall conform to Fig. C.5.

17.3 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.

17.4 Rough machined journals and wheel seats shall be 1/8 in. to 1/4 in. over the finished diame-ters and longitudinally 1/8 in. to 1/4 in. of metal shall be allowed at each change of cross section for finish machining.

17.5 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.

18.0 WEIGHT

The approximate weights of the passenger and freight car axles covered by this specification are shown in Specification M-101.

19.0 WORKMANSHIP AND FINISH

19.1 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.”

19.2 Finish

The axles shall be free from injurious defects. The machining shall be done in a workmanlike man-ner.

19.3 The interpretation of injurious defects in axles shall comply with Appendix A , “Interpreta-tion of Defects Considered Injurious in Axles.”

20.0 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.

21.0 INSPECTION

21.1 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 mate-rial is being furnished in accordance with these specifications. Tests and inspection for acceptance shall be made at the place of manufacture.

21.2 The purchaser may make tests to cover the acceptance or rejection of the material in pur-chaser’s own laboratory or elsewhere. Such tests shall be made at the expense of the purchaser. 21.3 The inspector shall examine each axle in each heat for workmanship, defects, and confor-mity 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.

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Wheels and Axles

M-101

22.0 REJECTION

22.1 Any axle that fails to meet the requirements of these specifications will be rejected.

22.2 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. 23.0 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.

24.0 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.

25.0 The following supplementary requirements shall apply only when specified by the purchaser. Details shall be agreed upon by the manufacturer and the purchaser.

25.1 Macroscopic 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.”

25.2 The purchaser may specify axle wheel seat diameters 1/8 in. larger than those shown under dimension “I” in Fig. C.3.

26.0 This specification includes Appendices A , B, C, Figs. C.1 through C.5, and Specification M-101.

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Wheels and Axles

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 condi-tions:

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.

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Wheels and Axles

APPENDIX A M-101

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.

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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Wheels and Axles

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 16.6.1.1.1. 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 dis-tance-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

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Wheels and Axles Wheels and Axles APPENDIX C

APPENDIX C M-101M-101

APPENDIX

APPENDIX C

C

QUALIFICATION OF MANUFACTURER’S PLANT AS A PRODUCER OF

AXLES

AXLES F

FOR AAR I

OR AAR INTERCH

NTERCHANGE SER

ANGE SERVICE

VICE

1.0

1.0 Applications for Applications for approval are approval are to be to be submitted to submitted to the AAR. the AAR. Applications shall be Applications shall be provided inprovided in electronic file format and must provide a general description of the facility and the equipment to electronic file format and must provide a general description of the facility and the equipment to be used in the production of axles. In the event it is desired to deliver mounted wheel sets, 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 information indicating that equipment is available to comply with the wheel mounting requirements of the AAR

requirements of the AAR Manual Manual of of Standards and Standards and Recommended Practices,Recommended Practices, Section G, Part II, Section G, Part II, “Wheel and Axle Manual,” should be included.

“Wheel and Axle Manual,” should be included. 2.0

2.0 After After satisfactory satisfactory review review of of the the data data submitted submitted with with the the application, application, the the Committee Committee willwill authorize the applicant to contact the AAR for information concerning product testing. This 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 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.

costs are to be paid by the applicant upon notification of the testing charges. 3.0

3.0 Subsequent to the satisfactory completion of the tests Subsequent to the satisfactory completion of the tests and approval by the Committee of testand approval by the Committee of test results, the AAR will inspect for proper equipment the plant where the axles are to be produced results, the AAR will inspect for proper equipment the plant where the axles are to be produced per

per S-649S-649. If mounted wheels are to be provided, an AAR inspection will be arranged for the wheel. 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 shop. These inspections will require that all costs be paid by the applicant. Upon the granting of AAR approval, c

AAR approval, company marks to bompany marks to be stamped on the axle stamped on the axle end face will be assigne end face will be assigned.ed. 4.0

4.0 All All plants desiring plants desiring to to maintain their maintain their status as status as an an AAR-approved manufacturer AAR-approved manufacturer of of axles axles forfor use in AAR interchange service must be inspected as described in

use in AAR interchange service must be inspected as described in S-649S-649. The costs of inspection. The costs of inspection are to be borne

are to be borne by the axle producer. In the event that a facility fails to satisfy by the axle producer. In the event that a facility fails to satisfy inspection or testing inspection or testing expense obligation, the AAR, in conjunction with

expense obligation, the AAR, in conjunction with the Committee, reserves the right to the Committee, reserves the right to withhold orwithhold or withdraw approval.

withdraw approval. 5.0

5.0 In the event that a facility ceases production for less than a year and has not received itsIn 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 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 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 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.

than 2 weeks prior to reopening. 6.0

6.0 In the event a plant does not receive its annual inspection or ceases production of axles forIn the event a plant does not receive its annual inspection or ceases production of axles for AAR interchange service for more than 1

AAR interchange service for more than 1 yearyear, requalification will be required prior to , requalification will be required prior to delivery of delivery of any items for use in AAR interchange service.

any items for use in AAR interchange service. 7.0

7.0 In addition to the foregoing, axle manufacturers must meet the requirements of the AARIn addition to the foregoing, axle manufacturers must meet the requirements of the AAR Manual of Standards and Recommended Practices

Manual of Standards and Recommended Practices, Section J, Specification M-1003, “Specification, Section J, Specification M-1003, “Specification for Quality Assurance.”

for Quality Assurance.” 8.0

8.0 All All plants desiring plants desiring to to maintain their maintain their status as status as an an AAR-approved manufacturer AAR-approved manufacturer of of axles axles forfor use in AAR interchange service must also have their steel suppliers and heat-treating 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 subcontractors inspected if they do not use their own facility. These inspections will be made in conjunction with the facility inspection, and the

conjunction with the facility inspection, and the cost will be borne cost will be borne by the applicant.by the applicant. 9.0

9.0 Axle Axle manufacturers manufacturers using using a a native native language language other other than than English English are are responsible responsible for for thethe accurate communication of all applicable AAR and customer requirements within the plant.

accurate communication of all applicable AAR and customer requirements within the plant. 9.1

9.1 Plant practices and the final product must conform to the English language versions of anyPlant practices and the final product must conform to the English language versions of any applicable standards or

applicable standards or specifications.specifications. 9.2

9.2 Critical records are defined as the standards, internal procedures, and forms necessary toCritical records are defined as the standards, internal procedures, and forms necessary to demonstrate compliance with this

demonstrate compliance with this Specification M-101Specification M-101 and with and with MSRP MSRP Section J, Specification Section J, Specification M-1003. Critical records must be kept up

M-1003. Critical records must be kept up to date with production and to date with production and be maintained in English.be maintained in English.

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APPENDIX C APPENDIX C M-101

M-101

Fig. C.1

Fig. C.1 StandaStandard round tensiord round tension test specimen test specimen with 2-in. gauge lengn with 2-in. gauge lengthth Parag

Paragraphraph 1111.3.3

NOTE: NOTE:

THE GAUGE LENGTH, PARALLEL SECTION, AND FILLETS SHALL BE AS SHOWN, THE GAUGE LENGTH, PARALLEL SECTION, AND FILLETS SHALL BE AS SHOWN, BUT THEBUT THE ENDS MAY BE OF ANY SHAPE TO FIT THE HOLDERS OF THE TESTING MACHINE IN SUCH A ENDS MAY BE OF ANY SHAPE TO FIT THE HOLDERS OF THE TESTING MACHINE IN SUCH A WAY THAT THE LOAD SHALL

WAY THAT THE LOAD SHALL BE AXIAL.BE AXIAL.