www.rdso.indianrailways.gov.in

Annual Report 2010-2011

METALLURGICAL & CHEMICAL

RESEARCH, DESIGN & DEVELOPMENT

General

Failure Investigations

n

n

n

n

Metallurgical & Chemical Directorate impartsspecialized technical services on M&C aspects ofRailway technology to the Design Directorates of RDSOin R&D and Standardization activities. The Directoratealso imparts training on ultrasonic testing to thesupervisors of track maintenance and Metallurgical &Chemical supervisors for rolling stock axles and wheels.The Directorate also undertakes developmentalprojects to identify better material and processes forRailway applications.

A total of 110components were investigated identifyingthe causes of failure and wherever possible remedialmeasures were suggested in terms of material & designmodification. Highlights of some of the vitalinvestigationreport is summarised below:-

Three pieces of broken rails counter to eachother involved in derailment of 2566 DN (BiharSamparkKranti express) in Safedabad Yard werereceived from Sr.DEN/Co , Northern Railway formetallurgical investigation and reported videreport No. 91/10. Investigation revealed that Railmaterial conforms to specification. Breakage ofrail had taken in fatigue manner covering about55% of fractured area in first broken rail and 50%in second broken rail. Breakage of rail in fatiguemanner initiated from gauge corner side may beattributed to presence of shear cracks formedduring service caused by concentrated loading.

The kidney in the rail head caused due totransverse cracks in the rail head surface andcould not be detected in the last USFD becauseof small size and propagated to such stage due toapparently higher GMT rather than stipulated9.17 GMT. NR is suggested to verify thecorrectness of GMT which is stated to be 9.17 per

annum. If periodicity of testing is used on verifiedGMT, these defects could have been detected insubsequent testing.

Two pieces of failed axles of Loco No. 14580WDG3A at R5 location were received fromSr.DME/DSL/GY/SCR for metal lurgicalinvestigation and reported vide report No. 17/10.The failure of axle is considered attributable toinitiation of multi nuclei fatigue from journal fillet.The fatigue flaw in the axles was detectable atlast ultrasonic testing.

Three nos. of rail pieces collected from theaccident site following the accident of 2102Gyaneshwari Express at Km. 134/7-9 betweenKhemasuli-Surdiha station of SE Railway inKharagpur-Tata section were received from Sr.DEN/West for metallurgical investigation andreported vide report No.117/10.

Investigation revealed that the sudden fracturesof rails & flash butt welded rail are not consideredattributable to metallurgical properties of rails &welded joint.

One broken CBC coupler of RIL make wascollected during the joint inspection & received

Photograph showing fractured face of leading end of sample

Photograph of fracture face showing the fatigue zone

Photograph showing battered location of initiation of fracture

40

www.rdso.indianrailways.gov.in

Annual Report 2010-2011

from Director/I&L for metallurgical investigationand reported vide report No. 93/10.

Two broken rail pieces involved in weld failure

causing derailment of engine of 2808 SamtaExpress in Sambalpur Division were receivedfrom Sr.DEN/Co./ECoR/Sambalpur formetallurgical investigation and reported videreport No. 119/10.

Investigation revealed that the failure of the railacross heat affected zone initiated from thebottom in a fatigue manner may be attributable tocoarsening of grain size because the carboncontent (0.75%) was towards the upper limit ofIRS:T-12.

Two no. of broken piece of one Axle Box Helical

spring & four pieces of two Brake Hangers werereceived from Sr.DEE/NR/GZB for metallurgicalinvestigation and reported vide report No.176/10.

Investigation revealed that breakage of helicalspring from flat surface of the spring in fatiguemode may be attributable to presence of pits onthe seating area of the spring and the failure ofbrake hanger may be attributable to use of wrongclass of steel &presence of as forged elongatedgrains. The microstructure of this hanger

revealed that it was not subjected to normalizingheat treatment and its shape was cylindrical dueto which it was prone to initiation of fatigue onaccount of reverse bending forces.

One set of wheel disc containing Axle was

received from Director/Carriage/RDSO formetallurgical investigation and reported videreport No. 193/10.

Investigation revealed that circumferentialthrough cracking due to poor strength of webhaving clusters of inclusions resulted in multinuclei fatigue. The strengthening of web by

n

n

n

Photograph showing grinding & indentation marks

Photograph showing fracture initiated in shear manner &progressed in fatigue manner

Photograph showing the fractured face of the spring

Photograph showing the location of breakage of brake hanger

Metallurgical & Chemical

41

www.rdso.indianrailways.gov.in

Annual Report 2010-2011

change of material and change in design wassuggested.

A total of nos. of the components of metals andalloys, rubber, plastics, composites, fuel oil, lubricants,paints, welding consumables, fuel oil related to R&Dactivities, quality audits, vigilance, premature failuresreceived from Design Directorates and QA Dtes.weretested as per relevant Specification and test reportswere submitted to the concerned Dtes. The summary ofsamples tested is given below:-

693

A total of cases were referred by different Design141

Material Testing and evaluation

Advisory studies referred by Design Dtes.

BranchingCrack

CircumferentialCrack

BranchingCrack

S. Nature of Materials No. of Samples Tested Total

R&D QA Others

Total 307 228 158 693

No.

1 Metals andAlloys 46 15 34 95

2 Rubber Plastics & composites 40 93 02 135

3 Fuel Oil & Lubricant 160 03 56 219

4 Welding Electrode 06 99 36 141

5 Paint and Corrosion Protection 15 18 04 37

6 UST & Radiography & Phase analysis of porcelain by XRD Eqmt. 40 Nil 26 66

Dtes.seeking technical advises on various aspects suchas material selection, review/ modification ofspecification, scrutinyofQAPs,STRsand tendersetc.

The NDT Training centre of the Dte imparted training to

552 personnel under various courses organizedonUltrasonic Testing. The details of which have beentabulated below.

Training and Re-certification UST Certification of Welders onAT welding

A total of welders engaged by AT welding firms for ATwelding of rails were certified.

1. Certification (Part-II) 40

2. Re-Certification 48

The Dte reviewed/ re-affirmed/ framed specificationsand codes as well as assisted other Dtes for similaractivities. The details of which are given below:

Revision of Specification for high performanceepoxy paint (two pack) M&C/PCN/123/06.

Schedule of technical requirementSTR No. M&C/MTD/STR/101/2010 (Rev.0) for infrastructure ,manufacturing ,testing & quality control for

approval/re-approval of contractors and their ATwelders for AT welding of rails with TPP/NRportion & technique on zonal Railways have beenframed.

Revision of STR No. 050/10 for exterior paintingof coaches.

Specification M&C/MTD/104/2010 (Rev 0) of 3piece pre fabricated mould manufactured by ATportion manufacturers for use during AT weldingof rails as per IRS:T-12/94 have beenframed.

Revision of SpecificationM&C/NDT/111/2001(Rev.1) for AC/Half wave DC Electromagnet,Yoke type.

Revision of specificationM&C/NDT/125/2004 forDigital Ultrasonic Flaw Detector.

Comments offered on Draft specification

88

S. Certification/ No. ofAT WeldersNo. Re-Certification

Review & framing of Specifications

n

n

n

n

n

n

n

Personnel From Axles & Wheels Rail & Rail welds

Regular Refresher Appreciation Regular Refresher Appreciation

Zonal Railways & PUs 105 167 04 91 95 09

Other Organization Nil Nil Nil 36 45 Nil

Metallurgical & Chemical

42

www.rdso.indianrailways.gov.in

Annual Report 2010-2011

RDSO/SPN/NEW/2010 Version 0 of SignalDte.for double walled corrugated HDPE ducts forRailway signaling.

R e v i s i o n o f t e c h n i c a l s p e c i f i c a t i o nM&C/NDT/129/2005 of digital ultrasonicequipment for welded rail joint with LCD screen,trigonometric function and A-scan storage alongwith data set up.

R e v i s i o n o f t e c h n i c a l s p e c i f i c a t i o nM&C/NDT/122/2001 of collapsible stand forultrasonic flaw detector (Axle Tester).

Revision of technical specification for digitalultrasonic single rail tester with coloured signalsandA-scan logging along with data set up.

Revision of technical specification of digitalultrasonic testing equipment for welded rail jointwith LCD screen, trigonometric function and A-scan storage along with data set up.

Revis ion of Indian Rai lway Standardspecification IRSM:28-2011 for classification ,testing and acceptance criteria of Manual MetalArc Welding Electrodes and Gas Welding Rods.

The Dte assisted different Design Dtes and Zonal Rlysby standardizing the processes and products as perdetails given below:

Field trial of 100 joints forAT welding technique 52Kg 90 UTS using CAPPH preheating, 3 piecemould(Zircon washed) , auto tapping thimble,centre top pouring , 25 mm gap of M/s PerfectThermic , Lucknow.

Field trial of 100 joints forAT welding technique 60Kg 90 UTS using CAPPH preheating, 3 piecemould(Zircon washed) , manual tapping , centretop pouring , 25 mm gap of M/s OTPL, Noida.

Welding parameters have been standardized for52 Kg 90 UTS rails using Mobile flash buttwelding plant model K 920 , HWH0100-54procured by M/s Indu Projects Ltd. , Hyderabad.

Welding parameters have been standardized for52 Kg 90 UTS rails using stationary flash buttwelding plant ESAB of flash butt welding plant ,Sabarmati , W.Railway ,Ahmedabad.

Lab evaluation for development of AT weldingtechnique for 52 Kg 90 UTS rails using CAPpreheating system , 3 piece mould and autotapping thimble offered by M/s Harshad ThermicIndustries , Raipur has been carried out andfound to be satisfactory as per IRS T-19-1994.

A welding procedure to weld ‘C’ section plate withlong beam of electric locomotive to providecompressor under slug mounting (No.RDSO/2010/MC/146) has been prepared and

issued to Electrical Dte.

Welding parameters of mobile flash butt weldingplant K-920 (model 3406) manufactured by E.O.Paton Canada for 60 Kg 90 UTS rails of M/sRahee WeldTechnologies , Kolkata has beenstandardized.

Welding parameters of mobile flash butt weldingplant AMS 100 (S.No. 30611) Schalatter ,Switzerland make for 52 Kg 90 UTS rails of M/sITC , Kanpur have been standardized.

Welding parameters of mobile flash butt weldingplant K-355 (Holland make) for 52 Kg 90 UTSrails of M/s PCM Cement Concrete (P) Ltd. havebeen standardized.

Welding parameters of flash butt welding plant ,Sabarmati , W.Railway for 60 Kg 90 UTS NCC TONCC rails & NCC to normal rails have beenstandardized.

Welding parameters of mobile flash butt weldingplant K-920 (S.No. H-37) Canada make , for 60Kg 90 UTS rails of M/s HTIPIL, Raipur have beenstandardized.

Welding parameters of mobile flash butt weldingplant K-920 (CW 643 H1000 SN 108) Hollandmake , for 52 Kg 90 UTS rails of M/s Rail TechInfraventure (P) Ltd. , Allahabad have beenstandardized.

Lab evaluatin for development of AT weldingtechnique for 60 Kg 90 UTS rails using CAPpreheating system , 3 piece mould and autotapping thimble offered by M/s Harshad ThermicIndustries , Raipur has been carried out andfound to be satisfactory as per IRS T-19-1994.

Procedure for direct range calibration in digitalSRT/DRT has been framed and sent to TrackDesign dte. for its inclusion in USFD manual.

Tentative code of procedure for ultrasonic testingof DMU/MG axle to Drg. No. MG/EMU/M2-0-2-201 prepared and issued to NE Railway.

Code of procedure (MC-135) for detection ofloose inner races and circumferential biting ofaxle journal in situ by UST of electric locomotivetype WAG5 , WAM4 & WCG2 in service havebeen prepared and issued.

Welding parameters of mobile flash butt weldingplant model K355A S.N. MASCH NR-76 , for 60Kg 90 UTS rails of M/s Rail welders JV , Kolkatahave been standardized.

Welding parameters of mobile flash butt weldingplant ESAB machine at FBW/AJJ , for 60 Kg 90UTS NCC rails to NCC rails and NCC rails tonormal rails have been standardized.

Welding parameters of mobile flash butt welding

n

n

n

n

n

n

n

n

n

n

n

n

n

n

n

n

n

n

n

n

n

n

n

n

PROCESSAND PRODUCT STANDARDIZATION

Metallurgical & Chemical

43

www.rdso.indianrailways.gov.in

Annual Report 2010-2011

plant model CHEM 110-W/110 Ton AC poweredNo YZD282C095853 , model No. C28180XB ,manufactured by CHEMTRON/USA procuredand run by M/s PCM Cement Concrete Pvt. Ltd. ,Siliguri for 52 Kg 90 UTS & 60 Kg 90 UTS railshave been standardized.

Code of procedure for ultrasonic testing ofarmature shaft of EMU stock traction type 4ERA1858A to Drg. No. WR/MX/EL-1798 R3 /3-84-AC-DC-TM-245 prepared and issued toW.Railway.

Rolling contact fatigue initiation inthe rail material is required to be studied in orderto that some ideaon the subject since it is causeof serious concern to Indian Railway.

To assess rolling contact fatigue lifeof rail material using rolling contact of wheel & railsteels.

Project completed and Report No. MC-145 published.

Director / Wagon vide his letter No.MW/STL dt. 03.02.2010 has requested M&C Dte.to under take test ing on samples ofduplexstainless steel of ASTM S 32101 forassessing suitability for use of this material inwagon superstructure.

To evaluate mechanical properties ,weldability& corrosion resistance property ofDuplex stainless steel (ASTM S 32101) andassess its suitability for use in wagonsuperstructure.

Project completed and Report No. MC-153 published.

MP Dte. advised about largenumber of loco bogie frames are failing due toinitiation of cracks at various location in servicecausing detention of loco and highermaintenance cost.

To develop cast steel bogie frame withadequate mechanical properties and improvedweldability (low carbon equivalent)

Project completed and Report No. MC-152 published.

The officers and staff of the Dte.with official fromDesignDtes. jointly carried out inspections of developmentalitems, the details of which are given below:

About 16360 MT of welded components of steelbridges were inspected for Zonal Railways.

Inspection of 148 nos. of cmscrossing .

Assessment of M/s J. Sons Ltd., Meerut forimproved SEJ.

Prototype inspection of diamond crossing (singleslip) at R V Rail , Raipur.

Inspection of 06 nos. of DRT , 13 nos. of SRT , 36nos. of AT weld tester ,19 nos. of axle tester and06 nos. of Data Logger.

Inspection of prototype diamond crossing(without slip)at R V Rail , Raipur.

Inspection of 35 nos. of single slip diamondcrossing.

Inspection of 558 nos. of improved SEJ .

Inspection of 15 nos. of diamond crossing doubleslip at M/s VAE VKN, Sonepat.

Inspection of antigraffiti painting system on RCFpainted stainless steel coaches.

Inspection of prototype diamond crossing doubleslip at M/s R V Rail , Raipur.

Inspection of coaches painted by anti graffiticoating at BBQ, Chennai.

Inspection of 200 nos. of thickweb and UIC 60rails.

Inspection of prototype heat treated weldedcrossing manufactured by M/s HEI , Kolkata.

The progress of cases related to renewal and newregistration of vendors is given below

The directorate earned Rs. throughtesting charges of materials and other activities asshown in table.

Shri C. Sengupta , Director/M&C delivered threelectures on Ferrous & Non-Ferrous Metallurgy

33,77,153.00/-

n

n

n

n

n

n

n

n

n

n

n

n

n

n

n

n

n

n

n

PROJECTS COMPLETED

Study on rolling contact fatigue of Rail wheelinteraction.

Background :

Objective :

Status :

Study the metallurgical and chemicalbehavior of duplex stainless steel andexplore possibilities for using it as a materialfor manufacturing superstructure of wagonsin place of present ferritic stainless steel ofASTM 409 M grade.

Background :

Objective :

Status :

Framing of specification for three axle caststeel Tri-mount bogie frames & flexi-coilbogie frame and bolster for BG locomotivesin Indian Railways.

Background :

Objective :

Status :

DEVELOPMENTAL INSPECTION

VENDOR RENEWALAND REGISTRATION

REVENUE EARNED THROUGH TESTING ANDOTHERACTIVITIES

MISC. IMPORTANTACTIVITIES

Metallurgical & Chemical

44

www.rdso.indianrailways.gov.in

Annual Report 2010-2011

at IRIEEN , Nasik.

Smt. SadhanaSrivastava , ARO/M&C delivered

three lectures on Rubber , Plastic & Composites

at IRIEEN , Nasik.

ShriBaijNath , ARO/M&C delivered six lectures

on welding technology at IRIMEE , Jamalpur.

Shri V. Bhattacharya , ARO/M&C delivered lecture

on manufacturing and quality control of Elastic

Rail Clips to officers of Zonal Railways in the

training programme organized byQACivil Dte.

ShriR.K.Vijay , MS(R) delivered lecture onRadiography at IRIMEE , Jamalpur.

n

n

n

n

S. Category New cases Renewal cases Up-gradation Deletion/

TOTAL 16 26 11 16

No. registered as from Part-II DownPart-II to Part -I gradation

1 Paints 01 04 02 01

2 Welding consumables 14 18 09 14

3 Lubricants 01 01 Nil Nil

4 USFD 01

5 AT welding using TPP portion & technique Nil 02 Nil 01

Metallurgical & Chemical

45