AAR Manual of Standards and Recommended Practices Wheels and Axles M-101
AXLES, CARBON STEEL, HEAT-TREATED HEAT-TREATED Specification M-101 Adopted: 1914; Last Revised: Revised: 2016 2016 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 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 manufacturers must meet the requirements requirements of the AAR AAR Manual of Standards and 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. 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 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 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 4.0 COOL COOLIN ING G AND AND HEAT HEATIN ING G
are produced, they shall shall be slow-cooled in closed containers, containers, hoods, hoods, or fur4.1 After axle blooms are naces. 4.2 Blooms shall be reheated for working in a manner that will prevent internal bursts and overheating.
axles shall be slow-cooled in closed containers, containers, covered conveyors, or in 4.3 After reduction, axles hoods. If axles (Grades F, G, and H) are heat-treated directly from reduction, they shall be slow-cooled following the final heat treatment. 06/2013
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F, G, and and H) that are heat-treated heat-treated directly directly from reduction 1) shall shall be cooled 4.4 Axles (Grades F, below the transformation transformation temperature or to approximately 1,000 1,000 °F before any reheating operation; and 2) must not be permitted to cool below 500 500 °F without slow-cooling as defined in paragraph paragraph 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, and item 2 of paragraph paragraph 4.4 may be omitted, but axle axle blooms must then be pile cooled.
paragraphs 4.1, 4.3, and item 2 of paragraph 4.4 may be 4.6 The slow-cooling requirements of paragraphs 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
treatment shall shall be reheated gradually gradually and and uniformly uniformly to a suitable suitable temperature temperature 5.1 Axles for heat treatment to refine the grain structure. 5.2 5.2 Norm Normal aliz izin ing g After being heated heated to a suitable temperature, temperature, the axles shall be withdrawn withdrawn from the furnace furnace and allowed to cool uniformly in air. 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 treatment shall shall be permitted permitted when all other requirements for Grade F Note: A single normalizing can be met. 5.4 Quenchi ching After being heated heated to a suitable temperature, temperature, the axles axles shall be quenched quenched in a suitable medium medium under reasonably uniform conditions. A furnace charge thus treated is termed a quenching charge. 5.5 Temperin ring Axles shall be reheated reheated gradually to, to, and held at, a suitable temperature temperature below the critical 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 temperatures lower than 950 °F shall be followed by stress relieving or an applicable heat treatment.
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7.0 7.0 CH CHEMI EMICA CAL L COMPO COMPOSI SITI TION ON Effective January 1, 2013, the steel shall conform to the requirements for chemical composition shown in Table Table 7.1. Table 7.1 7.1 Chemical Chemical composi composition tion Grade F
Grades G and H Heat-Treated
Min.
Max.
Min.
Max
Carbon, percentage
0.45
0.59
—
—
Manganese, percentage
0.70
1.00
0.60
0.90
Phosphorus, percentage
—
0.045
—
0.045
Sulphur, percentage
—
0.050
—
0.050
Silicon, percentage
0.15
—
0.15
—
Vanadium, percentage
0.02
0.08
—
—
8.0 8.0 LADL LADLE E ANAL ANALYS YSIS IS
analysis of each heat of steel shall be made made by the the manufacturer to determine the percent8.1 An analysis age of carbon, manganese, phosphorus, sulfur, sulfur, silicon, and vanadium. The chemical composition thus determined shall be reported to the purchaser or purchaser’s representative representative and shall conform to the requirements of paragraph 7.0. 8.2 Identificatio Identification n of Heats in Consecut Consecutive ive Strand Castings 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, 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 portion. 9.0 9.0 CH CHEC ECK K ANAL ANALYS YSIS IS Analysis may be be made by the purchaser purchaser from one axle representing representing each heat. The chemical composition thus determined shall shall conform to the requirements requirements of paragraph 7.0, subject to tolerances tolerances included in Table Table 9.1. The sample for these analyses shall be taken 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
Vanadium
0.001
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10.0 10.0 TENSI ENSION ON TES TESTS TS
F, G, and H axles shall conform to the requirements in Table 10.1. 10.1 Grades F, Table 10.1 Tensile 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
20
35
—
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.
Table 10.1 shall be determined by the 10.4 The tensile properties for all grades listed in Table procedure described in ASTM A 370, “Standard Methods and Definitions for Mechanical Testing of Steel Products.” Products.” The yield strength shall be determined using the 0.2% offset technique. A Class B2 or more accurate extensometer extensometer shall be 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 11.0 TENSION ENSION TEST SPECIME SPECIMENS NS 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.
Tension test specimens shall conform to dimensions shown in Fig. Fig. C.1. 11.3 Tension Tension tests from the prolongations shall have minimum tensile strength and yield point 11.4 Tension values 5% greater than shown in Table Table 10.1. For For example, Grade Grade F tension tests from axle axle prolongations shall have 92,500 psi minimum tensile strength s trength and 52, 500 psi minimum yield point. Tension test specimens from axles shall be taken from the journal of the axle at the 11.5 Tension mid-radius, halfway 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 halfway between the surface and center, with the gauge dimension parallel to the axis of the axle.
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12.0 12.0 PROLO PROLONG NGATI ATION ON FOR FOR TES TEST T 12.1 Each size classification of each heat in each heat-treating lot must be tested. Test samples shall be taken either from prolongations or from the axle journal. 12.2 For axles without prolongations, axle journals may be used for test procurement.
prolongation sizing prior to test or the use of axles for test. 12.3 Test reports shall state prolongation 13.0 MICROSCOPIC MICROSCOPIC TEST TEST FOR FOR HEAT-TREATED HEAT-TREATED AXLES (GRADES (GRADES F, F, G, AND H) H)
classification of each heat in each heat-treatment heat-treatment lot, 13.1 A specimen, representing each size classification shall be taken for microscopic test from the tension test specimen. 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. 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 14.0 NUMB NUMBER ER OF TESTS ESTS
purchaser, mechanical tests for grades and sizes shown in 14.1 Unless otherwise specified by the purchaser, Table Tabl e 10.1 shall be made from heat-treated axles axles as covered in 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 together, whether in heat-treatment lot . Each heat-treatment lot of axles shall be heat-treated together, 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 15.3 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 tensile test specimen is not flawed, the results of a second test from a prolongation (or from an axle) cannot be substituted for the failed test result.
F, G, or H axles does not conform to 15.3 If the result of the mechanical test of any lot of Grade F, the requirements specified, the axles may be retreated, but not more than three additional times, and retests shall be be made in accordance accordance with paragraph 10.0.
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AAR Manual of Standards and Recommended Practices Wheels and Axles M-101
16.0 16.0 ULTRASO ULTRASONIC NIC TEST TESTING ING—RAD —RADIAL IAL AND AND AXIAL AXIAL 16.1 Scope This section describes axial and radial ultrasonic test requirements for new axles. The radial UT test became effective July 1, 2009. 16.2 16.2 Time Time of Insp Inspec ectio tion n
Axial—anytime during production following axle end facing facing and center drilling. drilling. 16.2.1 Axial—anytime Radial—anytime during production following initial rough turn (forged surfaces cannot be 16.2.2 Radial—anytime effectively radial UT-tested). 16.3 16.3 Test est Equ Equip ipme ment nt 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 between the face of the transducer transducer and the test surface. Same Same couplant to be used for test and calibration.
Machine Calibration
At least annually and each each time the system receives receives maintenance that affects system performance.
16.3 16.3.1 .1 Axia Axiall Tran Transd sduce ucers rs Frequency
1.0– 2.25 MHz
Size/shape
0.75–1.00 in. diameter or 1.00 in. 2
16.3 16.3.2 .2 Radia Radiall Tra Trans nsduc ducer ers s Frequency Range
1.0–5.0 MHz
Size/shape
0.50–1.00 in. diameter or 1.00 in. 2
16.4 16.4 Person rsonne nell
performing ultrasonic inspection inspection operations must be qualified to 16.4.1 All personnel performing non-destructive testing (NDT) Ultrasonic (UT) Level 1, at a minimum. Qualification shall be in accordance with American Society for Nondestructive Testing Testing (ASNT), Recommended Practice SNT TC-1A, latest edition. ultrasonic inspection systems must be qualified to NDT UT Level 2, 16.4.2 All personnel setting up ultrasonic at a minimum. Qualification shall be in accordance with ASNT, ASNT, Recommended Practice SNT TC-1A, latest edition. Each manufacturer must employ the services of an individual who is qualified to NDT UT Level 3, at a minimum. Qualification shall be in accordance with ASNT, ASNT, Recommended Practice SNT TC-1A, latest edition.
16.4.3
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 procedural specific specification ation for each each validated validated UT process (current (current revision) revision) • A posted controlled copy copy of each each UT specification specification in each UT testing equipment equipment area(s) (current revision) • All individual individual axle test results in printable printable form, including individual heat, heat, axle serial number, number, and date of inspection (10 years from date of manufacture)
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ASNT, Recommended 16.5.1 Personnel certifications for UT testing must be in accordance with ASNT, Practice SNT TC-1A, latest edition. Each certification must be endorsed by a responsible official of that facility and the verifying NDT UT Level 3 (10 years). 16.5.2 Reference block semiannual validation record, including the inspector’s name/ID, revalidation date, and measured surface finish of the reference block. (10 years) 16. 16.6 Valid alidat atio ion n Validation Validation (system testing) must be performed performed using the same couplant couplant used during axle axle testing. All contact surfaces surfaces must be smooth with with a surface roughness better better than 125 microinch for axial axial test and 500 microinch for the radial test. It also should be free from dirt and grit. 16.6.1 16.6.1 Axial Axial Penetrat enetration ion Test 16.6.1 16.6.1.1 .1 Calibr Calibrati ation on and and System System Test Tests s The ultrasonic inspection system must be validated initially upon installation and at least once every year after initial installation.
Calibration—1/8 in. flat-bottom hole at 15-in. 15-in. depth, set up at 20% full-screen height 16.6.1.1.1 Calibration—1/8 using 16-in.-long reference block manufactured from a Grade F axle forging. 16.6.1.1.2 Reference standards must be inspected and certified semiannually for surface finish on the inspection face(s) of 125 microinch or better. better. 16.6 16.6.1 .1.2 .2 Perio eriodi dic c 16.6.1.2.1 Periodic tests shall be made during production testing against the calibration block as described in paragraph 16.6.1.1.1, and adjustments adjustments shall be made to instrument instrument controls to ensure compliance with the specifications. 16.6.1.2.2 Periodic tests must be made at least once every 4 hours of use. 16.6 16.6.1 .1.3 .3 Cont Contin inuo uous us 16.6.1.3.1 Unscheduled system tests shall be made during production testing against the calibration block as as described in paragraph 16.6.1.1.1 and adjustments adjustments shall be made to instrument controls to ensure compliance with the specifications. 16.6.1.3.1.1 Tests must be made every time there is a change of system operators. 16.6.1.3.1.2 Tests must be made every time there is a change of transducers, cables, or any other system hardware or accessories. 16.6.1.3.1.3 Tests must be made every time there is an equipment malfunction or upon powering on. 16.6.2 6.2 Rad Radial 16.6.2 16.6.2.1 .1 Calibr Calibrati ation on and and System System Test Tests s 16.6.2.1.1 The ultrasonic inspection system must be validated initially upon installation and at least once every year after initial installation.
Calibration—The system must be set up on the largest diameter (typically the wheel 16.6.2.1.2 Calibration—The seat) for testing the journal, wheel seat, and body to exhibit a 100% full-screen-height response from the backwall backwall reflection. 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. 06/2013
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16. 16.7 Inspe nspect ctio ion n 16.7.1 General ral 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 penetration test and the radial loss of backwall reflection test, an additional 6 dB shall be added to to the reference or sensitivity sensitivity level for scanning purposes. purposes. If scanned at the higher sensitivity, sensitivity, the loss of backwall reflection evaluation shall be performed after removing the addition additional al 6 dB. dB. 16.7.2 16.7.2 Axial Axial Penetrat enetration ion Test
indications. These 16.7.2.1 The variation in cross-section of the axle may produce spurious indications. expected indications must be recognized and are not cause for rejection. better. 16.7.2.2 The axle end faces must be prepared with a surface finish of 125 microinch or better. 16.7.2.3 If any backwall reflection does not exceed 40% of screen height, the axle is rejected. At the discretion of the manufacturer, manufacturer, axles may be retreated; refer to paragraph 15.3. 16.7.3 Rad Radial
indications. These 16.7.3.1 The variation in cross-section of the axle may produce spurious indications. 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 or with a method that provides equivalent or better coverage. Two radial sweeps must be performed along the axle length offset by about 90°. At a minimum, the axle surface must be rough-turned with a surface finish of 500 microinch or better.
reflection of 80% or 16.7.3.3 The axle shall be rejected for any location showing a loss of backwall reflection greater, unless the loss can be attributed to geometry. 16.8 Marking All axles that that are to be tested radially must must have the the character “R” immediately immediately following the axle grade marking. All axles failing the radial test must be immediately identified and segregated for scrapping. 17.0 17.0 DIMENS DIMENSION IONS S AND TOLERANC OLERANCES ES 17.1 For other than the standard freight and passenger car axles referenced in this specification, standard tolerances and allowances will apply, apply, if not specified in axle drawings provided by the purchaser.
Fig. C.5. 17.2 Axle centers shall conform to Fig. purchaser, the overall length shall range 17.3 For all axles ordered for finished end facing by the purchaser, 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 diameters and longitudinally 1/8 in. to 1/4 in. of metal shall be allowed at each change of o f 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 specified otherwise in Fig. C.3.
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18.0 WEIGHT The approximate weights of the passenger and freight car axles covered by this specification are shown in Recommended Practice RP-622. 19.0 19.0 WORKMA ORKMANS NSHI HIP P AND FIN FINIS ISH H
machined to a smooth machined machined finish between between the wheel seats. seats. The wheel 19.1 Axles shall be machined seats and journals shall be rough machined; the rough machining shall be free from objectionable ridges and chatter marks. Journals, 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 manner. 19.3 The interpretation of injurious defects in axles shall comply with Appendix A, “Interpretation of Defects Considered Injurious in Axles.” 20.0 MARKING
characters not less less than 1/4 in. high high in accordance 20.1 Axles shall be legibly cold stamped with characters with the AAR standard standard marking requirements shown in Fig. Fig. C.2. 20.2 Effective April 1, 2012, bar code labels must be affixed to axles that require them in accordance with the Manual of Standards and Recommended Practices Practices , Section F, Standard S-920, paragraph paragraph 1.4 and Appendix A. A. 21. 21.0 INSPE NSPEC CTION TION
entry, at all times while the work 21.1 The inspector representing the purchaser shall have free entry, on the contract of the purchaser is being performed, to all parts of the manufacturer’s 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. 21.2 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. purchaser.
workmanship, defects, and confor21.3 The inspector shall examine each axle in each heat for workmanship, 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. 22.0 REJE EJECTION
fails to meet the requirements requirements of these specifications specifications will be rejected. rejected. 22.1 Any axle that fails injurious defects subsequent to their original inspection inspection and acceptance acceptance at 22.2 Axles that show injurious the manufacturer’s works or elsewhere will be rejected and the manufacturer shall be notified. 23.0 REHEARI ARING 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 24.0 CERT CERTIF IFIC ICAT ATIO ION N Upon request of the purchaser in the contract or order, 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. 06/2013
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25.0 25.0 SUPP SUPPLEM LEMENT ENTARY ARY REQUIRE REQUIREMEN MENTS TS The following supplementary requirements shall apply only when specified by the purchaser. purchaser. Details shall be agreed upon by the manufacturer and the purchaser. purchaser. 25.1 25.1 Macro Macrosco scopi pic c Tests ests 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. 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. Fig. C.3.
specification includes includes Appendices Appendice s A, B, C, Figs. Figs. C.1 through C.5, C.5, and Specification Specific ation M-101. M-101 . 26.0 This specification
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APPENDIX A
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.
circumferential seams, seams, cracks, or laps of indeterminate indeterminate depth on the axle 3.0 Any transverse or circumferential surfaces other than the discolorations discolorations listed in paragraph 4.0, regardless of their location, are 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.
longitudinal discontinuity discontinuity,, variously termed hairline, hairline, stringer, stringer, or fine seam, in machined 5.0 Any longitudinal fillets is considered to be injurious and is cause for rejection without further conditioning. 6.0 6.0 JOURN JOURNAL ALS S AND AND DUS DUST T GUARD GUARDS S 6.1 6.1 Rolle Roller r Bear Bearin ing g Axle Axles s Fine longitudinal discontinuities on the finished (burnished or ground) surfaces variously termed hairlines, stringers, 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.
length of such imperfections over 1/4 in. long must not exceed 2 in. in any one end of 6.1.3 Total length axle. 7.0 7.0 WH WHEE EEL L AND AND GEA GEAR R SEAT SEATS S 7.1 Freigh Freightt Car Car Axles Axles (Roller (Roller Bearing 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.
imperfections, 1/4 in. to 2 in. long, must not exceed 4 in. in any one end 7.1.3 Total length of such imperfections, of axle.
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AAR Manual of Standards and Recommended Practices Wheels and Axles APPENDIX A
M-101
7.2 7.2 All All Oth Other er Axle Axles s 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:
o f wheel or gear seat. 7.2.1 Must not extend within 1 1/2 in. of either end of 7.2.2 Must not be over 1/2 in. long individually.
length of such imperfections, 1/4 in. to 1/2 in. long, must not exceed 3 in. in any one 7.2.3 Total length end of axle. 8.0 AREAS AREAS BETWEEN BETWEEN WHEEL WHEEL (AND GEAR) GEAR) SEATS SEATS (BODY) (BODY) 8.1 8.1 Mach Machin ined ed Bodi Bodies es Longitudinal discontinuities 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 body length. length.
longitudinal discontinuities discontinuities in the body in in excess of those described in 8.1.4 Axles containing longitudinal 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
APPENDIX B VACANT VACANT
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AAR Manual of Standards and Recommended Practices Wheels and Axles APPENDIX C
M-101
APPENDIX C QUALIFICATION OF MANUFACTURER’S PLANT AS A PRODUCER OF AXLES FOR AAR INTERCH INTERCHANGE ANGE SERVICE SERVICE 1.0 Applications for approval are to be submitted to the AAR. Applications shall be provided in 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, 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.
review of the data submitted submitted with the application, application, the Committee Committee will 2.0 After satisfactory review 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 company marks to be be stamped on the axle axle end face will be assigned. assigned.
their status as an AAR-approved AAR-approved manufacturer manufacturer of axles for 4.0 All plants desiring to maintain their 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, 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 interchange service for more than 1 year, year, requalification will be required prior 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 Standards and Recommended Recommended Practices , Section J, Specification M-1003, “Specification for Quality Assurance.” Assurance.”
their status as an AAR-approved AAR-approved manufacturer manufacturer of axles for 8.0 All plants desiring to maintain their use in AAR interchange service must also have their steel suppliers and heat-treating subcontractors inspected if they do not use their own facility. facility. These inspections will be made in conjunction with the facility inspection, and the cost will be borne by the applicant. language other than English English are responsible for the 9.0 Axle manufacturers using a native language accurate communication of all applicable AAR and customer requirements within the plant. 9.1 Plant practices and the final product must conform to the English language versions of any applicable standards or specifications. 9.2 Critical records are defined as the standards, internal procedures, and forms necessary to demonstrate compliance with this Specification M-101 and with MSRP Section J, Specification M-1003. Critical records must be kept up to date with production and be maintained in English.
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AAR Manual of Standards and Recommended Practices Wheels and Axles M-101
APPENDIX C
NOTE: THE GAUGE LENGTH, 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 Standard round tension tension test specimen specimen with 2-in. gauge length length Paragraph Paragraph 11.3 11.3
AAR STANDARD AXLE MARKINGS NOTES: 1. LAB LAB ORATORY ACCEPTANCE STAMP—FOR USE BY PURCHASER TO SIGNIFY ACCEPTANCE OF AXLES SO MARKED MARKED PRIOR PRIOR TO SHIPMENT SHIPMENT BY PRODUCER PRODUCER 2. SERIAL NUMBER. 3. MANUFACTURER’S NAME OR BRAND (SEE TABLE BELOW) 4. MONTH AND YEAR YEAR MADE 5. GRADE GRADE OF AXLE AXLE F =DOUBLE NORMALIZED NORMALIZED AND TEMPERED TEMPERED G =QUENCHED AND TEMPERED TEMPERED H =NORMALIZED, QUENCHED AND TEMPERED TEMPERED U =UNTREATED =UNTREATED
GENERAL NOTES: • REFER TO THE LATEST LATEST MECHANICAL MECHANICAL DIVISION DIVISION CIRCULAR LETTER LETTER LISTING OF AAR-APPROVED AXLE MANUFACTURERS FOR CURRENT APPROVAL STATUS. • ALL MARKS WILL BE BE DEEPLY AND LEGIBLY LEGIBLY STAMPED STAMPED WITH CHARACTERS NOT LESS THAN 1/4 IN. HIGH. • ALL MARKS MARKS FOR FREIGHT CAR CAR ROLLER BEARING BEARING AXLES MUST BE LOCATED ADJACENT TO THE PERIPHERY OF THE CENTERING HOLE. • MANUFACTURERS MANUFACTURERS MUST FINISH FINISH ONE END OF OF THE AXLE FOR STAMPING. • THE ABOVE ARE ARE THE MINIMUM MINIMUM MARKING REQUIREMENTS, REQUIREMENTS, BUT BUT THE LOCATIONS ON INDIVIDUAL ITEMS MAY VARY FROM THAT ILLUSTRATED.
6. HEAT IDENTIFICATION IDENTIFICATION NUMBER 7. R = RADIAL RADIAL UT
Fig. C.2 AAR standard standard marking marking requireme requirements nts (page 1 of 2) Paragraph Paragraph 20.0
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AAR Manual of Standards and Recommended Practices Wheels and Axles APPENDIX C
M-101
anu acture acturerr s ame or ran MW
MWL MWL Roda Rodass & Eixos x os LTDA TDA (For (Forme merl rlyy Maf Mafer ersa sa))
Caca Cacapa pavz vz,, Sao Sao Paul Paulo, o, Brazil
O SW SW
Ni pp ppo n St ee ee l & Sumi to to mo mo Met al al Co rp rpor at at io n
Os ak ak a, a, J ap ap an an
QRSS
Qiqihar Railway Rolling Stock Ltd.
Qiqihar, PRC
RW SCOTa/
S. C. SMR S.A. Scot Forge
Bals, Romania Clinton, Wisconsin
Brazil
SFC or Sa/
Standard Forgings British Steel
AXIS
AXIS LLC
Paragould AR
BF
Bumar-Fablock S.A.
Chrzanow. Poland
BSa/ BT-BED
Bethlehem Steel Corporation Bahntechnik Brand-Erbisdorf (B (BBE)
CAF CAF
Cons Constr truc ucci cion ones es y Auxi Auxililiar ar de Ferr Ferroc ocar arri rile less (CAF (CAF))
Johnstown, PA Brand-Erbisdorf, Germany Beas Beasai ain, n , Spai Spainn
CBa/
Cobrasma
CCC CCC
CNR CNR Cha Chang ngch chun un Rail Railwa wayy V Veh ehic icle le Fac Facililit itie iess Co.,Ltd.
Jilin Province, China
SPTa/
CF
Valdunes (formerly Creusot-Loire)
Dunkerque, France
SSD
Standard Steel LLC.
CSGR CSGR
Shan Shanxi xi Guor Guorui ui Rai Raill Vehi Vehicle cle Equ Equip ipme ment nt Com Compa pany ny Limited Ba ot ot ou ou
SMI
Sumitomo Metal Industries LTD.
Osaka, Japan
SW
SWASAP Works
Ta/
British Steel
Germiston, South Africa Trafford Park Works, England
CHB CHT CHT
Jiaocheng, Shanxi Province, PRC Ba ot ot ou ou I nn nne r Mon go go li a PRC Jinxi Jinxi Axle Axle Comp Compan anyy LTD LTD.. (For (Forme merly rly Norin Norinco co Jinxi) Jinxi) Taiyu aiyuan an Cit Cityy, Shan Shanxi xi Province, PRC
CSR
CSR Yangtse Rolling Stock Co. Ltd.
DDAP
DDAP/RAX
Templebourough Works, England Burnham, Pennsylvania
Tongling City, Anhui Province PRC Dneprderzhinsk, Ukraine Datong, Shanx i Prvince, PRC
THM or TZ Taiyuan aiyuan Heavy Heavy Industry Industry Railway Railway Transit Transit Equipment Co., Ltd.
Taiyuan City, Shanxi Province, PRC
TW plus a/
Hawker Siddeley
Trenton Canada
TY
Tai yu yu an an He av avy In In du du st st ry ry R ai ai lw lwa y Tr an ans itit Equipment Co., Ltd.
Taiyuan, Shanxi Province, PRC
DEL
CNR Datong El ec ectric Locomoti ve ve CO., LTD
UF
Ural Forge
Chebarkul, Russia
DSS HM
JSC Dneprospetsstal , Zaporozhye (DSS) Huta Gliwice-Osie Sp. zo.o
Zaporozhye, Ukraine Gliwice, Poland
USS-Fa/ USS-Ga/
United States Steel Corp. United States Steel Corp.
Fairfield Works Gary Works
JAW
Standard Forged Products
Johnstown, PA
USS-Ha/
United States Steel Corp.
Homestead Works
KWa/
Klockner Lucchini Sidermeccanica SpA (Formerl y Temi )
West Germany Lovere, Ital y
V WAP WAP
LCKZ
LugCentroKuZ
Lugansk, Ukraine
Valdunes (formerly Creusot-Loire) Rail Rail Whee Wheell Fac Facto tory ry Indi Indian an Railw Railway ayss (For (Forme merl rlyy Wheel and Axle Plant)
Valenciennes, France Yelahanka, Bagalore, India
LP
Hu ta ta L. W. ( Fo Fo rm rme rlrl y Lu cc cc hi hi ni ni Po la nd nd)
Wa rs rs aw aw, Pol an and
ZB
Bonatrans a.s. (Formerly ZAD)
MKa/ MRF
Makrotek Standard Forged Products
Mexico McKees Rocks, Pennsylvania
Bohumin, Czech Republic
L
a/ No Longer in Production
Fig. C.2 AAR standar standard d marking marking requiremen requirements ts (page 2 of 2) Paragraph Paragraph 20.0
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APPENDIX C
RP-634, Fig. 5.8
NOTES: 1. “I” DIMENSION TOLERANCE TOLERANCE IS +0.015 –0.015. –0.015. 2. MAXIMUM ALLOWABLE ALLOWABLE RUNOUT BETWEEN “G” AND “H” IS 0.006" TOTAL DIAL INDICATOR. INDICATOR. 3. MAXIMUM ALLOWABLE ALLOWABLE RUNOUT BETWEEN “G” AND “I” IS 0.008" TOTAL DIAL INDICATOR. INDICATOR. 4. FOR 7" × 12" JOURNALS, END CHAMFER CHAMFER IS 4° 15' 5/8" ±1/8". 5. REQUIRED FOR PRESS FIT OF ROLLER BEARING BEARING BACKING RING WHERE THE “H” DIAMETER IS TOLERANCED. FINISH TO 125 ΜIN. MAXIMUM WHEN TOLERANCED. 6. THE "W" DIMENSION CANNOT EXCEED THE TOLERANCE TOLERANCE LIMITS OF THE GAUGE SHOWN IN MSRP SECTION G-II, G-II, RP-634, FIG. 5.27. 7. RUNOUT ON JOURNAL SURFACE “G”, WHEN ROTATED ROTATED ON CENTERS, MUST NOT EXCEED 0.015" TOTAL DIAL INDICATOR. 8. DIMENSIONS “B” AND “N” ARE CONSIDERED ENGINEERING ENGINEERING DATA DATA FOR TRUCK DESIGN AND DO NOT NECESSARILY AGREE WITH AXLE MANUFACTURING TOLERANCES. 9. JOURNAL FINISH MUST NOT EXCEED EXCEED 63 ΜIN., IF GROUND OR TURNED ONLY. IF TURNED AND ROLLED, ROLLED, THE TURNED TURNED FINISH MUST NOT EXCEED EXCEED 125 125 ΜIN., AND THE ROLLED FINISH MUST NOT EXCEED 16 ΜIN.
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Fig. C.3 Axle for freight car car roller bearing—raised bearing—raised wheel seat seat (page 1 of 2) Standard 1963; Revised 1984, 1998; Effective March 1, 1985 Paragraph Paragraph 17.5 and Paragr Paragraph aph 25.2
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AAR Manual of Standards and Recommended Practices Wheels and Axles APPENDIX C
M-101
" 8 Y ° 2
" 8 ° 2
" 8 ° 2
" 5 1 ° 4
° 0 1
—
4 " / 4 " / 4 " / " 0 " 8 0 4 1 / 4 1 / 4 1 8 2 . - 1 / - 1 / - / / 1 5 0 X / 1 / — 5 2 0 0 0 ± . 1 1 1 ± + + + " " " 6 " " " 6 6 1 1 4 7 1 / / 1 3 / / 0 5 3 W 1 1 9 2 1 . . 1 0 1 8 1 0 1 8 1 1
S N O I S N E M I D
" 8 V / 7 1
" 2
" U 6 6
" 8 / 1 6 6
—
— " 0 0 0 . 9
" 8 / 1 2 " 8 / 1 6 6
" 4 / 1 2 " 8 / 1 7 6
" 8 / 1 2 " 4 9 2 . 9 6
7 – " 8 / 1 1
7 – " 4 / 1 1
7 – " 8 / 1 1
8 – " 1
7 " 6 1 / 3 1 1
7
7
7
7
" 6 1 / 5 2
" 7 9 3 . 3
3 9 2 . 3
0 0 5 . 3
" 6 1 / 7 6
" 6 1 / 5 1 5
" 3 5 8 . 4
7 5 4 . 4
0 5 7 . 4
" 2 " 6 8 0 . 9 6
" 8 / 1 2 " 0 0 5 . 9 6 7 – " 8 / 1 1
) 2 f o 2 e g " " " 6 " 6 " " " a 6 4 1 8 8 1 8 / / / 1 / / / p / R 3 ( 5 1 5 1 5 1 1 1 t 1 2 2 2 2 1 1 a e " " " " " s " 0 8 8 4 6 l / " / / 5 5 0 . 8 5 1 1 5 e O 1 . 5 . 8 6 9 9 7 e 8 7 8 8 8 8 8 h w " " " " " " " 8 9 9 9 8 9 N 7 d 7 7 7 7 7 7 7 e " " " " " " " s i 2 2 2 2 / 2 2 2 / / / / / / a 1 1 1 1 1 1 M 1 r 2 2 2 2 2 2 2 6 6 6 6 6 6 6 — g " " " " " n 6 6 8 8 8 i 1 / " / 1 " r / / K / 7 3 8 3 8 7 7 a 5 7 7 6 6 e b " " " " " " " r 6 6 6 6 4 8 8 1 / 1 / 1 1 e / / / / J / l 3 7 l 5 9 7 5 9 6 7 o 7 8 7 7 8 r " r " " " " " " 6 a 4 4 2 / 4 4 2 1 / / / / / I / c 1 3 1 3 1 1 9 t 8 8 9 8 8 9 7 h g " 2 0 2 0 2 0 2 0 2 0 2 0 i 8 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 7 8 8 7 7 7 7 7 7 f 6 r o 5 5 5 5 5 5 4 3 5 5 5 5 0 0 f 1 0 1 0 1 0 0 0 1 0 1 0 4 3 9 9 9 9 9 9 0 0 9 9 9 9 0 0 e 1 . 1 . 6 . 6 . 1 . 1 . . . 1 . 1 . 6 . 6 . 5 . 5 . l G 5 5 5 5 6 6 7 7 5 5 6 6 x . 6 6 x n . x . x . a . x . x . A x n x n i n n n n 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 . " " " " " " " C E 3 3 3 3 3 3 3 . g " " " " " " " i 8 8 8 8 8 8 8 / / / / / / F D / 5 5 5 5 5 5 5
9 – T " 8 / 7
8 – " 1
7
7 " 6 1 / 3 1 1 " 6 1 / 5 1 5
" 4 C / 3 1 " 2 B / 1 5 0 1 × 2 / 1 5
1 1 × 6
2 1 × 2 / 1 6
2 1 × 7
9 × 2 / 1 6
8 × 6
9 × 7
I E F I N L O S I X D S A T A A F L C C O
E
F
G
K
L
M
L F A O N R E Z I U O S J
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AAR Manual of Standards and Recommended Practices Wheels and Axles M-101
APPENDIX C
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. SPECIFIED.
Fig. C.4 Pin-type gauge for cap screw screw holes in in ends of roller bearing axles Standard 1979; Revised 1982, 1998
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AAR Manual of Standards and Recommended Practices Wheels and Axles APPENDIX C
M-101
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 ARE RECENTERED, RECENTERED, DIAMETER AND DEPTH MAY MAY BE INCREASED INCREASED SUFFICIENTLY SUFFICIENTLY TO PRODUCE PRODUCE AN ACCURATE ACCURATE 60º CENTER.
Fig. C.5 Axle centering centering and gauge for axle center and lathe center Adopted 1944; Revised 1966, 1979 Paragraph Paragraph 17.2
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