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METALLURGICAL & CHEMICAL

RESEARCH, DESIGN & DEVELOPMENT

General

Failure Investigations

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Metallurgical & Chemical Directorate imparts specialized technical services on M&C aspects of Railway technology to the Design Directorates of RDSO in R&D and Standardization activities. The Directorate also imparts training on ultrasonic testing to the supervisors of track maintenance and Metallurgical & Chemical supervisors for rolling stock axles and wheels. The Directorate also undertakes developmental projects to identify better material and processes for Railway applications. The investigation revealed that the failure of

cylinder liner may be attributable to presence of improper shape and distributions of graphite flakes A total of 136components were investigated resulting in initiation of cracking through inter identifying the causes of failure and wherever possible connected graphite flakes and some unusual thermal remedial measures were suggested in terms of and mechanical stresses during service.The laser material & design modification. Highlights of some of hardened depth for may be specified as 0.6 to 1.0mm the vital investigation report is summarized below:-instead of 0.38 to 0.64mm, so as enhance the wear One cylinder liner no.11F1589 of M/s EDS, USA resistance.The casting process of liner needs to be make of loco no. 40074 was received for controlled properly by suitable inoculation practice so metallurgical investigation from MP Dte. of as to achieve random distribution of A type graphite RDSO as shown in Fig.1. Visual examination of flakes of ASTM size 4 to 6 instead of 3 to 5. inner surface of the liner revealed two large size

One cracked piece of rail was received for cracks forming conical shape (Fig.2). The inner metallurgical investigation from N.C. Railway. surface also indicated spiral bands throughout Visual examination revealed that the rail had the circumference as well as scoring marks in cracked in head portion of the rail. Crack was the vertical direction. The cracked portion of the vertical split in head of the rail towards gauge liner was opened up, which revealed black side. Length of vertical split crack about 220 mm appearance as shown in Fig.3.(fig.1, 2 & 3). Cross-section of the rail head containing vertical split is shown in fig.4. Two bolt holes were noticed on the received rail piece. Both ends of the rail piece were saw cut. The investigation revealed that the vertical splitting of the rail along the head may be

Fig.1 Photograph Showing Cylinder Liner in as Received Condition.

Conical Shape

Cracks

Laser Hardening

Bands

Fig. 2 Photograph Showing Crack and Laser Hardening Bandson the Inner Surface

Black Appearance

Fig. 3. Photograph Showing Black Appearance Along the Crack Portion.

Fig. 2 Photograph Showing Location of Vertical Crack on Head of the Rail.

Vertical crack

Fig. 1 Photograph of Rail Piece in as Received Condition.

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Metallurgical & ChemicalMetallurgical & Chemical

from wheel disc and the lowest thickness towards rim end was found to be about 15mm. The photographs of this wheel piece are shown in fig.1, 2, 3 & 4.

attributable to presence of lamination defect which is a manufacturing defect and unusually high inclusion in rail material.

One gas cut wheel disc was received for metallurgical investigation from Carriage Dte. of RDSO. A crack having length about 52 cm was noticed on the web portion. When crack was opened it revealed fatigue zone on the web portion. The examination of tread surface of the failure wheel disc revealed shelling throughout the tread surface. Thickness of web section was measured at different places after cutting a slice

The fatigue fracture of the wheel disc circumferentially among the web portion may be attributable to the combined effect of ;

Excessive stresses due to low web section (15 mm) lower tensile strength.

Elongated grains of non -uniform grain size due to lack of proper heat treatment and the wheel at the time of fracture was in condemning stage.

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Vertical crack

Fig. 3 Photograph Showing Location of Vertical Crackon Below the Rail Head.

Fig. 4 Photograph Showing Vertical Split on Transverse

Section of the Rail Head.

Crack

Fig.1 Photograph Showing Crack on the Web Portion.

Fig.2. Close View of Fig.1 Photograph Showing Crack at theWeb Portion Rounded by Chalk Mark.

Crack Rounded by C halk

Fatigue Zone

Fig.3. Photograph of Fatigue Zone AfterOpening the Crack.

Shelling Marks

Fig.4. Photograph Showing Shelling Marks on Rim Portion


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Material Testing and Evaluation premature failures received from Design Directorates and QA Dtes.were tested as per relevant Specification A total of 841 nos. of the components of metals and test reports were submitted to the concerned and alloys, rubber, plastics, composites, fuel oil, Dtes. The summary of samples tested is given below:-lubricants, paints, welding consumables, fuel oil

related to R&D activities, quality audits, vigilance, S. Nature of Materials No. of Samples Tested Total

No. R&D QA Others

1 Metals and Alloys

2 Rubber Plastics & composites 10 70 33 113

3 Fuel Oil & Lubricant 171 3 28 202

4 Welding Electrode 18 Nil 51 69

5 Paint and Corrosion Protection Nil 40 31 71

6 UST & Radiography & Phase analysis of porcelain by XRD Eqmt. 65 Nil 195 260

Total 297 167 377 841

33 54 39 126

Personnel From Axles & Wheels Rail & Rail welds

Regular Refresher Appreciation Regular Refresher Appreciation

Zonal Railways & PUs 156 79 06 136 142 10

Advisory Studies Referred by Design Directorate Training and Re-certification UST

A total of 124cases were referred by different The NDT Training centre of the Dte imparted training Design Dtes. seeking technical advises on various to 635 personnel under various courses organized on aspects such as material selection, review/ Ultrasonic Testing. The details of which have been modification of specification, scrutiny of QAPs, STRs tabulated below.and tenders etc.

A part from this training centre also conducted testing and acceptance criteria of filler wires certification examination on UST of Rails for MIG/MAG welding (with & without gas (outsourcing) of 106 Personnel of non-railway shielding) organization and firms on payment of certification charges. The Dte assisted different Design Dtes and

Zonal Rlys by standardizing the processes and A total of 111welders engaged by AT welding products as per details given below:

firms for AT welding of rails were certified. Lab evaluation for development of AT welding S.No. Certification/ No. of AT technique for 60 Kg/90 UTS rails using CAP

preheating system , 3 piece mould and automatic Re-Certificationtapping thimble offered by M/s SIRIL, Hyderabad 1. Certification (Part-II) 51has been carried out and found to be satisfactory as

2. Re-Certification 60 per IRS-T-19-1994.

The welding parameters have been approved The Dte reviewed/ re-affirmed/ framed for flash butt welding of 52 Kg/90 UTS and 60 Kg/90

specifications and codes as well as assisted other UTS rail sections using mobile flash butt welding Dtes. for similar activities. The details of which are machine AMS 100 0.3 (Sl. No. 30865) Schlatter, given below: Switzerland make (6th Plant of M/s ITC, Kanpur.)

Revision of STR No. M&C/STR/Lub/01/2011 Welding parameters of MFBW plant model H-Rev 1 for M&P lubricants. 1000, S.N.125K,Holland LP make of M/s L&T Reaffirmation of RDSO specification No. Chennai for 60 Kg/HH rail has been standardized.M&C/Lub/101/01 for pneumatic tool oils. Field Trail of AT welding technique for Reaffirmation of RDSO specification No. 60kg/90UTS rail section by using 3Pc Mould, Auto M&C/Lub/102/01 for machine tool-way oils. thimble and CAPPH preheating of M/s ITC, Kanpur

is completed.Revision of Indian Railway Standard Specification IRS:M46 for classification , Final inspection of 100 field trial joints of AT

Process and Product Standardization

Certification of Welders on AT Welding

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Welders

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welding technique for 60kg/90UTS rail section by manufacturing wagons and it is understood that using 3Pc Mould, Auto thimble and CAPPH preheating RCF is also planning to manufacture the entire of M/s HTIPL,Raipur is completed. coach from the same steel. Since this steel has

to pass through 496 degree Celsius during Final inspection of 100 field trial joints of AT fabrication of wagon and coach components by welding technique for 52kg/90UTS rail section welding and also the wagons & coaches are by using 3Pc Mould, Auto thimble and CAPPH required to work under environment conditions preheating of M/s HTIPL, Raipur is completed.where the temperature may become as low as Final inspection of 100 Field Trail joints of AT 3-4 degree Celsius.welding technique for 60kg/90UTS rail section Objective : To provide fatigue strength data for by using 3Pc Mould, Autothimble and 496 sensitized IRS M-44 ferritic stainless Compressed air -LPG pre-heating, of M/s welded steel. This data can be used for OTPL, Noida is completed.estimating the resistance of the same against Fatigue joint of AT welding technique for 52 initiation of embedded flaws.Kg/90 UTS, rails using CAP preheating Optimizing Preheating Parameter in AT system, three piece mould and Automatic WeldingTapping Thimble developed by M/s

RMPL,Bilaspur, has been executed as per Background : During AT welding of rails, rail IRS-T-19-1994. ends are preheated by different heating

equipments to a predetermined temperature so Field Trail of AT welding technique for that the fusion of rail ends with the portion may 52kg/90UTS rail section by using 3Pc Mould, be ensured. If preheating is inadequate, the Auto thimble and CAPPH preheating of M/s lack of fusion defect is generated in the AT weld ITC, Kanpur is completed.joint whereas the excessive preheating leads to Standardization of welding parameters for rail higher Heat Affected Zone (HAZ). The section i.e. 52 Kg/90 UTS with MFBW Plant preheating should be optimum. The rail ends (Model.CMW109/110TON DC Weld Head, temperature is supposed to be around 650-700 S.No.CMW-1009 Make- CHEMETRON, USA) degree Celsius after preheating. Thus it is of M/S NCC, Hyderabad is done.highly essential to really measure the

Standardization of welding parameters for rail temperature of rail ends by some method so section i.e. 52 Kg/90 UTS Servo controlled that the standardization of preheating time is MFBW machine with EO Paton Model H-1000 established.(K-920), S.No.145 AR, and manufactured by

Objective : To achieve the standardized Holland L.P.USA of M/S PCM Siliguri is done.preheating time which ensures the proper

Standardization of welding parameters for i.e. fusion of rail ends with portion along with least 52 Kg/90 UTS&60 Kg 90 UTS rail section of M/s HAZ. Thermit welding of rails had been RaheeInfratech Limited, Kolkata using Mobile introduced in IR for economy and smooth Flash Butt Welding Machine K-922(HK) Sl.No. running and comfortable riding in train. 127 manufacturer E O PATON (HONG KONG) Standardization of preheating parameters will have been done and parameter approved. result in producing sound AT weld joints with Lab evaluation for development of AT welding least HAZ and free from lack of fusiondefect. technique for 52 Kg/90 UTS, rails using CAP Railway will be benefited by having reliable joint preheating system, three piece mould and with enhanced strength and service life.Automatic Tapping Thimble fitted with one shot Developmental Inspectioncrucible offered by M/s ITC, Kanpur has been

The officers and staff of the Dte.with official from carried out and found to be satisfactory as per Design Dtes. jointly carried out inspections of IRS-T-19-1994.Verification of manufacturing of developmental items, the details of which are given one shot crucible has also been carried out. below:Fatigue joints were also made.

About10546 MT of welded components of steel Field Trail of AT welding technique for bridges were inspected for Zonal Railways.52kg/90UTS rail section by using 3Pc Mould, Inspection of 656 nos. of cmscrossing .Auto thimble and CAPPH preheating of M/s

SIRIL, Hyderabad, is completed Inspection of 45 nos. of DRT , 25 nos. of SRT ,6 nos. of AT weld tester and 29 nos. of axle tester .

Ultrasonic testing of 2594nos. of Rails.Study on fatigue properties of ferritic stainless steel used for wagon and coaches Inspection of 844nos. of improved SEJ .

Background : Ferritic stainless steel of IRS M- Capacity & Capability assessment of M/s Maruti 44 specif icat ion has been used for Steel Fab , Pune for manufacturing and supply

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of steel bridge girders. The capacity & capability assessment of M/s, Vijay Engineering, Bhopal for mfg and supply of The capacity and capability assessment have steel bridge girders.been completed for elastomeric and POT-PTFE

bearing at M/s DeevinSeamack Pvt. Ltd. Inspection of one fabricated bogie frames of Bhopal. HTSC Fab-II type type.

The capacity and capability assessment have The capacity capability assessments have been completed for CMS crossing at M/s been carried out at M/S Reliable Hitech Ltd., Calcutta Spring Ltd. , Kolkata. Rourkela.

The capacity and capability assessment of Capacity and capability assessment of M/s three firms M/s Sneha Bearing Pune, M/s Alliance Integrated Metaliks Ltd., Rajpura for Trycome Polymer Mumbai and M/s Kanta manufacturing and supply of steel bridge Rubber Hyderabad have been done. girders.

Capacity and capability assessment of two Capacity & capability assessment of M/s Metal firms for fabrication of bridge girder. Feb High Tech Pvt. Ltd., Nagpur. for

manufacture and supply of steel bridge girders.Assessment of M/s BRG Iron & Steel Co. (P) Ltd., Odisha for manufacture and supply of Welder qualification test for 164 nos. of welders.material as per IRS: M-44/97 .

Inspection of two fabricated bogie frames of The progress of cases related to renewal and Fab-II type and two bogie frame of disc brake new registration of vendors is given below:type.

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Vendor Renewal and Registrationn

S. Category New cases Renewal cases Up-gradation Deletion/ No. registered as from Part-II Down

Part-II to Part -I gradation

1 Paints 01 04 02 01

2 Welding consumables 04 31 06 14

3 Lubricants 01 06 Nil 04

4 USFD 01 05 Nil Nil

5 AT welding using TPP portion & technique Nil Nil Nil Nil

TOTAL 18 57 07 38

Revenue Earned ThroughTesting and Other Activities n

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Railway/Mancheswar, Bhubaneswar.

Dr L.K. Srivastava , ARO/MTD delivered lecture The directorate earned Rs.1,33,24,715.00 through on AT Welding quality awareness at testing charges of materials and other activities. CETA/Kanpur.

Misc. important Activities b. ShriBaijNath , ARO/M&C delivered lecture on welding basics , concept of WPSS, WPQR and Shri V. Bhattacharya, ARO/M&C delivered different welding process etc. at IRICEN, Pune.technical lecture at STC ,Charbagh , N.

Railway, Lucknow. Joint inspection & discussion of BLC & BOXN axles with ACMT/Dahod.ShriAnup Singh Dagur delivered technical

lecture at STC ,Charbagh , N. Railway , Quality audit on UST of axles at Parel Lucknow. Workshop, Central Railway.

Shri V. Bhattacharya, ARO/M&C delivered 03 Nos. of lectures on Iron carbon Diagram, technical lecture on metallurgical perspective Heat treatment , Destructive Testing , Non on inspection of ERC during Training course destructive Testing and Failure Investigation organized by QA/Civil Dte. for officers of were delivered by Shri V. Bhattacharya , Engineering Department. ARO/M&C at IRIEEN, Nasik.

Joint inspection of WAG-7 Electric Loco axle at 03 Nos. of lectures on Rubber, Plastic & BHEL /Jhansi supplied by RWF regarding Composites were delivered by ShriSuraj Singh , ultrasonic testing and Magnetic Particle Testing. ARO/M&C at IRIEEN, Nasik.

Quality audit of Ultrasonic Testing of Axles at Quality audit of UST of Axle have been Carriage Repair Workshop, East Coast conducted in Electric Loco Shed, Bhilai.

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