apparent porosity

R e f r a c t o r y :

Apparent porosity & Bulk Density:-

Apparent porosity:

This is the amount of the total closed and open pores in the refractory materials in

percentage.The good refractory material should have a minimum

porosity vale except in the case of the insulation bricks.

Bulk Density:

This is the ration of weight to the volume of the refractory materials in gram/cc.The

good refractory material shouls have a high bulk density value for its better

performance.

Remove the outer layer of the bricks by sample cutting machine.Take the sample size

oe 65x65x40mm and remove the moisture by putting them in air oven at 120 deg.

C.Take out and allowed to cool.Take the dry weight in gm(D).Put the samples in the

vessel containing water.Boil for about one hour.Take out and vipe out the excess water

by a wet cloth.Take the wet weight(W).The the suspended weight while the sample is

immersing in the water.(S)

(W – D)

AP% = x 100

(W-S)

W

BD gm/cc =

(W – S)

Refractoriness under load:-

The resistance of the refractory materials under specified conditions of

load,temperature,time etc.

Take the sample size of 50 mm diameter and 50 mm height(+ / - 0.5 mm) by a RUL

sample cutting machine.Calculate the area in cm2.Put the sample in the RUL testing

machine .Apply the of 2 kg per cm2.Set the dial gauge of 0.01 mm accuracy.Switch on

the RUL furnace to heta the sample.RUL temperature(t 0 C) is the temperature at

which 0.3 mm deformatation take place ie. Measure the temperature when the dedle of

the dial gauge is at 30th

division after deformation taking place.

Pyrometric cone equivalent:-

This is the resistance of the refractory material to soften during service temperature.

2

Take the composite sample of the refractory material in 150 micron size.Remove the

iron by a magnet.Make the PCE sample of a regular tetrahedron of base in 8 mm and

height in 25 mm by using a PCE mould with the help of water and dextrose as a

binder.

Place the sample on a refractory flake along with the standard cone(Ortan/Sekher

cone).Put the flake with the samples in a PCE furnace and raise the temperature.

Standard

Sample

PCE temperature is the temperature at which the sample bend and its tip just tough the

plane of the flake and can measure by a optical pyrometer. This is the comparison test

and can compare with the standard sample. ie. if the standard bends first and the

sample is intact

then the PCE value is + of the standard cone PCE number. If the sample bends first

and the standard is intact then the PCE value is minus of the standard cone number or

if both the sample and standard are bend simultaneously then the PCE value is the

same value of the standard cone number.

Cold Crushing Strength:-

This is the ratio of the breaking load to the area in cm 2 of the refractor materials. The

good refractory material should have high value of the cold crushing strength.

Make the sample of size of 75 mm3 by sample cutting machine.Remove the moisture

the moisture by putting them in a air oven.After air cooling measure the area of the

sample and place the sample in to the ccs machine with the cushion above and below

of the sample.Apply the load and note the crushing load in kg and calculate the CCS

value.

Crushing load

CCS kg/cm2 = kg/cm2

Area of cross section.

Permanent linear change:-

The expansion of the refractory during service temperature in percentage is called as

permanent linear change.

3

Cut the sample of size 125x40 mm by a sample cutting machine and try in an air oven

to remove the moisture. Measure the length of the specimen in mm. Place the sample

in a PLC furnace and switch on the furnace. soak the samples in the specified

temperature for the specified period. Allow the samples to cool in the furnace itself.

After cooling to the room temperature measure the final length of the specimens in the

same location and calculate the PLC value in %

Initial length – Final length

PLC% =. X 100

Initial length

War page:-

This is the bend of the refractory material. The good refractory material should free

from war page.

Place the war page gauge on the bigger area ie. On the surface of 230x115 mm2 of the

ladle brick and measure the bend/war page in mm.

4

P h y s i c a l:

Tensile test:-

This is the ratio of the maximum load per area of the cross section on the tensile test

piece.

Make the tensile sample as per IS-1608/latest.Measure the diameter of the sample and

make two dots apart 5 times of diameter of the test piece. Place the sample in to the

tensile testing machine and apply the load. Note the yield load and the maximum load

and measure the reduced diameter of the broken sample.Calculate the tensile

strength.The sampling frequency shall be one per cast for axles and 1 for 1000,1 for

500 and 1 foro 250 for Box-N,Carriage and loco wheels respectively.

Maximum load

Tensile strength = Kg/mm2

Area of cross section

Final length - Initial length

Elongation% =

(GL-5.64 root A0 ) Initial length

Initial area – Final area

Reduction area % = x 100

Initial area

Micro grain size:-

This is the number of grains per square inch at 100x.

Take the micro sample and grind wheel by a grinding machine. Use the emery papers

of various grades from rough to fine and while changing the next emery paper the

polishing direction should be perpendicular to the previous paper. Use the diamond

paste for final polishing .Clean well by alcohol/dish paper and etch the polished

specimen in 1:1 HCl.After drying check the micro grain size under metallurgical

microscope at 100 magnification. This is the comparison test and compare the grain

size with the standard chart as per IS-2853/latest.

5

Inclusion content:-

This also the comparison test and compare the inclusion rating with the stand chart as

per IS-1463/latest and report as follows. Carry out the test before etching.

Type Thin Thick

Sulphide(A type)

Alumina(B type)

Silicate(C type)

Oxide(D type)

Macro examination.

Take the vertical slice of wheel or axle. Mill it and heat in 1:1 HCl to the temperature

75 - 80 degree centigrade for about half an hour. Take out the etched sample clean by

water and dry. Examine with the naked eye or low magnifying glass of less than

10x.This also a comparison test and compare the macro piece with the standard chart

as per Astm-381/latest.The etched sample should free from crack, non-metallic

inclusion, flake, lap mark, segregation, pipe, pin holes, cavity and any other defects.

Hardness survey:

Take a vertical slice of one inch thickness, mill it and take the indentation by 10 mm

hardened steel ball in presence of 3000 kg load. Measure the diameter of the

indentation by a Brinel microscope and find out the value from the chart of clculate the

values by the following formulae.The sample frequency shall be one in 1000 for Box-

N,one in 500 for Carriage and one in 250 for loco wheels.The hardness values should

be in desending in nature from flange to the hub of the wheel.

2P

BHN =

3.14xD(10 – ( Root D2 - d2)

Where P - Load

D - Diameter of the indenter and

d - diameter of the indentation

Closer test:

This is the indication of the wheel contains a residual compressive stress after

quenching. Mark two points between 100 mm on the flange and the back rim. Take out

a slice of one thickness of a vertical slice by two radial saw cuts in a Do all machine

6

and after taking out the slice for the hardness survey measurer the distance between the

two points. The wheel should close and the minimum closer value should be +1 mm.

Closer test of wheel:

Puch 2 points apart 100mm on the flange

Takeout a wheel slice of 1” thickness by radial saw cut machine(Do all)

Take the final measurement and it shols be +1mm minium.

Hardness of wheel:

Mill both sides of the vertical wheel slice taken out during closer test.

Take BHN indentations by I” gap fron flange to hub of the wheel by a

BHN machine containing 10mm hardened steel ball&3000kgs load.

The hardness value should decreasing in trend from flange to the hub.

Axle.

Ultrasonic testing of axles.

Purposes :

To evaluate the quality of the axles by detecting the discontinuities which are harmful

to the axle service.

Principle:

Pass the ultrasonic sound in to the axle under test from one end face of better surface

finishing of 3.2 micron. The sound rays will penetrate through out the axle and after

reaching the opposite end the sound rays will reflect back t o the home position by the

reflection of the air medium.

Method - Pulse echo method

Equipment used - USD-15S,Khruatkrammer,German make or equivalent.

Normal probe - PZT typeof 20-26 mm diameter and 2 – 2.5 MHz

frequency

of Kruatkrammer,German make or eqivallent.

Low angle probe - Gun assembly contains 1.3,19.3&24.3 degree probes to

detect the the discontinuities in body,up to inner wheel

seat fillet and up to the outer wheel seat fillet

respectively.

Couplant - Grease dissolved in oil

Stage of inspection - Surface finish shall be better than 3.2 micron

7

Standardization:

406

Probe 25

381

Initial echo Back wall

Flaw echo (12.5%)

Place the normal probe just opposite to the 3.2 mm dia artifishal made flat bottom hole

and adjust the gain to get 12.% of the flaw height. Not the gain and is called as FBH

standard gain.

Standardization for Gun assembly:

Probe

6mm saw cut Gun assembly

Initial echo Flaw echo(75% height) Back

wall

8

Place the gun assembly on the standard axle containing 6 mm artifishal saw cut and

adjust the flaw height to 75% and note the gain.It is the standard gain for

Gunassembly scanning.

9

Fax No.0343-2546625

Kind attn to Shri.ChandrasekharRao,CMT,RWF Inspection cell

C/o. R & C Lab. /ASP.

Standardization for radial scanning(As per R-16/’95):

200

3.2

25±2

150

Initial echo Flaw echo(60%) back wall

Range = 250 mm

Place the probe exactly opposite to the artificial flaw of 3.2 mm diameter and adjust

the gain to get 60% flaw height and note the gain. This is called as FBH standard gain

for radial scanning of R-16 / ’95 axles.

10

Fax No.0343-2546625


C/o. R & C Lab. / ASP.

Standardization for radial scanning(As per R-43/’92):

260

3.2

25±2

150

Initial echo Flaw echo(60%) back wall

Range = 400 mm

Place the probe exactly opposite to the artificial flaw of 3.2 mm diameter and adjust

the gain to get 60% flaw height and note the gain. This is called as FBH standard gain

for radial scanning of R-43 / ’92 axles.

11

Fax No.0343-2546625


C/o. R & C Lab./ASP.

Standardization for End – End scanning: (As per R-16’95&R-43/’92)

406

Probe 25

381

3.2(At mid radius)

Initial echo Back wall

Flaw echo (12.5%)

Place the normal probe just opposite to the 3.2 mm dia artificial made flat bottom hole

and adjust the gain to get 12.5% of the flaw height. Note the gain and is called as FBH

standard gain.

(All dimensions are in mm)

12

Fax No.0343-2546625



Standardization for Gun assembly: (As per RWF)

Gun assembly

6mm saw cut Gun assembly

Initial echo Flaw echo(75% height) Back

wall

Place the gun assembly on the standard axle containing 6 mm depth artificial saw cut

and adjust the flaw height to 75% and note the gain.It is the standard gain for

Gunassembly scanning.

13

Fax No.0343-2546625



DAC blocks for drawing DAC curve: As per IRS specifications R-16/’95&R-43/’92)

Zone Length of DAC block in mm Diameter of FBH in mm

I 101.6

177.8

279.4

406.4

3.2

3.2

3.2

3.2,6.4(Use for II zone also

as a first block)

II 533.4

660.4

787.4

6.4

6.4

6.4,9.5(Use for III zone

also as a first block

II 914.4

1041.4

1168.4

9.5

9.5

3.2,6.4,9.5

14

Visual inspection:

Check the face, CTA, Journal, wheel seat and body of the axle visually by naked

eye/low magnifying lens etc. If the axle contains gouge mark, end crack of the defects

due to the RWF’s process make it as defective non-source(S).If the axle is getting

rejected ultrasonically made as UT rejected® and if contains inclusion crack of any

other defects due to the manufacturer of the bloom make it as defective Source(S) and

enter in LAN record.If the defect may go by further machining make it as others(O) or

if it is free from any defects carry out the ultrasonic testing.

Penetrability test:-

Clean the face of the axle and apply the couplant.Do the preliminary adjustments of

the UFD and scan with normal probe.If the wack wall at FBH gain is mere than 25%

further carry out the testing and the penetrability test is ok..If it is <25% mark it for

RHTMore than two RHT is not permitted and the axle is rejected.

Far end scanning:-

Clean the face of the axle and apply the couplant.Do the preliminary adjustments of

the UFD and scan with normal probe&observe any signal between initial and back

wall.If it is due to the shape/geometry of the axle it is ok.If it is due to flaw, reduce the

gain in the setting FBH gain and if it is more the 12.5% amplitude height it is cause for

rejection and enter in LAN as ut rejected®.

Testing by Gun assembly:-

Place the gun assembly on the axle face and rotate slowly at least twice in clock and

another twice in the anti clock directions and observed the ut screen. If there is no flaw

signal the axle is ok and if there is a flaw signal with more than 75% of the amplitude

height at FBH gain is a cause for the rejection.

Manual radial scanning:-

Do the preliminary adjustments and apply the couplant on the axle laterally. Scan and

if the axle is free from the flaw signal it is ok. Otherwise follow the following rejection

norms for the radial scanning of the axle.

a) Flaw signal with more than 60% at FBH gain and more than 2 probe length

on Journal & Wheel seat and more than three probe length on body is cause

for rejection.

b) If the distance between two isolated signals is lesser than 200 mm is a

cause for rejection.

c) More than three isolated signals throughout the axle is a cause for rejection.

d) Flaw signal with 60% of amplitude height provided the location is between

and mod-radius & surface f the axle is cause for rejection.

Manufacture of Box-N axle:

Billet cutting:-

Cut the bloom in 975 +/- 5 mm by saw/gas cutting carefully

Preheating in RHW:-

15

Charge the billets in the RHW and heat to 1150 – 1200 deg C for about 6 hours

Forging:-

Forge the preheated billets by long forging machine

End cutting:-

Remove sufficient discards by gas cutting

Number stamping:-

Stamp the serial number of the axle by automatic stamp punching machine in hot

condition

Intermediate cooling:

Allow the hot axle to cool to 200 - 250 deg. C through the intermediate cooling bed

Heat treatment:

Normalizing:-

Charge the cooled axles at 200 – 250 deg. C in to Normalizing furnace and heat to 840

- 860 deg C for about 6 hours.


Allow the normalized axles to cool to 200 deg. C through the intermediated cooling

bed.

Tempering:-

Charge the air cooled axles to 200 deg. C in to the Tempering furnace at the

temperature of 550 - 640 deg. C for about 8 hours 45 minutes.

Air cooling:-

After tempering allow the tempered axles to air cool for about 24 hours.

Lab. Test:

Take two samples of size 250x25x25 mm size from the center portion of the prolonged

journal portion of the heat treated axle and conduct all the required tests to conform

following requirements as per R-16-/1995.

Physical properties:-

Sl.No. Characteristics Requirements as per R-

16/’95

1 Yield strength N/mm2 Min. 320

2 Tensile strength N/mm2 550 650

3 Elongation% Min. 22

16

(Gl-5.65 root A0 ) Where, Ao - area of

cross section of test piece.

4 Micro grain size @ 100x Not coarser than ASTM

grain size No.5

5 Macro examination Should not reveal any

defects and central

segregation should be

better than C2

6 Micro structure Uniform fine pearlitic

structure

Chemical composition:-

Sl.No. Elements Requirements as per R-

16/’95

1 C% 0.37 + 0.03

- 0.00

2 Mn% 1.12 + 0.06

- 0.00

3 Si% 0.46 + 0.04

- 0.00

4 P% 0.04 + 0.005

- 0.000

5 S% 0.04 + 0.005

- 0.000

6 Cr% 0.3 + 0.05

- 0.00

7 Ni% 0.3 + 0.02

8 Cu% - 0.00

9 Mo% 0.05 + 0.00

- 0.00

10 V% 0.05 + 0.00

- 0.00

Machining of the axle:-

a. Cup turn,end mill and make the lathe center bore.

Number stamping:-

Punch the serial No. and Cast No. of the axle manually on the axle face.

Ultrasonic testing:-

Scan the axle ultrasonically thoroughly and if the axle is passing allow to further

machining by putting the UT stamp on the axle number face.

17

Further machining:-

b. Rough turn the axle

c. Semi finishing of the axle except body

d. Body finishing

e. Finishing of the axle except body

f. Drilling, tapping and recentering of the axle

g. Furnishing of wheel seat

h. Centreless grinding of journal, dust guard etc.

Magnetic particle testing of axle:-

Conduct the MPT of the axle and if it is passed allow the passed axle for pressing by

putting the MPT stamp on the axle face opposite to the UT stamp.

Magnetic Particle Testing of axle:(MPT)

Equipment used:

Magnaflux,USA make of DH 5455 model.

Current used:

Half wave DC for coil&Contact magnetization

AC for Demagnetisation

Current used for

Coil magnetization = 1200 Amps.

Contact magnetization = 1800 Amps.

Demagnetization = 3000 Amps.

Bath oil = MX-MG Carrier Oil-II supplied by M/s.ITW Signode,Hyderabad.

MPT Powder = Magnaflux-14A supplied by M/s.ITW Signode,Hydreabad.

Amount of powder per litre = 1.25 gram/litre.

Concentration of the bath = 0.2 - 0.30 ml/100 ml after half an hour.

Watt of the UV lamp = 100 watt.

Intensity of the UV lamp = 525 micro watt/centimeter square.

Principle:

Magnetize the axle under test.Magnetic force of lines will develop.Spray the bath containing containing

iron particle coated with flourescent material.If there is a defect,the magnetic force of lines will leak

i.e. leakage of magnetic flux arround the defect and attract more particle around the defect and can seen

under UV lamp.

Coil magnetization:

Place the coil over wheel seat and pass the current through the coil to develop longitudinal field.Spray the.

bath and after few seconds inspect under UV lamp to detect the verticle discontinuities.The discontinuity

will develop polority and will attract more powder arround the defect and can seen under UV lamp.If the defect

may go by re work mark for rework.

Contact magnetization:

Press the contact pad and pass the current through the axle to develop circular magnetic field to detect the

longitidinal discontinuities.Spray the bath and inspect under UV lamp as above.

Demagnetization:

Press the contact pad and pass the AC current through the axle to demagnetize the magnetized axle.The

residual magnetic field shall be plu or minus 5 gauss.

Imperfections not permisciple:

1. Any type of verticle,circumferential discontinuities any where on the axle not permitted.

2 Any type of discontinuities on the fillet not permitted.

18

Imperfection permiciple:

Journal:

Heat diagram of Box-N axle:

Heat diagram of BGD axle:

19

Iron - Carbon System

1600

Liquid

Delta iron

1539

Delta iron + Liquid

0.53%

0.08% Austenite Liquid

1490 +

Cemintite

Austenite+Liquid

1400

Liquid+

Austenite+ Austenite 1146 oC

Delta

T Austenite+Ferrite Austenite Cemintite

e 910 + +

m Aus+ Ledeburite Ledeburite

p 768 Cemin +

e tite Cemintite

r 727 oC

20

a oC

t 0.02%

u P

r e Pearlite

e a +

Ferrite r Transform- Cemintite

l ed Ledebu- +

Pearlite + i Pearl- rite + Ledeburite

Ferrite t ite + Cementite

e Fe3C

0 0.8 2 4.3 6.67

Steel Cast Iron

Hypo Hyper Hypo Hyper

Eutectoid Eutectoid Euectic Eutectic

Carbon% wt

Fe-C system is a graphic representation of various transformation of carbon % weight at various

temperatures.

Phases: Ferrite:- It is an interistial solid solution in which carbon in BCC iron .The maximum solubility is 0.02%

maximum at 227 degree centigrade. It exists from 910 degree centigrade to minus 273 degree centigrade.

Austenite: It is an interstitial solid solution of carbon in FCC iron. The maximum solibility is 2.1 % at 1146

degree centigrade.

Delta iron:

It is an interstitial solid solution of carbon in BCC iron. The maximum solibility is 0.08 % at 1400 degree centigrade.

It is from 1539 degree centigrade which is the melting point of iron to 1400 degree centigrade.

Pearlite:

This an alternative arrangement of parallel plates of ferrite and cemintite

Cemintite:

It is an intermetalic compound represented by the formula Fe3O4.the structure is orthorhombic and the number of

atom is 25% but the C weight % is 6.67.Hence after 6.67% of carbon the Fe-c system is not extended.

Transformations:

Iron-Carbon System:

21

The various transformations place in Fe-C system is as follows.

1.Feritectic reaction:

Reaction Delta iron + Liquid Gama iron

Structure BCC -- FCC

C% wt. 0.08 0.53 2.1

Liquid and delta irons react together and forms austenite at 1400 degree centigrade temperature.

2.Eutectic reaction:

Reaction

Liquid

Austenit

e + Cemintite

Structure -- FCC Ortorhombic

C% wt. 4.3 2.1 6.67

Liquid iron will become austenite and cemitite on cooling at 1146 degree centigrade temperature.

3.Eutectic reaction:

Reaction Austenite + Ferrrite + Cemintite

Structure FCC BCC

Orthorhombic

C% wt. 0.80 0.02 6.67

Critical temperatures:

These are the temperatures at which various transformations tking place and are as follows.

1.Gama iron will become ferrite and cemintite on cooling at 727 degree centigrate and represened

by the symbols A,c,r etc., On slow cooling Ac1=Acr=727 degree centigrade.

On normal cooling there is thermal hysterisis and Ac1>Acr.

2.The next higher is curie temperature of ferrite iron & represented by the symbol A2 and is 768

degree centigrade at which

frrrite will undergo magnetic transition from ferro to para magnetic stage.

3.The temperature corresponds to the phases Gama+ferrite/gama iron is A3 and it is steeper

degreses from 910 degree

centigrade to 727 degree centigrade.Unlike A1 this is function of carbon % weight.

4.The temperature corresponds to the phase Gama iron+cemintite/gama iron is ACM and is increased

from 727 to 1146 degree

centigrades.This also a function of carbon % weight.

5.The curie temperature of ferrite is A0 and is 210 degree centigrade.

Micro structure of steel:

22

1.Eutectiod steel:

The structure is pearlite and the chemical composition is '0.80% C weight. The amount of ferrite &

cementite can be calculated By lever rule and is as follows.

6.67 - 0.80

Ferrite% = x 100 =

88.3

6.67 - 0.02

0.80 - 0.02

Cementite= x 100 =

11.7

6.67 - 0.02

or

100 - 88.3 = 11.7%

2.Hypo eutectoid steel:

The chemistry is < 0.80 % c weight.For example in 0.2% C steel the amount of

consitituents in 0.2 % C weight are '0.80 - 0.2

Ferrite% = x 100 = 76.9

0.80 - 0.02

'0.20 - 0.02

Pearlite % =

x 100 = 23.1

'0.80 - 0.02

3.Hyper eutectic steel:

The chemistry is '0.80 - 2.1 % C weight.In 1.2% Carbon steel the amont of consistituents are ' 6.67 - 1.2 Pearlie % =

x 100 = 93.2 6.67 - 0.80 Cemintite = 100 - 93.2 = 6.8

Wheel defects:-

Defect Code Description

3 Off analysis

8 Low Brinell

9 Tramp elements

10 Crack&Checks

12 Ceramic-Metal-Refractory

13 Slag

15 Pin holes

16 Ultrasonic

23

20 Rabit ears(Sand expansion)

30 Off center hub cut

31 Wrong hub cut

32 Gough bore

33 Hole in bore

35 Goughed riser

38 Damaged stampimg

39 Unknown heat number

40 Gas hole in tread

42 Thin flange

43 Wrong mould machining

44 Insufficient spray

45 Hole in riser

46 Pocker

47 Eroded mould

48 Pin at apex

49 Mould shift

50 Poured short

51 LAP

52 Clusters of small holes on rim

53 Gas holes in rim

54 Hollow sprue

55 Shrinkage riser stubs

56 Hollow hub face

57 Swollen beads

58 Run out

59 Closed down wrong

60 Stopper broken

61 Run back

62 Mould inclusions

63 Defective tube

64 Porous sprue

65 Buckled pad

66 Hollow hub feeding

67 Defective core

68 Depressed pad

70 Dela processing

71 War page

72 Spoiled normalizing

73 Spoiled handling

90 Spoiled mounting

91 Spoiled grinding

92 Spoiled machining

93 Spoiled mechanical

94 Spoiled power

24

95 Spoiled electrical

96 Experimental

97 Obsolete

98 Missing

99 New design

121 Black, gray tube inclusion

122 Small,irregula,combined brown

123 Splatter of 122

124 Refractory

125 Defective tube

126 Unknown

128 Small red orange

129 Blowing tube

131 Slag on tread

135 Pin in slag

138 Furnace slag

139 Slag splatter

621 Spray

622 Asbestos

623 Rat tail(Seams in throat)

624 Graphite or sand

625 Spray or sand

626 Graphite

627 Fused sand

628 Raw sand

629 Sand splatter

25

Specifications:

Specn. Analysis H2 N2 Red.Ratio C% Mn% Si% S% P% S+P% Cr% Ni% Cu% Mo% V% UTS YS Min.

E%(GL= 5.65 root A0

GS @ 100x

Macro

R-16/95

LA 3 PPM Max.

70 PPM Max.

2-1/Ingot - Bloom 1.5-1/ Ingot-bloom provided 5-1/ ingot axle 3-1/ Ingot-axle 3-1/ Concast bloom-axle

0.37 Max.

1.12 Max.

0.46 Max.

0.04 Max.

0.04 Max.

0.07 Max.

0.3 Max.

0.3 Max.

0.3 Max.

0.05 Max.

0.05 Max.

550-650 N/ mm

2

320 N/ mm

2

22 % Min.

Not coarser than 5 @100x

Better

than

C2&No

any

other

defects

PA(Over LA the following shall be permitted)

-- -- 2-1/Ingot - Bloom 1.5-1/ Ingot-bloom provided 5-1/ ingot axle 3-1/ Ingot-axle 3-1/ Concast bloom-axle

+0.03 - 0

+0.06 - 0

+0.04 - 0

+0.005 - 0

+0.005 - 0

-- +0.05 -0

+0.05 -0

+0.02 -0

-- +0.02 -0

-do- -do- 22 -do- -do-

R-43/92

LA / Ctategory-A

2 PPM Max.

70 PPM Max.

2-1/Ingot - Bloom 3-1/ Ingot-axle 1.5-1/ Ingot-bloom provided 5-1/ ingot axle

0.40-0.55

0.60-0.90

0.15 Min.

0.05 Max.

0.045 Max.

-- -- -- -- -- -- 570-685 N/mm2

50% of UTS Min.

17-21 6-8 @100x

-do-


-- -- 2-1/Ingot - Bloom 3-1/ Ingot-axle 1.5-1/ Ingot-bloom provided 5-1/ ingot axle

+/-0.03 Max.

+/-0.03 Max.

+0.0 -0.15

+0.005 +0.005 -- -- -- -- -- -- -do- -do- -do- -do- -do-

R-19(III) /1995

LA 3 PPM

70 PPM

-- 0.57-0.67

0.60-0.80

0.40 Max.

0.03 Max.

0.03 Max.

-- 0.15 Max.

0.25 Max.

-- 0.06 Max.

-- 930 N/mm2 Min./ Rim

50% of UTS Min.

4.5 Min. -- -do-

PA -- -- -- +0.03 –0.02

0.01 0 +0.005 - 0

+0.005 - 0

-- 0.05 0.05 -- +0.02 -- -- -- -- -- -do-

Specn. Analysis H2 N2 Red.Ratio C% Mn% Si% S% P% S+P% Cr% Ni% Cu% Mo% V% UTS YS Min.

E%(GL= 5.65 root A0

GS @ 100x

Macro

R-16/95

LA 3 PPM Max.

70 PPM Max.

2-1/Ingot - Bloom 1.5-1/ Ingot-bloom provided 5-1/ ingot axle 3-1/ Ingot-axle 3-1/ Concast bloom-axle

0.37 Max.

1.12 Max.

0.46 Max.

0.04 Max.

0.04 Max.

0.07 Max.

0.3 Max.

0.3 Max.

0.3 Max.

0.05 Max.

0.05 Max.

550-650 N/ mm

2

320 N/ mm

2

22 % Min.

Not coarser than 5 @100x

Better

than

C2&No

any

other

defects


-- -- 2-1/Ingot - Bloom 1.5-1/ Ingot-bloom provided 5-1/ ingot axle 3-1/ Ingot-axle 3-1/ Concast bloom-axle

+0.03 - 0

+0.06 - 0

+0.04 - 0

+0.005 - 0

+0.005 - 0

-- +0.05 -0

+0.05 -0

+0.02 -0

-- +0.02 -0

-do- -do- 22 -do- -do-

R-43/92

LA / Ctategory-A

2 PPM Max.

70 PPM Max.

2-1/Ingot - Bloom 3-1/ Ingot-axle 1.5-1/ Ingot-bloom provided 5-1/ ingot axle

0.40-0.55

0.60-0.90

0.15 Min.

0.05 Max.

0.045 Max.

-- -- -- -- -- -- 570-685 N/mm2

50% of UTS Min.

17-21 6-8 @100x

-do-


-- -- 2-1/Ingot - Bloom 3-1/ Ingot-axle 1.5-1/ Ingot-bloom provided 5-1/ ingot axle

+/-0.03 Max.

+/-0.03 Max.

+0.0 -0.15

+0.005 +0.005 -- -- -- -- -- -- -do- -do- -do- -do- -do-

R-19(III) /1995

LA 3 PPM

70 PPM

-- 0.57-0.67

0.60-0.80

0.40 Max.

0.03 Max.

0.03 Max.

-- 0.15 Max.

0.25 Max.

-- 0.06 Max.

-- 930 N/mm2 Min./ Rim

50% of UTS Min.

4.5 Min. -- -do-

PA -- -- -- +0.03 –0.02

0.01 0 +0.005 - 0

+0.005 - 0

-- 0.05 0.05 -- +0.02 -- -- -- -- -- -do-

Parts of the axle.

Body

Inner

W/s fillet

Wheel

seat

CTA

LCB

Face

Journal

Outer

w/s

fillet

Axle flow chart.

ON LINE ULTRASONIC TESTING OF CAST STEEL WHEELS MANUFACTURED

AT RWF

Introduction

All the cast wheels shall be ultrasonically tested with minimum of 6 transducers in two

directions (radially and axially) through rim section in accordance with IRS R-19/1993

(Part III). The Calibration reference standard and rejection level of each wheel design is

established by making test set-up wheel. Procedure for ultrasonic testing of cast steel

wheels are followed as laid down in the relevant specification.

Standardization of Ultrasonic testing system is carried out in the beginning of each shift

or whenever there is a break down or any change of component in on line system or

change in wheel design under process.

The custom built ultrasonic system is in compliment with the production process to detect

all possible casting defects in rim section of the wheel.

Ultrasonic scanning system

In casting of wheels by controlled pressure pouring technique, defects like shrinkage

porosity, gas holes etc., which occur during solidification within the rim section. In RWF

the ultrasonic testing methodology employed is automatic on line immersion technique in

water medium incorporating 6 transducers connected to a microprocessor based multi-

channel computer controlled scanning system.

Preheating

at RHF (1150

-1200)

Forging by

LFM(1100

-900)

Normalizing

(1150-1200

deg. C

Cooling

Billet cutting

by Gas/Saw

cutting)

Cooling Temp-

ering(550-

640)

CTA, LCB&End

Milling

Lab.

testing

Air

cooling

UT

Further

machining

MPT Assembly

28

Convergent beam Transducers of 2.25MHz & 5.0MHz frequency and 20 mm crystal

diameter are employed. Each transducer is identified as 1A, 2A, 3A, 1B, 2B & 3B.

Transducer 1A(2.25MHz) – is focused axially closer to tread for detecting defects

like gas holes below the front rim face and closer to tread.

Transducer 1B(2.25MHz) – is adjusted axially for detecting gas holes that may

occur below the front rim face farther away from tread and for cavities below the

sprue area.

Transducer 2A(5.0MHz) – is adjusted radially located below the tread for detecting

defects at the central line.

Transducer 2B(5.0MHz) – is focused radially located below the tread for detecting

defects at 1/8” away from the central line towards back rim.

Transducer 3A(5.0MHz) – is adjusted axially through front rim for detecting

defects at the central line.

Transducer 3B(5.0MHz) – is adjusted radially located below the tread for detecting

defects below the sprue.

All above 6 transducers are assembled in manipulator probe assembly immersed in tank

containing continuous flow of water.

Test Set Up

An ultrasonic standard test wheel of each design is fabricated by saw cutting the rim

cross-section and artificial reference holes of 1/8”dia ½” length are introduced at

shrinkage co-ordinates of the respective locations. Slices are welded back to match the

original profile of the wheel.

The above wheel is used as a standard-set-up-wheel for setting up probes so as to achieve

maximum response from the artificially drilled holes in the wheel rim.

Sensitivity of the equipment is set by using UT standard manufactured from the same

design wheel with 1/8” flat bottom hole, which will not be disturbed during the normal

testing process.

Testing System

RWF has employed microprocessor based computer controlled automatic on-line

ultrasonic system, which consists of basic ultrasonic machine, multiplxer, oscilloscope,

and computer with dedicated custom built software. The whole system is inter-linked

with PLC for communication and control. The Speed of the wheel is kept at 4 rpm and

minimum of 2 revolutions for a complete test cycle is ensured for every wheel. All the

testing parameters are displayed on screen and reference location is measured by the help

of an encoder. During the test, any signal from the defect location exceeding the set level

will be indicated on the screen as “REJECTED” and wheel stops automatically.

Inspectors ensure the defect & location manually and send the wheel to the scrap line.

29

Other wise, wheel automatically deemed as “PASSED” by the system and moves for

further processing. Ultrasonic status of the all the wheels tested is entered into the LAN

for record.

Equipment in use

Presently RWF is using 2 customized ultrasonic testing system designed and supplied by

M/s ULTRASONIC SCIENCES LIMITED

Unit 4-Spring Lakes Industrial Estate

GU-12 4 UH, Dead brook lane, Aldershot

Hampshire, ENGLAND

Tel: +44(0) 1252350550

Fax: +44(0) 1252350445

E-mail:[email protected]

Website:http://www.ultrasonic-sciences.co.uk

Ferro alloy calculation:

Points to be added x Tonnage of liquid metal x 10 Qty to be added= --------------------------------------------------------------

Efficiency of alloy

35 pts x 20 x 10 7000

For any alloy = -------------------------------------- = -------------

70% 70

= 100 kgs

100 kg of ferro

alloy to be added to raise 35 pts with 70 % efficiency

Conversely for 35 pts recovery (Recovery is 100%)

Accordingly recovery can be calculated.

30

Spray Mix – 100 lb. Batch – 35O Baume.

Ingredients:

CMC – 0.1% of the weight of fused Silica, 2 bags weighing 22.7 grams etch.

Veegum-T – 1.0% of the weight of Fused Silica, 3 bags weighing 152 grams each.

30 Micron Fuses Silica – 100 lbs (45,400 gms)

Formaldehyde – 120 ml (optional, depending on bacteria levels

Hot water – used with initial CMC or Veegum mixture, allows materials to go into solution more

readily.

Mixing Instructions:

a) To a clean mixing tank add 8 gallons of water. A permanent mark shall bemade on a rod

that relates 8 known gallons of water to a certain depth in the mixing tank. Turn mixer

on.

It is imperative that the mixing tank be thoroughly clean and completely empty.

Absolutely no spray mixture should remain in the tank from a previous batch.

b) Add 1 gallon of water to the specified mixing bucket. Turn waring blender on and add 1

bag (22.7 grams) of CMC powder slowly and uniformly to the water, while the agitator is

continuously in operation. Mix fore a minimum of 2 minutes, making sure that the CMC

is completely dissolved and free of lumps. Add this mixture to the larger mixing tank.

c) Repeat the above operation (b), using one gallon of water and 22.7 grams of CMC.

d) To the appropriate mixing bucket add 1 gallon of water and 1 bag (152 grams) of

Veegum-T, Mix for a minimum of 1 minute or until the Veegum-T is completely

dissolved and free of lumps.

e) Repeat the above operation (d), using one gallon of water and 1 bag (152 grams) of

Veegum T.

f) Repeat the above operation (d), using one gallon of water and 1 bag (152

grams) of Veegum-T.

g) After all the premixed CMC and Veegum-T has been added to the large mixing tank, wait

5 additional minutes before adding the fused silica. Each of the two 50 lb. Bags shall be

added separately and not until the prior bag has gone into solution. The lightening mixer

must be in operation at all times. Any paper from the bags that falls into the tank must be

removed.

h) After above solution has been mixed for 5 minutes, add 120 ml of

formaldehyde.

31

i) With the Baume instrument, measure the density of the spray

mixture. Adjust the consistency of the solution to 35O

- 40O Baume. (Baume may

be different from plant to plant depending non gun distance from mold and other

variables. This difference shall be verified through the Operating Department). If

the Baume is too high, add water slowly, and carefully bring down the Baume

within limits. If the Baume is too low, add Fused Silica slowly and carefully bring

up the Baume within limits. Determine the proper amount of water to add to the

mixing tank (in part (a)) in order to obtain a consistent Baume on the final spray

mixtures from batch to batch.

j) The Baume shall be recorded on the 302’s for the molds being sprayed.

6B. Mold Spray mix – 100 lb. Batch – 36O

Baume (Alternate method).

Ingredients:

CMC –0.1% OF THE WEIGHT OF fuses Silica, 1 bag weighing 45.4 grams.

Veegum – T – 1.0% of the weight of Fused Silica, 1 bag weighing 454 grams.

30 Micron Fuses Silica – 100 lbs. (45,400 gms).

Formaldehyde – 120 ml (optional depending on bacteria levels).

Hot water – used with initial CMC and Veegum Solution.


a) To a large clean mixing tank add 7 gallons of water. A permanent mark shall be made on

rod that relates 7 known gallons of water to a certain depth in the mixing tank. Turn

mixer on.

It is imperative that the mixing tank be thoroughly clean and completely empty.

Absolutely no spray mixtures should remain in the tank from a previous hatch.

a) Add 3 gallons of water to a mixing bucket (Detail-D) or sufficient water to bring

water level upto a known marker. Turn Waring Blender on and add 1 bag (45.4 grams) of

CMC powder slowly and uniformly to the water while the agitator is continuously in

operation. Mix for a minimum of 5 minutes making sure that the CMC is completely

dissolved and free of lumps. Add this mixture to the larger mixing tank.

a) To the mixing bucket add 3 gallons of water (or sufficient water to bring water

level upto a known marker) and add 1 bag (456 grams) of Veegum-T. Mix for a

minimum of 5 minutes or until the veegum-T is completely dissolved and free of lumps.

Again the mixer should be turning prior to adding the Veegum-T in a slow and uniform

manner. Add this mixture to the larger mixing tank.

a)

After all the premixed CMC and Veegum-T have been added to the large mixing tank,

wait 5 additional minutes before adding the Fused Silica. Each of the two 50 lb. Bags

shall be added separately and not until the prior bag has gone into solution. The lightning

mixer must be in operation at all times. Any paper from the bags that fall into the tank

must be removed.

32

a) After above solution has mixed for 5 minutes, add 120 ml of formaldehyde.

b) With Baume instrument, measure the density of the spray mixtures. Adjust

the consistency of the solution to 35O - 40

O Baume. (Baume may be different

from plant to plant depending on gun distance from mold and other variables.

This difference shall be verified through the Operating Department). If the

Baume is too high, add water slowly and carefully bring down the Baume

within limits. If the Baume is too low, add Fused Silica slowly and carefully

bring up the Baume within limits. Determine the proper amount of water to

add to the mixing tank (in part (a)) in order to obtain a consistent Baume on

the final spray mixture from batch to batch.

c) The Baume shall be recorded on the 302’s for the molds being sprayed.

7A. Mold Spray mix – 125 lb Batch – 36O Baume

CMC –0.1% OF THE WEIGHT OF fuses Silica, 2 bags

weighing 28.4 grams.

Veegum – T – 1.0% of the weight of Fused Silica, 3 bags

weighing 190.0 grams each.


Formaldehyde – 150 ml (optional depending on bacteria

levels).



a) To a large clean mixing tank add 11.25gallons of water. A

permanent mark shall be made on rod that relates 11.25 known

gallons of water to a certain depth in the mixing tank. Turn mixer

on.

It is imperative that the mixing tank be thoroughly clean and completely

empty. Absolutely no spray mixtures should remain in the tank from a

previous hatch.

a) Add 1 gallons of water to a appropriate mixing bucket. Turn Waring Blender

on and add 1 bag (28.4 grams) of CMC powder slowly and uniformly to the

water while the agitator is continuously in operation. Mix for a minimum of 2

minutes making sure that the CMC is completely dissolved and free of lumps.

Add this mixture to the larger mixing tank.

c) Repeat the above operation (b), using 1 gallon of water and 1 bag (28.4 grams) of

CMC.

d) To the small mixing bucket add 1 gallons of water and add

1 bag ( 190.0 grams) of Veegum-T. Mix for a minimum of 1

33

minute or until the veegum-T is completely dissolved and free of

lumps. Again the mixer should be turning prior to adding the

Veegum-T in a slow and uniform manner. Add this mixture to the

larger mixing tank.

a) Repeat operation (d), using 1 gallon of water and 1 bag (190.0 grams) of

Veegum-T.

b) Repeat operation (d), using 1 gallon of water and 1 bag (190.0 grams) of

Veegum-T.

g) After all the premixed CMC and Veegum-T have

been added to the large mixing tank, wait 5 additional minutes

before adding the Fused Silica. Each of the two 50 lb. Bags shall

be added separately and not until the prior bag has gone into

solution. The lightning mixer must be in operation at all times.

Any paper from the bags that fall into the tank must be removed.

d) After above solution has mixed for 5 minutes, add 150 ml of formaldehyde.

e) With Baume instrument, measure the density of the spray mixtures. Adjust

the consistency of the solution to 35O - 40

O Baume. (Baume may be different

from plant to plant depending on gun distance from mold and other variables.

This difference shall be verified through the Operating Department). If the

Baume is too high, add water slowly and carefully bring down the Baume

within limits. If the Baume is too low, add Fused Silica slowly and carefully

bring up the Baume within limits. Determine the proper amount of water to

add to the mixing tank (in part (a)) in order to obtain a consistent Baume on

the final spray mixture from batch to batch.

f) The Baume shall be recorded on the 302’s for the molds being sprayed.

34

7B. Mold Spray mix – 125 lb Batch – 36O Baume




weighing 568 grams each.



levels).



a) To a large clean mixing tank add 10.25 gallons of water. A

permanent mark shall be made on rod that relates 10.25 known

gallons of water to a certain depth in the mixing tank. Turn mixer

on.



previous hatch.

b) Add 1 gallons of water to a appropriate mixing bucket

(Detail-D) or sufficient water to bring water level upto a known

marker. Turn Waring Blender on and add 1 bag (56.8 grams) of

CMC powder slowly and uniformly to the water while the agitator

is continuously in operation. Mix for a minimum of 2 minutes

making sure that the CMC is completely dissolved and free of

lumps. Add this mixture to the larger mixing tank.

c) To the mixing bucket add 3 gallonss of water are sufficient

water to bring water level upto a known marker)and add 1 bag (

568.0 grams) of Veegum-T. Mix for a minimum of 5 minute or

until the veegum-T is completely dissolved and free of lumps.

Again the mixer should be turning prior to adding the Veegum-T in

a slow and uniform manner. Add this mixture to the larger mixing

tank.

d) After all the premixed CMC and Veegum-T have






e) After above solution has mixed for 5 minutes, add 150 ml of formaldehyde.

35

f) With Baume instrument, measure the density of the spray mixtures. Adjust the

consistency of the solution to 35O - 40

O Baume. (Baume may be different from plant to plant

depending on gun distance from mold and other variables. This difference shall be verified

through the Operating Department). If the Baume is too high, add water slowly and carefully

bring down the Baume within limits. If the Baume is too low, add Fused Silica slowly and

carefully bring up the Baume within limits. Determine the proper amount of water to add to the

mixing tank (in part (a)) in order to obtain a consistent Baume on the final spray mixture from

batch to batch.

g) The Baume shall be recorded on the 302’s for the molds being sprayed.

36

8A. Mold Spray mix – 200 lb Batch – 36O Baume

Ingredients:

CMC –0.1% OF THE WEIGHT OF fuses Silica, 4 bags weighing 22.7 grams.

Veegum – T – 1.0% of the weight of Fused Silica, 3 bags weighing 152 grams each.

30 Micron Fuses Silica – 4 bags weighing 50 lbs each or a total weight of 200 lbs. (90,800 gms).

Formaldehyde – 240 ml (optional depending on bacteria levels).



a) To a large clean mixing tank add 16 gallons of water. A permanent mark shall be made

on rod that relates 16 known gallons of water to a certain depth in the mixing tank. Turn mixer

on.

It is imperative that the mixing tank be thoroughly clean and completely empty. Absolutely no

spray mixtures should remain in the tank from a previous hatch.

b) Add 1 gallons of water to a appropriate mixing bucket. Turn Waring Blender on and add

1 bag (22.7 grams) of CMC powder slowly and uniformly to the water while the agitator is

continuously in operation. Mix for a minimum of 2 minutes making sure that the CMC is

completely dissolved and free of lumps. Add this mixture to the larger mixing tanks.

b) Repeat the above operation (b), using 1 gallon of water and 22.7 grams of CMC.

b) Repeat the above operation (b), using 1 gallon of water and 22.7 grams of CMC.

c) Repeat the above operation (b), using 1 gallon of water and 22.7 grams of CMC.

d) To the appropriate mixing bucket add 1 gallons of water and add 1 bag ( 152.0

grams) of Veegum-T. Mix for a minimum of 1 minute or until the veegum-T is

completely dissolved and free of lumps.

c) Repeat operation (f), using 1 gallon of water and 1 bag (152.0 grams) of

Veegum-T.

d) Repeat operation (d), using 1 gallon of water and 1 bag (152.0 grams) of

Veegum-T.

e) Repeat operation (d), using 1 gallon of water and 1 bag (152.0 grams) of

Veegum-T.

f) Repeat operation (d), using 1 gallon of water and 1 bag (152.0 grams) of

Veegum-T.

g) Repeat operation (d), using 1 gallon of water and 1 bag (152.0 grams) of

Veegum-T.

37

l) After all the premixed CMC and Veegum-T have






m) After above solution has mixed for 5 minutes, add

240 ml of formaldehyde.

n) With Baume instrument, measure the density of the

spray mixtures. Adjust the consistency of the solution to 35O - 40

O

Baume. (Baume may be different from plant to plant depending on

gun distance from mold and other variables. This difference shall

be verified through the Operating Department). If the Baume is too

high, add water slowly and carefully bring down the Baume within

limits. If the Baume is too low, add Fused Silica slowly and

carefully bring up the Baume within limits. Determine the proper

amount of water to add to the mixing tank (in part (a)) in order to

obtain a consistent Baume on the final spray mixture from batch to

batch.

o) The Baume shall be recorded on the 302’s for the molds being sprayed.

8B. Mold Spray mix – 200 lb Batch – 36O Baume(Alternate method)

Ingredients




weighing 454 grams each.

30 Micron Fuses Silica – 4 bags weighing 50 lbs each or a total

weight of 200 lbs. (90,800 gms).


levels).



a) To a large clean mixing tank add 16 gallons of water. A

permanent mark shall be made on rod that relates 14 known gallons

of water to a certain depth in the mixing tank. Turn mixer on.



previous hatch.

38

b) Add 3 gallons of water to a appropriate mixing bucket or

sufficient water to bring water level upto a known marker. Turn

Waring Blender on and add 1 bag (45.5 grams) of CMC powder

slowly and uniformly to the water while the agitator is continuously

in operation. Mix for a minimum of 5 minutes making sure that the

CMC is completely dissolved and free of lumps. Add this mixture

to the larger mixing tank.

a) Repeat the above operation (b), using 1 gallon of water and 45.5 grams of CMC.

d) To the mixing bucket add 3 gallons of water or sufficient

water to bring water level upto a known maker and add 1 bag (

454.0 grams) of Veegum-T. Mix for a minimum of 1 minute or

until the veegum-T is completely dissolved and free of lumps.

Again the mixer should be turning in a slow and uniform manner

prior to adding the Veegun-T. Add this mixture to the larger

mixing tank.

e) Repeat operation (f), using 1 gallon of water and 1 bag

(152.0 grams) of Veegum-T.

f) After all the premixed CMC and Veegum-T have been

added to the large mixing tank, wait 5 additional minutes before

adding the Fused Silica. Each of the two 50 lb. Bags shall be added

separately and not until the prior bag has gone into solution. The

lightning mixer must be in operation at all times. Any paper from

the bags that fall into the tank must be removed.

g) After above solution has mixed for 5 minutes, add 240 ml

of formaldehyde.

h) With Baume instrument, measure the density of the spray

mixtures. Adjust the consistency of the solution to 35O - 40

O

Baume. (Baume may be different from plant to plant depending on

gun distance from mold and other variables. This difference shall

be verified through the Operating Department). If the Baume is too

high, add water slowly and carefully bring down the Baume within

limits. If the Baume is too low, add Fused Silica slowly and

carefully bring up the Baume within limits. Determine the proper

amount of water to add to the mixing tank (in part (a)) in order to

obtain a consistent Baume on the final spray mixture from batch to

batch.

i) The Baume shall be recorded on the 302’s for the molds being sprayed.

39

2. Typical Mixes to Obtain 29-33 Baume with 15 Micron Min-U-Sil.

15

Micron

Min U

Sil

Total Quantities

ML

FORMAL

DEHYDE

Order of Addition

15

Micron

Min-U-

Sil

ML

Formal

Dehyde

Gals

Water

GRS

CMC

GRS

Veegum

Gals

Water

In

tank

GRS

CMC

+

1 Gal.

Water

GRS

Veegum

+ 1 Gal.

Water

10 2.0 4.54 45.6 12 0 4.54 45.6 10 12

20 3.8 0.09 91.2 24 1.8 9.08 91.2 20 24

30 5.7 13.6 136.8 36 3.7 13.62 136.8 30 36

40 7.6 18.16 182.4 48 5.6 18.16 182.4 40 48

50 0.5 22.70 228.0 60 6.5 22.70 114.0

114.0

50 60

60 11.4 27.24 273.6 72 8.4 27.24 136.8

136.8

60 72

70 13.3 31.78 319.2 84 9.3 15.89

15.89

159.6

159.6

70 84

80 15.2 36.32 364.8 96 11.2 18.16

18.16

182.4

182.4

80 96

90 17.1 40.86 410.4 108 12.1 20.43

20.43

136.8

136.8

136.8

90 108

100 19.0 45.40 456.0 120 14.0 22.70

22.70

152.0

152.0

152.0

100 120

110 20.9 49.94 501.6 132 15.9 24.97

24.97

167.2

167.2

167.2

110 1332

120 22.8 54.48 547.2 144 17.8 27.24

27.24

182.4

182.4

182.4

120 144

130 24.7 59.02 592.8 156 19.7 29.51

29.51

197.6

197.6

197.6

130 156

140 26.6 63.56 638.4 168 19.6 21.19

21.19

21.19

159.6

159.6

159.6

140 168

150 28.5 68.10 684.0 180 21.5 22.70

22.70

22.70

171.0

171.0

171.0

171.0

150 180

160 30.4 72.64 729.0 192 23.4 24.21

24.21

24.21

182.4

182.4

182.4

182.4

160 192

D. MIXING EQUIPMENT

1. Mixer – Mixing Equipment Co., Inc., C/o Fuente and Webster, 549 West Randolph

Street, Chicago, Illinois.

Model S-1,1/3 H.P. “Lightning” Mixer 110 Volt with 36” long # 304 stainless shaft

and two # 304 stainless steel 4” – 3 blade propellers.

40

2. Mixer Tank and Fixtures. Chicago Carb-O-Tank Co.,

746 West Fullerton, Chicago, Illinois

1 – 60 gallon type “H” 304 stainless steel tank complete with three 16” legs

1 – ¾” female outlet

1 – figure 11 brass N.P. faucet ¾”

1 – SS bracket (Portable agitator bracket for use with “Lightning” S-1 ,Mixer)

1 – SS cover slotted for “Lightning” S-1 – 1/3 H.P. Mixer

3. Blender Mixer. Master Elect Service Co., 835 West Washington Blvd., Chicago,

Illinois

Warning Mixer 1 gallon size, Part 004180 Alternate – 3 gallon mixing bucket –

Griffin Drawing E-606. 3-1, Detail-D

41

Heat treatment of axle:

The process involving heating&cooling to egt the desired properties suitable for

serviceby changing the structure,composition etc.

Stages of heat treament:

1. Heating to the required temperature

2. Holding(Soaking) at this temperature for a period of time to attain

uniform temperature throughout the section.

3. Cooling the steel at specified rate.

Principle of heat treatment

Normalizing:

It is the process of heating the steel to above the upper critical temperature followed by cooling in

air.

Normalizing

Austenite

910

Temperature

O C 723

Ferrite + Pearlite +

Pearlite Cemintite

0.8 2 C% wt

Purpose:

1. To relieve the internal stress

2. To refine the grain structure

Existing structure and

properties of steel Existing

structure and

properties of steel

Tempering

Normalizing

Air

cooling

Quenching

42

3. To improve the machinability

4. To improve strength&toughness

Temperature&time of NF:

Zones Temperature in o C Time in hrs(Cycle time x capacity

of the furnace) Required Set

Pre heating 840 - 860 850 2

Main heating 840-870 855 2

Soaking 850-880 865 2

Tempering:

Process of heating the axle to a temperature below lower critical temperature followed by air

cooling.

Purpose:

1. To reduce the thermal stress

2. To stabilize the structure of the axle

3. To reduce the brittleness and

4. To increase the toughness&ductibility.

Austenite

910

Temperature

O C 723

640 Tempering 550

0.8 2 C% wt

Temperature&time of TF:

Zones Temperature in o C Time (Cycle time x capacity of the

furnace) Required Set

Pre heating 550-640 610 2 hrs 55 min.

Main heating 610-640 610 2 hrs 55 min.

43

Soaking 610-640 610 2 hrs 55 min

Quenching:

The process of heating the axles to austenite phase followed by sudden cooling in polymer

quenchant which is echo friendly for about half an hour.

Purpose of hardening followed by tempering :

1. To develop high hardness, wear resistance and

2. To improve the strength and toughness

Austenite

Hardnening 910

Temperature

O C 723

640 550

0.8 2 C% wt

44

Suspended Particulate Matter from Duct:

i. Take the initial weight of the moisture free thimble in gm - 1.5210 gm

ii. Measure the stack pressure(h) mm H2O - 2.06 mm H

2O

iii. Measure the Stack temperature(Ts) in kelvin - 77 + 273 = 350 oC

velocity:

C = Pitet tube constant x Root of h x Ts m/sec. - 0.2022x 2.06 x350

iv. Select the nozzle (An) = 5.43 m/sec

Flow rate:

Qm = V x A x 60 x 1000 LPM - 5.43 x 60x1000 x3.165x10-5

10.31 LPM / ¼” Nozzle

- 5.43 x 60 x 1000 x7.123x10-5

- 23.21 LPM / 3/8” Nozzle

- 5.43x60x1000x7.917x10-6

- 2.58 LPM / 1/8” Nozzle

After Normalization flow rate:

298 298

Qn = Qm x LPM - 23.21x

TS 350

- 19.76 LPM

v. Collect the sample of 1000 litres min.

1000 1000

Sampling time = Min. -

Qn 19.76

- 50 Min.

vi. Measure the ambient temperature(Ta) in o K - 31+273=304

oK

vii. Measure the meter pressure mm - 20 mm Hg

viii. Calculate the volume of the sample collected

Vs = Qn x Time of sampling liter - 19.76x50=988 lit

ix. Actual volume of sample collected:

Vsx (750-Pm) x 298 19.76x(750-20)x298

Vn = -

760 x Ta 760 x 304

- 18.61 x 50=930.5 Litre at STP

x. Take the final weight of the thimble - 1.5413gm

Wt of dust =Fwt-Iwt - 1.5413-1.5210

- 0.0203 gm

Wt of dust 0.0203

SPM = x 106 Mg/Nm

3 - x10

6

Vs 930.5

45

- 21.8121.82 Mg/Nm3

Measurement of SPM of ambient air quality:

a) Take the initial weight of the moisture free filter paper in gm

b) Place the paper on the air sampler,set the time for 24 hours and switch on.

c) Note the flow rate in M3 per min.

d) Calculate the volume of air sample(V) m3/Min

V = Flow rate x Time in hours(24 hrs)

e) Take the final weight of the filter paper in gm

Wt of dust

SPM = x 106 µm / m

3

V

Eg)

FWt = 4.1970 gm

IWt = 2.8627 gm

Wt of the dust = 1.3343 gm

Flow rate = 1.435 m3 / min.

Tsampling = 24 x 60 Min.

V = 1.435 x 24 x 60 M3

1.3343

SPM = x 106

1.435 x 24 x 60

SPM = 645.71 µm / m3

46

Manufacturing of Wheel:

Furnace used:

High power basic direct electric arc furnace.The charge is melted by the heat produced by the arc

by passing high power electric current through the graphite electrodes.The charge is loaded as

heavy,medium&light scraps in bottom,middle&top of the furnace respectively.

Charge:

The raw material contains axle end cuts, risers, wheel cuts, medium scraps like sleeper, steel

plate,rods,buffes,spikes,keys etc.,borings,shereded scraps etc.The weight od each in the buckect

is as follows.

Sl.No. Type of scraps Number of magnets Weight in MT

approximately

1 Axle end cuts 2 2.5

2 Wheel risers 3 4 – 4.5

3 Wheel cuts 3 6

4 Medium scraps 5 - 7 4

5 Borings 2 - 3 2

6 Shredded scraps 2 2

7 Lime stone / Calcined lime -- 1.7 / 1.25

Melting:

The scrap is melted under a basic oxidizing slag consisting of lime stone and mill scales

providing cutting os scrap / collapses of bridges by O2 lancing..Consequently the Si,Mn&P

present are observed in to the basic oxidizing slag(Black) and when the process is completed,the

slag is completely removed without drain of steel melt.Take sample and send to spectro for

analysis. The oxidation reaction reactions are:

2FeO + Si = SiO2

+ 2Fe

FeO + Mn = MnO

FeO + SiO2 = FeO.SiO

2

MnO + SiO2 = MnO.SiO

2

5FeO + 2P = 5Fe + P2O5

3FeO + P2O5 = (FeO)3.P2O5

(FeO)3.P2O5 + 3CaO = 3FeO + (CaO)3 . P2O5

=

In the next stage new slag is formed by adding reducing slag mixture to deoxidize the bath.

Deozidation occurs due to the unoxidized Mn left during the first stage.Lime reacts with C to

form CaS which will further deoxidize and fix the S as CaS.The reactions are:

FeO + Mn = Fe + MnO

47

3C + CaO = CaC2 + CO

3FeO + CaC2 = 3Fe + CaO + 2CO

3MnO + CaC2 = 3Mn + CaO + 2CO

Sulphur present in the steel as FeS&MnS.and eliminated in the following way.

3FeS + CaC2 + 2CaO = 3Fe + 2CO + 3CaS

3MnS + CaC2 + 2 CaO = 3Mn + 2CO + 3CaS

FeS + C + CaO = Fe + CO + CaS

MnS + C + CaO = Mn + CO + CaS

CaS is insoluble in steel and will join with slag(White) and CO will maintain reducing

atmosphere in the furnace.Add Fe-Mn/Si-Mn to pick up the Mn containt in the bath(0.35 -

0.45%).Decarboration/recorporation may done by O2 lancing/by adding graphite powder as per

the spectr sample result.Stir the bath and maintain the temperature as 1640 – 1650 oC and take the

pre tap sample.After stirring the bath again take the 2nd

pretap sample within 2 -3 minutes.Raise

the temperature to 1680 - 1740 and tap the metal bath by opening the tap hole through the spout

in to the pre heated ladle containing calculated quantity of Graphite powder,Ferro-Silicon,Ferro-

Manganese/Silico-Manganese as per the spectro sample result.

Transfer the ladle with the molten metal in to the slaggoff station and remove the slag from the

center by slag coated metallic rabble through the lip of the ladle.Take slagoff sample for spectro

analysis and transfer the mladle in to John-mohr pressure pit.Measure the temperature by the TC

tip and when the temperature is 1620 oC add Al star of weight 450 gms each in to the bottom of

the ladle with the help of metallic rod to kill the steel.Take samples for ladle anslysis & H2&N2

measurement by spectro&Leco gas determinater respectively.

Casting:

Start the casting at 1610 - 1520 oC by bottom pressure pouring technique after closing the

pressure pit by the lid containing preheated ceramic pouring tube at its center by using graphite

mould(Assembled Cope&Drag moulds).When the molten metal touch the probe inserted in one

of the riser the pressure will drop and simultaneously the clay graphite stopper head will close the

entrance of the molten metal to prevent the run back. Add sufficient quantity of rice hull to

prevent the dropping of temperature and transfer the mould for solidification.

Splitting:

After calculated time(10-12 Min.)split the mould using the split grain.If dropping of metal is

observed increase the solidification time of reduce the solidification time if the risers are not

fallen during the splitting.Pass the hot wheels through the hot wheel kiln foe further hot

processing.

Sprue Wash:

Wash the protruded sprue by copper cotted electrode of one inch thichickness by using the

current of 1200-1800 Amps and minimum temperature of the sprue wash shall be of 380 oC to

prevent the sprue crack formation.

Number stamping:

Stamp the correct number of the heat on the back hub face by automatic number stamping

maching.

Hub cutting:

Make the hub bore by oxi-acetylene flame by using required pressure.

Heat treatment:

48








Heat


Normalizing:


air.

Normalizing

Austenite

910

Temperature

O C 723


Pearlite Cemintite

0.8 2 C% wt

Purpose:






properties are wiped out.Metal is now in a

condition to receive

new structure.

Existing

structure and

properties of steel

Tempering

Normalizing

Hub

cooling

Quenching

Air cooling

49




Pre heating 840 - 860 850 2


Soaking 850-880 865 2

Quenching:

The process of heating the Wheels to austenite phase followed by sudden cooling of rim by

water for about 4 - 4.5 min.




Austenite

Hardnening 910

Temperature

O C 723

640 550

0.8 2 C% wt

Tempering:


cooling.

Purpose:





50

Austenite

910

Temperature

O C 723

640 Tempering 550

0.8 2 C% wt







Hub cooling:

Cool the hub by the mixture of air&water for about 2.5 minutes.

Air cooling:

After complition of the heat treatment allow the wheels to air cool.

Apex gring;

Remove pins on the apex of the wheel by apex grinding machine about one full rotation.

Steel shot blasting;

Remove oil,crease,dirt,sand grains,spray particles and othe inclusions by steel shot blasting in a

closed chamber.

Magnaglow:

Do visual inspection followed by spraying the magnaglow bath on the magnetized wheel and

inspect und UV lamp.If free from any defects stock the wheel as first line stock otherwise send

the wheel containing defects to the grinding line and reinspect.

Ultrasonic testing:

Evaluate the quality of the rim portion of the wheel by detecting the discontinuities which are

harmful to service by automatic immersion technique in a water tank by radially & axially by

using 5&2 MHz convergent beam probes of six numbers respectively(3 for axile&other 3 for

radial).The wheel containg 3.2 diameter flaw ore shall be the cause for rejection.

51

Brinel Hardness testing:

Remove the scale on the front rim by automatic grinding machine and measure the BHN by

giving indentation by 10 mm hardened steel ball with the load 30000 kgs.

Warpage:

Check the warpage of the wheel on the drag side to prevent the derailment of the wheel.

Wheel peening:

Peen the wheel in a closed chamber by steel shots of SAE-550 grade or equivalent to improve the

fatigue strength of the wheel,to weldup the HLCs on the surface,distribute the locked up strees

uniformely through the wheel.

Hub bore:

Make the hub bore to the required diameter by Hub borer.

Final inspection:

Measure all dimensions of the wheels,rotundity,circumference and others by using suitable

measuring gauges and record the weight of the stocked wheel also.

Heat treatment of wheel:








Heat


Normalizing:

Existing structure and properties are wiped

out.Metal is now in a

condition to receive

new structure.


properties of steel

Tempering

Normalizing

Hub

cooling

Quenching

Air cooling

52


air.

Normalizing

Austenite

910

Temperature

O C 723


Pearlite Cemintite

0.8 2 C% wt

Purpose:








Pre heating 840 - 860 850 2


Soaking 850-880 865 2

Quenching:

The process of heating the Wheels to austenite phase followed by sudden cooling of rim by

water for about 4 - 4.5 min.




Austenite

Hardnening 910

Temperature

53

O C 723

640 550

0.8 2 C% wt

Tempering:


cooling.

Purpose:





Austenite

910

Temperature

O C 723

640 Tempering 550

0.8 2 C% wt







54

Hub cooling:

Cool the hub by the mixture of air&water for about 2.5 minutes.

Air cooling:

After complition of the heat treatment allow the wheels to air cool.

Preparation of coated sand:

55

Poring rate:

Fast pouring rate:

The flow of molten metal from the ladle in to the clay graphite head through ceramic pouring

tube is cast fast pouring rate.

Controlled pouring rate:

The flow of molten metal from the clay graphite stopper head through the wheel profile in to the

probe sensor in the riser is called as controlled flow rate.

The Pouring rate is given by the formula

Time

Pouring rate = Sec / PSI and can be read from the Anger-Gein chart

Pressure

plotted by time in second in Y axis and pressure in PSI in X axis.The X axis is calibrated as one

division is one PSI and the time in Y axis is 2.5 minutes.It shall be 2.25 – 1.25 Sec / PSI.

Eg)

The graph for the following values of time&pressure is as follows.

Time in seconds Pressure in Pounds per Square Inch

2.5 1.6

5 3.2

7.5 4.8

10 6

10

Pouring rate =

6

= 1.67 Sec / PSI.

Flow rate diagram

0

2

4

6

8

10

12

1.6 3.2 4.8 6

Pressure in PSI

Time in Sec.

56

Effect of pouring rate during wheel casting:

High pouring rate:

Porosity,gas holes,pin holes,cavity may form in the rim and below sprue portions

If the temperature is low flow rate may sufficiently increase to prevent the cold defects

Low pouring rate:

Low pouring rate may leads to cold defects like LAP

If the pouring temperature is high then low pouring rate is pemitted

If the bath temperature is low pouring rate may lead to cold defects.

Use of graphite moulds for wheel casting:

It has sufficient permeability

It has high thermal shock

It is easly machinable

It may re use after casting of one wheel for further casting

It has low thermal expansion

It has low linearity of coefficient

It has low ash content

It is less volatile

The chemical reaction between it and the molten metal bath is negligible

After casting easily cleanable without damage for further use

This is non-destructive mould

Less heat / thermal loss

The spray solution will easily adhere on the surface

It has sufficient strength.

It has high electric resistance

Repairable by machining

Sand testing:

GFN determination:

Take 100 gms of washed,dried and any other foreign material free sand and poured in the top of

the clean pre weighed test sieve series contains 600,425,300,212,150,106,75,53 micron sieves

and pan from top to bottom.Shake well for about 5 minutes by the sieve shaker motor and take

the final weight.Findout the % of the retention in each sieves and find out the GFN of the sand as

follows

Sieve size Initial

weight of

the sieve

Final

weight of

the seieve

Weight of

the

retention

% of the

retention

Factor Product

600 20

425 30

300 40

212 50

150 70

100 100

57

75 140

53 200

Pan 270

Total

Weight of the product

GFN = AFS.

Retention

Stick point determination(SP):

Spred thin layer of coated sand using metal feeder on the stick point apparatus.After one minute

brush out the un-sticking sand by camel hair brush to the point where sand has stuck to the bar

from the lower gradient side.Immediately measure the temperature by using the thermocouple at

the point where the sand has stuck.

Determination of CTS:

Make the test samples by pouring the coated sand on the brequtte shape on the bottom of the

heater at 232+/- 5 oC using aluminium scoop.flatten immediately and place the top heater on the

leveled surface.Soak for four minutes and remove the heater.After air cooling find out the CTS

value from the outermost scale(with the help of the movable magnet).Average of six samples will

be the CTS value of the coated sand.

Determination of HTS:

Pour the sample on the slot of brequtte shape of the bottom of the heater,flatten and immediately

place the heater overit.Bake 4 mintes and apply the load and read out the HTS value after

breaking the sample in hot condition.Average of the two samples will be the HTS value of the

coated sand.

58

Estimation of SiO2(Ram. mass):

Take 0.5 gm of dry sample in a beaker add 50 ml of 1:1 HCL and bake. It completelyExtract with

1;1 Hcl and wash thoroughly.Warm,cool and filter through 41 No. fiter paper.Take the ppt in a Pt

crucible ,chara and heat to 950 oC for about 30 minutes.9Filterate for the determination of

CaO&MgO)

Cool,moisten with conc.H2SO4 and add sufficient quantity of HF and evaporate on a hot

plate.Heat to 950 o c for 15 min,cool and weigh.

Wt before HFT - After HFT

SiO2 = x 100

Wt of the sample taken

Estimation of CaO:

Makeup the above filterate in to 250 ml in a SM flak.Pipette out 25 ml in a conical flask,add 10

ml NaOH(10 N).Make up the volume in to 50 ml,add 0.2 - 0.4 gm of P&R indicator & titrate Vs

0.02M EDTA soltion(7.44 gms in one litre of water).The end point is the appearance of the violet

blue colour.Note the volume of EDTA.

Vol. of EDTA consumed x 0.11216

CaO =

Wt of the aliquot taken

Estimation of MgO:

Pipette out 25 ml in a conical flask,add 30 of water and 25ml of buffer(68 gm of NH4Cl+570 ml

of Conc. NH in 1 litre) solution and few drops of EPT(0.5 gm EPTand 5 gm Hydroxlamine Hcl I

1 litre) indicator.Titrate Vs 0.02M EDTA till the colour changes from wine-red to blue.Note the

volume of EDTA consumed.

Vol. of EDTA consumed - Vol. of EDTA consumed for CaO

MgO = x 0.08062


Determination of Fe2O3:

Pipette out 50 ml of the filtrate obtained after filtration of Silica.Add 5 gm of NH4Cl,2 drops of

methyl orange(0.5gm in 1 litre) in and add NH4OH till the colour changes to

yellow.Warm&cool the solution and filtrate through 41 No. filter paper. Wash the ppt with hot

water and dissolve it in 50 ml of 1:1 Hcl and boil the solution.Add staneous chloride(6gm in

40ml Conc.Hcl&60ml dis.water,add few pieces of granulated tin and stored in amber coloured

bottle). till the soloution become colourless.Cool rapidely to room temperature.Add 10 ml of

stauraed mercuric chloride till the formation of silky white ppt.Add 20 ml of acid

mixture(Conc.Phosphoric acid&75ml Conc.Sulphuric acis in 350ml water),2-3 drops of BDAS

indicator(0.2-0.3gm in 100ml dis.water&stored in amber coloured bottle) and titrate Vs 0.01 N

Potassium dichromate solution(0.49gm in 1 litre) till the appearance of violet colour.

Vol. Of K2Cr2O7 consumed

Fe2O3% = x 7.984


59

Determination of Al2O3 in HA70% bricks:

Take 0.2-0.3gm sample and fuse with the fusion mixture at 950 deg. C & extract with 1:1

Hcl..Fllter through 41 No. filter paper and make it in to 250 ml in a SM flask.Transfer 25ml of

the aliquot and add sufficient amount of 0.01M EDTA (1 ml = 1.25gm of alumina)Add 2-3

drops of methyl orange and dilute with NH4OH(1:10) drop wise till the colour change to

yellow.Add 5ml acetate sodium acetate buffer(2ml acetic acid&21.5gm sodium acetate in 1 litre

of dis. Water-PH

–5.2),25ml water and heat toboilingfor 5 minutes.Cool and add 5-6 ml of xynol

orange indicator(0.1gm in 100ml dis. Water with 2 drops of 1:1 HCl) and titrate against standard

Zinc Acetate solution till the colour changes from yellow to orange or pink.Add 10ml of

ammonium fluoride solution and heat to boiling for 5 minutes.Cool and add 5ml buffer and 5-6

drops of zylenol orange indicator and titrate against standard Zinc Acetate solution till the colour

changes from yellow to pink.

Vol. of ZnAc consumed x 1.25

Al2O3 = x 100

Wt of aliquot

Alumina in Fe-Si:

Take 2.5gm in a Pt crucible and dissolve in 1:2 HF + HNO3 acid mixture till the samples

dsolved.Add 5ml of 50% Conc.HCl & fume till dense fumes evolved.Extract with 50ml of water

in 250ml beaker.Add 5ml of conc.hcl,boil then add 10gm of NH4cl,boil,cool and add NH2oH

and again boil till faint smell of NH3 persists.Filter through 41 No. filter paper,wash with hot

water and transfer the ppt in to 250ml beaker.Add 15ml conc.HNO3 +15ml conc.perchloric

acid.Fume to syrupy state with beaker covered with watch glass.Cool,add a drop of hcl,dilute to

20ml,boil and add50_60ml of 10% NaOH solution,boil on low heat,cool,filter through 41 filter

paper.Wash with hot water,collect the filtrate in to beaker,Add xynol orange indicator.Add hcl till

it turns from blue to yellow.Cool,make upto 250ml.Take an aloquot of 100ml,add 20ml of

0.01MEDTA,neutralize with 5% NaOH.Then add 5-10ml of acetate buffer.Boilfor

10minutes,cool,add xynol orange buffer and titrate against 0.01 M Zinc sulphate.

Carryout the blank with the same amount of EDTA and other reagents used above.

(Vol. of Zn Ac consumed for blank-Vol. of Zn Ac consumed for sample)

Al% = x 0.027

Wt of sample in the aliquot

Estimation of Silicon in Fe-Mn:

Take 1gm sample and dissolve in 30% conc.Nitric acid in a hot plate.Dry&bake for 1 hr at 100-

110 deg.C.Redissolve the baked mass in 40ml conc.Hcl by warming and dilute to 150ml with hot

water.Allow to settle and filter through 40 filter paper,wash 10-12 times alternatively with hot

1:20 Hcl and hot water.Ignite the ppt at 950 deg. C for about 30 minutes,cool and weigh.

60

Wt of silica obtained

Si = x 46.72

Wt of sample taken in gm.

Estimation of Mn:Take the filtrate obtained after removal of silica in a 500 ml conical flask and

treat with 10ml conc.Sulphuric acid and evaporate to fumes.Cool&dilute in to 100m.Boil until all

salts get dissolved.Make up in to 500ml.Pipetted out 25ml,add small amount of Zinc Oxide

emulsion till the liquid suddenly coagulates.Dilute to 200ml,boil and add 2-3 drops of conc.nitric

acid and titrate vs 0.1 N KmnO4 solution in hot condition itself.Agitate the contents in a conical

flask after each addition of 0.1 N KmnO4 and allow the ppt to settle and continue to titrate till the

supernatent liquid shows pink tinge.Take two such piolet readings so that in the 3rd

titration all

permanganate required can be added rapidly and the end point is noted.

Vol.Std KmnO4 consumed x Nor. Of KmnO4

Mn% = x 1.666

Wt in gm of the sample in the aliquot.

Estimation of Mn in Al star:

Dissolve 1gm sample in 3ml of acid mixture(Con.Sil.acid90ml +Conc.Nitric acid 50ml + Conc.

Phopouric acid 95ml + Dis. Water 765ml).Dissolve an accurately weighed sample of std steel

containing a known conc. Of Mn in 30ml of acid miture.Boil,cool and dilute to 100ml with

boiling water.Add 10ml of silver nitate solution and 30ml of 10% ammo.per-sulphate

solution.Heat till permanganic acid colour is obtained.Cool the solution to room temperature add

10ml of NaCl solution to pptAgCl.Titrate quickly the permanganic acid with std. Sod.Arsenite

solution until the pink colour disappears.

Vol. of std. Sodium Arsenite solution consumed

Mn% = x (A x B) / C

Wt. Of the sample taken

Where,

A = % of Mn in std steel sample

B = Wt of saple taken and

C = Vol. of std arsenite solution used for titration.

Settling test:

Fused silica poeder in water with the suspensions CMC&Veegum

Weigh 315gm of fused silic powder,0.315gm of CMC(0.1% of FSP)&1.575gm of

veegum(1% of FSP) in 2 pockects each containing 1.575gm

Dissolve CMC in 53ml distilled water& stir with mechanical stirrer for about 4 minutes

Repeat the same for both the pockets of veegum in a seprate beakers.

61

Take 432ml of distilled water in 1 litre measuring jar and add CMC& stir 4 minutes.

Repeat the same for the two pockets of vegum.

Add 315gm of FSP and stir for 4 minutes.

Keep it for 24 hrs and oserve any sttling take plac e or not.

Specific gravity of FSP:

Take the empty wt of clean,dry pyknometerw1

Fill with water and weigh-w2

Pour out the water and filled with 1/ of FSP&weigh-w2

Fill with water and weigh-w4

(w3-w1)

Specific gravity =

(w3-w1)-(w4-w2)

62

Parts of the wheel:

Cope side:-

Flange

Front rim

Riser pad

Sprue

Front hub face

Hub bore

Front hub fillet

Front plate

Front rim fillet

Drag side:-

Flange

Back rim

Back of flange or

Flange fillet of

Back rim fillet

Back hub face

Hub bore

Back hub fillet

Back plate

Back rim

63

Fracture toughness:

Eventhough the charpy&Impact tests have certain importants they are not considering

for engineering design.LEFM is used for the design problems.Fracture toughness is

one of the material properties like yield strees and used in designs.It is defnied as “the

resistance of the material to resists fracture starting from the preexisting crack /

defect”.

Testing of fracture toughness:

Sample preparation:-

There are so many sample preparation method and one of the method for the

preparation of the sample as per “ASTM,Philadelphiya STP 381133/1965 is as

follows.

Pin hole for apply load

Crack

L(4w) Slot

2C or W / 3

t Crack

w

The length of the specimen is 4 times of the width and the length of slot&crack is 1/3

of the width.Load is applying through the pins in which the sample is inserted.

Procedure:-

Do the preliminary adjustments for the Fracture Toughnes machine and insert the

specimen in to the pins.Apply the load and the material will fracture under plain

strain condition.Note the maximum load(pm ) for the calculation.

Pm w п c

Fracture Toughness (Kic) = x √ tan Mpa a½

w x t (1- ν 2 ) w

Where,

Pm = Maximum load

64

w = width

t = thickness

ν = poison ratio

п = 3.14 and

c = half of the crack length.

The material having higher Kic value will undergo brittle fracture at lesser load and

the material having higher Kic value will undergo ductile fracture.

Time Temp. Deg. C

1 100

2 200

3 300

4 300

5 300

6 300

7 400

8 500

9 600

10 700

11 800

12 900

13 1000

14 1100

15 1200

16 1200

17 1200

18 1200

19 1200

20 1200

65

Time Temp. Deg. C

1 100

2 200

3 300

4 400

5 500

6 600

7 600

8 600

9 600

10 600

11 700

12 800

13 800

14 800

15 800

16 800

17 850

18 900

19 950

20 1000

21 1000

22 1000

23 1000

24 1000

25 1025

26 1050

27 1075

28 1100

29 1125

30 1150

31 1175

32 1200

66

Ladle lining well type with mullite castable.

115

32 50

230

7

Top of molten metal

6

HA 70 230x115x76/70 &

HA 70 230x115x76/65

5 1698

(1650)

1588 4 (1540)

1870

3

2

Steel shell

1 460

HA 70 Mortar

40 Mullite castable

25 110 282

Dia 1655(Dia 1615)

Defect analysis of axle.

Billet cutting:

Working pressure:

DA - 0.8 - 1 bar

O2 - 10 bars

The distance between - Approx. equal to OD of the nozzle

Nozzle life - 1200 billets

Nozzle getting blocked due to back-firing,over used,poor quality etc

Conveyors should not move during cutting

Cleen the nozzle at the beginning of each and immediately in case of

back firingReplace the slag bins and never allow bins to overflow

Ensure proper seating of nozzle to torch

Cutting of correct billet length

Select proper billet to be cut as per the specification of R-16&43.

Forging:

LAP:

Improper corner breaking

Indexing problem during forging

Improper conditioning of the bloom surface

Ensure:

Correct corner breaking during forging

Correct 90o during corner breaking and during handover

Defect free surface on bloom and in case surface conditioning is done on

bloom the width of conditioning should be 10 times the depth(8 mm ) of

the conditioning.

Piping:

Insufficient material on forged ends leading to formation of hole in the

journal end face

Uneven distribution of material on both ends of ournal during forging.

Poor gripping marking on jaws / work piece jerking during during

marking

Improper setting / adjustment before cutting in axle cutting machine

Lack of material due to excess scale formation

Ensure

Correct length of billet loaded to RHw

GFM programme for forging is made considering equal distribution of

material for both ends

GFM chuck jaws are welded properly with grip marks to avoid jerking

during forging.

Maintain correct indicator point to point distance as indicated in work

instruction.Maintain 100 to 150 mm of minimum fish end length

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Ensure no ove saking of billects in RHF.In case of prolonged break

downs put off PHZ and reduced temperature to 1000 deg. C in SZ-I&II

Misfunction during forging:

Catastriphic failure of electrical or mechanical components/failure of

regular power supply leading to in complete forging

Ensure

Ensure machine condition with maint. Staff after PMS or after attending

to breakings.

Idle cycle(without work piece) is checked in auto sequence and check

whether all the blocks in t forging programme is correctly

executed.Ensure that the programme is correct and then recall the work

piece.

The case of failure is to be analyzed and is best when analyzed separately

depending on the case.

In case of power interruption or failure consult MRS for regular supply

of power before starting of forging.Allow 5 minutes for supply to

stabilize.

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AXLE FLOW CHART Blooms from ASP,Musco&Others. Billet cutting Billet heating in RHF of capacity 80 axles Forging by LFM End cutting Number stamping Cooling through ICB of capacity 30 axles. Normalizing in NF of capacity 80 axles Polimer quenching in quenching tank of capacity 80,000 litres. Cooling through ICB of capacity 42 axles.

Tempering Stock

Sampling for Physical Chemical,Micro,Macro

and Charpy tests at

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M.Lab. End milling,cup turning and centering at Stn - 1 UT Rough turning at Stns –2 Semi finish of J,D/g&W/s at Stns - 3 Body finish at Stns - 4 Drilling&Tapping at Stns - 5 Finisf of Stns - 3 W/s furnishing at Stns – 7. J&D/g grinding(Centerless Grinding) at Stns - 8 MPT at Stns - 9 W/s of axle Measuring (Automatic) Wheel hub boring(Wheels from Wheel shop stock yard) Wheel set assembly

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Inspection Painding&Packing

Despatch

Body

W/s fillet

Wheel seat

Journal

CTA

LCB

Body

Axle drawing in Stn-1.

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Body

W/s

Journal

CTA

Face

LCB

OW/s Flt-N.end

IW/s Flt-N.end

IW/s Flt-F.end

OW/s Flt.F.end

Journal Farend

CTA-Far end

Face Far end

Manfacturing of BG Loco axles.

Billet cutting:

Cut the fillet of 300/340 RCS of R-43/1992 bloom in to required length by Saw/Gas

cutting.

Charging in to RHF:

Charge the cut billets in to RHF and soak them at 150 – 1200 deg. C for about 8 hours.

Forging:

Forge the red hot billet at 900 – 1100 deg. C by 6 minutes by GFM long forging

machine.

End cutting:

Remove sufficient discards by gas cut.

Number stamping:

Stamp the serial number of the axle on wheal seat by hot number stamping maching.


Cool the axle through the intermediate cooling bed till the surface temperature becomes

200 – 250 deg. C.

Heat treatment:

Normalizing:

Charge the axles into NF and soak at 860 – 880 deg. C for about 8 hours.

Hardening;

Quench the normalized hot axles by the polymer quenchant for half an hour.

Tempering:

Charge the quenched axles in to the TF through the intermediate cooling bed and soak

at 610 – 660 for about 11.45 hours.

Air cooling;

Allow the tempered axles in to air cooling for about 36 hours.

Laboratory testing:

Take the lab. sample Each cast wise from the mid radius of wheel seat/journal and

conduct all the required testing .

Machining in AMS:

End milling, centering and LCB:

I f the lab test is ok load the axles in to station-1 in AMS and do the above operations at

station-1 with the surface finishing of 0.8 micron.

Ultrasonic testing:

Do visual examination and carryout the ultrasonic testing and if the axles are passed

stamp the UT punch mark.

Rough turning of axle:

Do the rough of the axle in station-2 as per the dimensions mentioned in the drawing.

Radial scanning of the axle.

Find the longitudinal defects by USL radial scanning machine/manual body scanning.If

the axle pass enter the status in LAN.

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Final inspection;

Carryout the final inspection thoroughly and if the axle is confirming to all the

requirements made the dispatch arrangements.

apparent porosity

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