Norma AAR M101 Axle 2007

IMP

LE

ME

NT

ED

01/

07AAR Manual of Standards and Recommended Practices

Wheels and AxlesM-10111/1/04AXLES, CARBON STEEL, HEAT-TREATED

SpecificationM-101

Adopted: 1914; Revised: 1996, 2004, 2005, 2007

1.0 SCOPEThese specifications cover heat-treated axles of all sizes for passenger cars and freight cars todesigns shown in Section G. These specifications also cover heat-treated locomotive axles. Thegrades of carbon steel axles are as follows:

2.0 QUALIFICATION AS MANUFACTURERQualification as a manufacturer of axles for use in AAR interchange service must be in accordancewith Appendix C of this specification. Qualification is effective until revoked for cause by the Com-mittee. Failure to maintain reasonable quality standards in manufacturing is an example of cause.Axle manufacturers must meet the requirements of the AAR Manual of Standards and Recom-mended Practices, Section J, Specification M-1003, Specification for Quality Assurance.

3.0 MANUFACTURE

3.1 ProcessThe steel shall be made by any of the following processes: open hearth, electric furnace, or basicoxygen.

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

3.3 Reduction PracticeThe axles may be made directly from the ingot or from blooms. The total reduction from ingot orstrand-cast bloom to forging or extrusion shall be not less than 3 to 1, unless otherwise specified.

Note: The process for manufacturing strand-cast blooms shall be designed to ensure freedom fromcenter porosity and undue segregation.

4.0 COOLING AND HEATING

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

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

4.3 After reduction, axles shall be slow-cooled in closed containers, covered conveyors, or inhoods. If axles (Grades F, G, and H) are heat-treated directly from reduction, they shall beslow-cooled following the final heat treatment.

4.4 Axles (Grades F, G, and H) that are heat-treated directly from reduction 1) shall be cooledbelow the transformation temperature or to approximately 1,000 F before any reheating opera-

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

Grade GQuenched and tempered.Grade HNormalized, quenched, and tempered.

Grades F, G, and HAxles are used in heavy duty service on locomotives, cars, and other equip-ment.11/1/04 G [M-101] 1

IMP

LE

ME

NT

ED

01/07AAR Manual of Standards and Recommended Practices

Wheels and AxlesM-101

11/1/04tion; and 2) must not be permitted to cool below 500 F without slow-cooling as defined inparagraph 4.3.Note: As the temperature of the axles approaches the minimum of 500 F, a supplemental heatsource may be necessary to ensure an effective slow-cooling cycle.

4.5 When properly vacuum-degassed steel is used, the slow-cooling requirements of paragraphs4.1, 4.3, and item 2 of paragraph 4.4 may be omitted, but axle blooms must then be pile cooled.

4.6 The slow-cooling requirements of paragraphs 4.1, 4.3, and item 2 of paragraph 4.4 may beaccomplished by piling and covering the piled blooms or axles with insulating materials in lieu ofusing closed containers, hoods, furnaces, and covered conveyors. Covered piles must be capable ofproviding effective cooling rates in accordance with the manufacturers procedure or specification.

5.0 HEAT TREATMENT

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

5.2 NormalizingAfter being heated to a suitable temperature, the axles shall be withdrawn from the furnace andallowed to cool uniformly in air. A furnace charge thus treated is termed a normalizing charge.Cooling may be accelerated by increased air circulation, which must be controlled to provide rea-sonably uniform cooling.

5.3 Double NormalizingThe procedure shall consist of two separate normalizing treatments. The second treatment shallbe performed at a lower temperature than the first treatment. A furnace charge thus treated istermed a double normalizing charge. Cooling may be accelerated by increased air circulation,which must be controlled to provide reasonably uniform cooling.

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

5.4 QuenchingAfter being heated to a suitable temperature, the axles shall be quenched in a suitable mediumunder reasonably uniform conditions. A furnace charge thus treated is termed a quenching charge.

5.5 TemperingAxles shall be reheated gradually to, and held at, a suitable temperature below the critical rangeand shall then be allowed to cool under suitable conditions. A furnace charge thus treated istermed a tempering charge.

5.6 Heat treatment may be performed in either batch-type furnaces or continuous furnaces.

6.0 STRAIGHTENINGStraightening shall be done before machining and preferably at a temperature not lower than950 F. Straightening performed at temperatures lower than 950 F shall be followed by stressrelieving or an applicable heat treatment.G [M-101] 2 11/1/04

IMP

LE

ME

NT

ED

01/


Wheels and AxlesM-10111/1/047.0 CHEMICAL COMPOSITIONThe steel shall conform to the requirements for chemical composition shown in Table 7.1.

8.0 LADLE ANALYSIS

8.1 An analysis of each heat of steel shall be made by the manufacturer to determine the percent-age of carbon, manganese, phosphorus, sulfur, and silicon. The chemical composition thus deter-mined shall be reported to the purchaser or purchasers representative and shall conform to therequirements of paragraph 7.0.

8.2 Identification of Heats in Consecutive Strand CastingsIf more than one heat is consecutively strand cast at one time, ladle analyses shall be obtained ofeach heat. If the ladle analysis of one heat does not meet the requirements of the specification, thebloom or blooms that comprise a mix of the two consecutive heats shall be deemed to be outside therequirements of the specification unless additional chemical analyses prove compliance. If bothladle analyses are in compliance with the specification, the heat number assigned to the cast prod-uct shall remain unchanged until all of the steel in the bloom is from the following heat. Alterna-tively, when all of the mixed portion of two consecutive heats is in one bloom, that bloom may begiven the heat number that comprises the larger portion of the bloom on either side of the mixedportion.

9.0 CHECK ANALYSISAnalysis may be made by the purchaser from one axle representing each heat. The chemical com-position thus determined shall conform to the requirements of paragraph 7.0, subject to tolerancesincluded in Table 9.1. The sample for these analyses shall be taken from one end of the test axle orfull-size prolongation at a point midway between the center and surface. If drillings are taken,they shall be obtained using a 5/8-in.-diameter drill, or turnings may be taken from a tensile testspecimen.

Table 7.1 Chemical compositionGrade F Grades G and H

Heat-TreatedMin. Max. Min. Max

Carbon, percentage 0.45 0.59 Manganese, percentage 0.60 0.90 0.60 0.90Phosphorus, percentage 0.045 0.045Sulphur, percentage 0.050 0.050Silicon, percentage 0.15 0.15

Table 9.1 Permissible variations for check analysisPermissible Variations, Over the Maximum Limit

or Under the Minimum LimitElements PercentageManganese 0.030Phosphorus 0.008Sulphur 0.008Silicon 0.02011/1/04 G [M-101] 3

IMP

LE

ME

NT

ED



11/1/0410.0 TENSION TESTS

10.1 Grades F, G, and H axles shall conform to the requirements in Table 10.1.

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

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

10.4 The tensile properties for all grades listed in Table 10.1 shall be determined by theprocedure described in ASTM A 370, Standard Methods and Definitions for Mechanical Testing ofSteel Products. The yield strength shall be determined using the 0.2% offset technique. AClass B2 or more accurate extensometer shall be used.

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

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

11.0 TENSION TEST SPECIMENS

11.1 Tension test specimens shall be taken from the test prolongation or an axle in accordancewith the provisions of paragraph 12.0.

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

11.3 Tension test specimens shall conform to dimensions shown in Fig. C.1.

11.4 Tension tests from the prolongations shall have minimum tensile strength and yield pointvalues 5% greater than shown in Table 10.1. For example, Grade F tension tests from axle prolon-gations shall have 92,500 psi minimum tensile strength and 52, 500 psi minimum yield point.

11.5 Tension test specimens from axles shall be taken from the journal of the axle at themid-radius, halfway between the surface and center, with the gauge dimension parallel to the axisof the axle. For tensile specimens removed from the prolongation, samples shall be taken from themid-radius, halfway between the surface and center, with the gauge dimension parallel to the axisof the axle.

Table 10.1 Tensile requirements for carbon steel heat-treated axlesSize

(Solid Diameter or Thickness)(in.)

TensileStrength

(psi)

YieldStrength

(psi)

Elongationin 2 in.

(percentage)

Reductionof Area

(percentage)Grade Over Not Over Min. Min. Min. Min.

F(Double Normalizedand Tempered)

8 88,000 50,000 22 37

G 4 90,000 55,000 20 39(Quenched 4 7 85,000 50,000 20 39and Tempered) 7 10 85,000 50,000 19 37

H(Normalized, 7 115,000 75,000 16 35Quenched, 7 10 105,000 65,000 18 35and Tempered)G [M-101] 4 11/1/04

IMP

LE

ME

NT

ED

01/


Wheels and AxlesM-10111/1/0412.0 PROLONGATION FOR TEST

12.1 For test purposes, prolongations shall be attached to at least 5% of the axles in each sizeclassification of each heat in each heat-treating lot.

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

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

13.0 MICROSCOPIC TEST FOR HEAT-TREATED AXLES (GRADES F, G, AND H)

13.1 A specimen, representing each size classification of each heat in each heat-treatment lot,shall be taken for microscopic test from the tension test specimen. This section for microscopic testshall be cut from the large undistorted portion of the tension test specimen in such a way as willgive a face transverse to the axis of the axle.

13.2 The face shall be polished practically free from scratches and shall be etched to define themicrostructure. The specimen shall be examined under a magnification of 100 diameters.

13.3 The entire specimen shall show a uniform, fine-grained structure, and shall have a grainsize of 5 or finer as measured in accordance with ASTM Standard Method E112, latest version.

14.0 NUMBER OF TESTS

14.1 Unless otherwise specified by the purchaser, mechanical tests for grades and sizes shown inTable 10.1 shall be made from heat-treated axles as covered in paragraph 14.2

14.2 One test per grade, per heat, per size classification is required, but each test shall representno more than 70 axles, including the test axle. The axles represented by this test shall be called aheat-treatment lot. Each heat-treatment lot of axles shall be heat-treated together, whether inbatch-type or continuous furnaces. In the event that the mechanical properties of a test do not con-form to the requirements specified, all of the axles from the heat-treatment lot are to be retreated inaccordance with paragraph 15.2 of this specification.

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

15.0 RETEST

15.1 If the results of the mechanical tests of any lot do not conform to the requirements specifiedbecause a flaw developed in the test specimen during testing, a retest shall be allowed if the defectis not caused by ruptures, cracks, or flakes in the steel.

15.2 If the result of the mechanical test of any lot of Grade F, G, or H axles does not conform tothe requirements specified, the axles may be retreated, but not more than three additional times,and retests shall be made in accordance with paragraph 10.0.

16.0 ULTRASONIC TESTING

16.1 Ultrasonic testing is required for all heat-treated axles.

16.2 Time of InspectionInspection shall be made after axle ends are machined and centered, but prior to drilling the capscrew holes.11/1/04 G [M-101] 5

IMP

LE

ME

NT

ED



11/1/0417.0 TEST EQUIPMENT AND INSPECTION PERSONNEL REQUIREMENTS

17.1 Test EquipmentThe instrument or ultrasonic flaw detector shall be a pulse-echo-type, broadband pass amplifierwith the capability of operating transducers in the range of .4 MHz to 10 MHz.

17.1.1 The ultrasonic transducer shall be operated at a 2 1/4 MHz frequency for both penetrabil-ity and discontinuity detection for heat-treated axles or equivalent such as ISO 9712 or othernational standards that have similar testing and certification requirements and have beenreviewed and deemed acceptable by the AAR. When equivalent processes are used, applicantswill forward their specifications to the AAR with their application under the provision of AppendixC.

17.1.2 The instrument may use various transducers or piezoelectric elements ranging in sizefrom 3/4-in. to 1-in. diameter or 1-in. square. The transducer type is at the option of the axle man-ufacturer. Other transducers of similar response capability as those described may be used.

17.1.3 Single or multiple transducers may be used for scanning. However, the signal for eachtransducer in a multiple set shall be individually monitored.

17.1.4 Ultrasonic test instrumentation shall be calibrated and certified annually or wheneverrepairs are made or parts replaced that may affect the performance of the instrument.

17.1.5 A suitable couplant shall be used between the test surface of the axle and the transducer.The transducer face, test surface of the axle, and couplant shall be free of contaminants that wouldaffect the quality of sound transmission.

17.2 Personnel Requirements for Ultrasonic Inspection

17.2.1 All personnel engaged in ultrasonic operations will be qualified to NDT (nondestructivetesting) Level I according to the qualification requirements as defined by the American Society forNondestructive Testing, Recommended Practice SNT-TC-1A, latest edition.

17.2.2 All personnel conducting inspection setups and machinery setups will be trained and qual-ified to meet the criteria for NDT Level II for ultrasonic testing as defined by the American Societyfor Nondestructive Testing, Recommended Practice SNT-TC-1A, latest edition.

17.2.3 Each manufacturer will employ the services of an individual who will be trained and qual-ified to meet the criteria for NDT Level III for ultrasonic testing as defined by the American Soci-ety for Nondestructive Testing, Recommended Practice SNT-TC-1A, latest edition.

17.3 RecordsEach facility shall maintain the following:

A procedure specification for each of its qualified ultrasonic testing procedures A copy of each of its qualified ultrasonic testing procedures posted in the ultrasonic testing

area Records of test results Certification records, based on the requirements in paragraphs 17.0 through 17.2.3, for all

qualified personnel engaged in ultrasonic inspection testing. These records shall be attested by a responsible official of the facility and shall be accessible to the AAR represen-tative.G [M-101] 6 11/1/04

IMP

LE

ME

NT

ED

01/


Wheels and AxlesM-10111/1/0418.0 INSTRUMENT SENSITIVITY, SCANNING, AND DISTANCE AMPLITUDE CORRECTION

18.1 Instrument Sensitivity

18.1.1 Prior to testing the instrument, sensitivity shall be adjusted to produce an indication ofthe amplitude specified in Table 18.1 below from a reference test block 16 in. long, manufacturedfrom a Grade F axle forging having a 1/8-in.-diameter, 1-in.-deep, flat-bottom hole drilled perpen-dicular to and at a distance of 15 in. from the test end face of the axle section.

18.1.2 Reference blocks shall be kept free of dirt, rust, grit, or defacement and shall be inspectedsemiannually for compliance with a surface finish of 80 in. to 125 in. Inspection certificationrecords shall be maintained and shall indicate inspector, inspection date, and surface finish.

18.1.3 At the sensitivity established in paragraph 18.1.1, the instrument shall detect inheat-treated reference axles a flat-bottom hole of the size and distance specified in Table 18.2.

18.2 Scanning

18.2.1 Scanning shall be performed from both end faces, which shall have a surface finish notexceeding 125 in. finish. The scanning shall include the maximum end face area obtainable bymanual or automated inspection techniques.

18.2.2 The end faces of the axles and the surface of the transducer shall be free of dirt or grit dur-ing testing. Periodic tests shall be made during production testing against the reference blockdescribed in paragraph 18.1.1 and adjustments shall be made to instrument controls to ensurecompliance with the specifications.

18.2.3 During scanning, the amplitude of the indication from the end face opposite the trans-ducer shall be monitored. The amplitudes of all discontinuity indications shall be evaluated notonly with respect to the distance from the test surface (see paragraph 18.3), but also with respectto the effect on the back reflection amplitude (see paragraph 19.1). During the discontinuityinspection test, an additional 6 dB minimum shall be added to the reference or sensitivity level forscanning purposes. All discontinuity evaluation shall be performed at the original recorded sensi-tivity level prior to final disposition.

18.2.4 Results of scanning of each axle shall be recorded by axle serial number. Records of resultsshall be maintained for at least 5 years.

18.3 Distance Amplitude CorrectionThe amplitude of an ultrasonic indication must be considered in relation to its distance from thetesting surface to evaluate its significance. This can be accomplished by an electronic device or bydistance-amplitude curves (DAC) that are described in Appendix B, paragraph 2.0.

Table 18.1 Instrument sensitivity settingIndication Amplitude

[% Full Screen Height (FSH)]Heat-treated axles 20

Table 18.2 Required size (flat-bottom holes) detectable at various distances from end facesTest Distance up to 15 in.

Heat-treated axles 1/8 in.Test Distance 15 in.30 in.

Heat-treated axles 1/4 in.Test Distance Over 30 in. to Mid-Length

Heat-treated axles 3/8 in.11/1/04 G [M-101] 7

IMP

LE

ME

NT

ED



11/1/0419.0 REJECTION

19.1 Longitudinal PenetrationAxles that do not produce a 40% minimum full screen height (FSH) back reflection from the endface opposite the search unit shall be rejected or made acceptable by heat treatment.

19.2 Discontinuity TestThe axle shall be rejected if the amplitude of any discontinuity indication exceeds the indicationlevels obtained from the flat-bottom holes listed in Table 18.2, considering the distance amplitudecorrection as described in paragraph 18.3

20.0 RECALIBRATIONCheck the calibration of the instrument using the calibration block and technique previouslyestablished when any of the following occur:

20.1 Every 4 hours of continuous use

20.2 Change in operators

20.3 Change in transducers, cables, and other accessories

20.4 Loss of power or equipment malfunction

21.0 DIMENSIONS AND TOLERANCES

21.1 For other than the standard freight and passenger car axles referenced in this specification,standard tolerances and allowances will apply, if not specified in axle drawings provided by thepurchaser.

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

21.3 For all axles ordered for finished end facing by the purchaser, the overall length shall rangefrom 1/8 in. to 1/4 in. over the specified minimum length.

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

21.5 The smooth machined body shall be to the specified size, with no more than 1/8 in. over onthe diameters and shall have no more than 1/8 in. allowance longitudinally at each change of crosssection, unless specified otherwise in Fig. C.3.

22.0 WEIGHTThe approximate weights of the passenger and freight car axles covered by this specification areshown in M-101.

23.0 WORKMANSHIP AND FINISH

23.1 Axles shall be machined to a smooth machined finish between the wheel seats. The wheelseats and journals shall be rough machined; the rough machining shall be free from objectionableridges and chatter marks. Journals, dust guard seats, and wheel seats of axles supplied in finishedform will comply with applicable provisions of the AAR Manual of Standards and RecommendedPractices, Section G, Part II, Wheel and Axle Manual.

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

23.3 The interpretation of injurious defects in axles shall comply with Appendix A, Interpreta-tion of Defects Considered Injurious in Axles.G [M-101] 8 11/1/04

IMP

LE

ME

NT

ED

01/


Wheels and AxlesM-10111/1/0424.0 MARKINGAxles shall be legibly cold stamped with characters not less than 1/4 in. high in accordance withthe AAR standard marking requirements shown in Fig. C.2.

25.0 INSPECTION

25.1 The inspector representing the purchaser shall have free entry, at all times while the workon the contract of the purchaser is being performed, to all parts of the manufacturers works thatconcern the manufacture of the material ordered. The manufacturer shall afford the inspector, freeof charge, all reasonable facilities and necessary assistance to satisfy the inspector that the mate-rial is being furnished in accordance with these specifications. Tests and inspection for acceptanceshall be made at the place of manufacture.

25.2 The purchaser may make tests to cover the acceptance or rejection of the material in pur-chasers own laboratory or elsewhere. Such tests shall be made at the expense of the purchaser.

25.3 The inspector shall examine each axle in each heat for workmanship, defects, and confor-mity to the dimensions given on the order or drawing. If in this inspection defects are found thatthe manufacturer can remedy, manufacturer may correct such defects.

26.0 REJECTION

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

26.2 Axles that show injurious defects subsequent to their original inspection and acceptance atthe manufacturers works or elsewhere will be rejected and the manufacturer shall be notified.

27.0 REHEARINGSamples of axles tested in accordance with these specifications that represent rejected materialshall be held for 14 days from date of the test report. In case of dissatisfaction with the results ofthe tests, the manufacturer may request a hearing within that time.

28.0 CERTIFICATIONUpon request of the purchaser in the contract or order, a manufacturers certification that thematerial was manufactured and tested in accordance with this specification, together with areport of the test results, shall be furnished at the time of shipment.

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

29.1 Microscopic TestsThe prolongation from the largest axle in each heat shall be sawed normal to the axis of the axleand shall then be split longitudinally. The transverse and the longitudinal face shall be etched formicroscopic examination. Reference shall be made to Specification ASTM E381, Standard Methodof Macroetch Testing Steel Bars, Billets, Blooms, and Forgings.

29.2 The purchaser may specify axle wheel seat diameters 1/8 in. larger than those shown underdimension I in Fig. C.3.

30.0 This specification includes Appendices A, B, C, Figs. C.1 through C.5, and M-101.11/1/04 G [M-101] 9

IMP

LE

ME

NT

ED


Wheels and AxlesAPPENDIX A M-101

11/1/04APPENDIX AINTERPRETATION OF DEFECTS CONSIDERED INJURIOUS IN AXLES

1.0 The conditions that have been most difficult for inspectors to evaluate are light lines visible tothe normal unaided eye, variously described as actual seams, hairlines, stringers, shadow seams,ghost lines, etc., that appear after the axles have been finish-machined and burnished or ground. Itis therefore advisable to describe these conditions in more detail.

2.0 The interpretation of injurious defects as enumerated below is not to be considered asprecluding other unforeseen or objectionable conditions not specifically listed. The right of thepurchaser is reserved to reject temporarily such axles and make final settlement on the basis offurther negotiations between representatives of the manufacturer and the purchaser who areespecially qualified to decide such questions.

3.0 Any transverse or circumferential seams, cracks, or laps of indeterminate depth on the axlesurfaces other than the discolorations listed in paragraph 4.0, regardless of their location, areconsidered to be injurious and are cause for rejection without further machining.

4.0 Ghost lines, shadow marks, or other similar discolorations, visible to the normal unaided eyethat are not actual separations in the metal are not considered injurious, regardless of location.

5.0 Any longitudinal discontinuity, variously termed hairline, stringer, or fine seam, in machinedfillets is considered to be injurious and is cause for rejection without further conditioning.

6.0 JOURNALS AND DUST GUARDS

6.1 Roller Bearing AxlesFine longitudinal discontinuities on the finished (burnished or ground) surfaces variously termedhairlines, stringers, or fine seams are not considered injurious if they meet the following condi-tions:

6.1.1 Must not extend into fillets.

6.1.2 Must not be over 3/4 in. long individually in the journal or 1/2 in. long individually in thedust guard seat.

6.1.3 Total length of such imperfections over 1/4 in. long must not exceed 2 in. in any one end ofaxle.

7.0 WHEEL AND GEAR SEATS

7.1 Freight Car Axles (Roller Bearing)Longitudinal seams in wheel seats of freight car axles are not considered injurious if they meet thefollowing conditions:

7.1.1 Must not extend into the dust guard or body fillets.

7.1.2 Must not be over 2 in. long individually.

7.1.3 Total length of such imperfections, 1/4 in. to 2 in. long, must not exceed 4 in. in any one endof axle.

7.2 All Other AxlesLongitudinal discontinuities on the finished machined surface of wheel and gear seats, variouslytermed hairlines, stringers, fine seams, tight seams, surface imperfections, etc., are not consideredinjurious if they meet the following conditions:

7.2.1 Must not extend within 1 1/2 in. of either end of wheel or gear seat.

7.2.2 Must not be over 1/2 in. long individually.G [M-101] 10 11/1/04

IMP

LE

ME

NT

ED

01/


Wheels and AxlesAPPENDIX AM-101

11/1/047.2.3 Total length of such imperfections, 1/4 in. to 1/2 in. long, must not exceed 3 in. in any oneend of axle.

8.0 AREAS BETWEEN WHEEL (AND GEAR) SEATS (BODY)

8.1 Machined BodiesLongitudinal discontinuities on the finished surfaces, variously termed hairlines, stringers, or fineseams, are not considered injurious if they meet the following conditions:

8.1.1 Must not extend into fillets adjacent to wheel or gear seat.

8.1.2 Must not be over 1/2 in. long individually.

8.1.3 Total length of such imperfections, 1/4 in. to 1/2 in. long, must not exceed 1 1/2 in. in any12 in. of body length.

8.1.4 Axles containing longitudinal discontinuities in the body in excess of those described inparagraphs 8.1.2 and 8.1.3 above may be reconditioned by grinding or machining, provided thediameter is not reduced below the specified limit.11/1/04 G [M-101] 11

IMP

LE

ME

NT

ED


Wheels and AxlesAPPENDIX B M-101

11/1/04APPENDIX BDISTANCE AMPLITUDE CORRECTION

1.0 ALTERNATE REFERENCE STANDARDSAlternate references may be used to establish the test sensitivity if they are cross-referenced withthe reference test block described in paragraph 18.1.1. For example, the following are alternatereferences for heat-treated axles that give equivalent sensitivity: 1) a 1-in. indication from a #1series A Alcoa block; and 2) a 1 1/2-in. indication from an ASTM E-127 block #1-0300.

2.0 DISTANCE-AMPLITUDE CORRECTIONThe amplitude of an ultrasonic indication from a given discontinuity size varies with its distancefrom the test surface. To compensate for this effect, a distance-amplitude relationship is employed.The relationship can be established by an electronic device or by curves. Because the dis-tance-amplitude relationship is influenced primarily by the ultrasonic transducer and instrument,it is necessary to relate this factor to the specific equipment used. Appropriate distance-amplitudecurves shall be developed. A typical example is shown in Fig. B.2 as related to the axle in Fig. B.1.

3.0 SPURIOUS ULTRASONIC INDICATIONS FROM CONTOUR VARIATIONSBecause an axle varies in cross-section, it is possible to produce spurious indications, particularlyat changes of cross-section. These must be recognized and are not reason for rejection. It is notpractical to define these indications in the specification, but the competent operator or technicianwill recognize these spurious indications as responses from axle contours.

4.0 NEAR-FIELD RESOLUTIONIt should be recognized that detection of discontinuities near the test surface is limited by theultrasonic test frequency. In the case of heat-treated axles, this is approximately 1 in. from the testsurface.

Fig. B.1 Showing location of reference holes in axles

Fig. B.2 Typical distance-amplitude curve for heat-treated axle (as determined with a Sperry reflectoscope, Type UM using a 1 1/8-in.-diameter, 2.25 MHz quartz transducer)G [M-101] 12 11/1/04

IMP

LE

ME

NT

ED

01/


Wheels and AxlesAPPENDIX CM-101

11/1/04APPENDIX CQUALIFICATION OF MANUFACTURERS PLANT AS A PRODUCER OF

AXLES FOR AAR INTERCHANGE SERVICE

1.0 Applications for approval are to be submitted to the AAR. AAR prefers electronicsubmissions. However, if an electronic copy is not provided, then applicant should provide 15copies of the printed documentation. Applicants should provide brochures and information thatwill provide a general description of the plant and the equipment to be used in the production ofaxles. In the event it is desired to deliver mounted wheel sets, information indicating thatequipment is available to comply with the wheel mounting requirements of the AAR Manual ofStandards and Recommended Practices, Section G, Part II, Wheel and Axle Manual, should beincluded.

2.0 After satisfactory review of the data submitted with the application, the Committee willauthorize the applicant to contact the AAR for information concerning product testing. This willconsist of the applicant furnishing three axles, at applicants expense, for testing by the AAR. Allcosts are to be paid by the applicant upon notification of the testing charges.

3.0 Subsequent to the satisfactory completion of the tests and approval by the Committee of testresults, the AAR will inspect for proper equipment the plant where the axles are to be producedper S-649. If mounted wheels are to be provided, an AAR inspection will be arranged for the wheelshop. These inspections will require that all costs be paid by the applicant. Upon the granting ofAAR approval, company marks to be stamped on the axle end face will be assigned.

4.0 All plants desiring to maintain their status as an AAR-approved manufacturer of axles foruse in AAR interchange service must be inspected as described in S-649. The costs of inspectionare to be borne by the axle producer. In the event that a facility fails to satisfy inspection or testingexpense obligation, the AAR, in conjunction with the Committee, reserves the right to withhold orwithdraw approval.

5.0 In the event that a facility ceases production for less than a year and has not received itsscheduled annual inspection, an inspection of the facility is required prior to the delivery of anyitems for use in interchange service. In the event a plant ceases production of axles for AARinterchange service for more than 60 days and less than 1 year, the AAR must be notified no laterthan 2 weeks prior to reopening.

6.0 In the event a plant does not receive its annual inspection or ceases production of axles forAAR interchange service for more than 1 year, requalification will be required prior to delivery ofany items for use in AAR interchange service.

7.0 In addition to the foregoing, axle manufacturers must meet the requirements of the AARManual of Standards and Recommended Practices, Section J, Specification M-1003, Specificationfor Quality Assurance.

8.0 All plants desiring to maintain their status as an AAR-approved manufacturer of axles foruse in AAR interchange service must also have their steel suppliers and heat-treatingsubcontractors inspected if they do not use their own facility. These inspections will be made inconjunction with the facility inspection, and the cost will be borne by the applicant.11/1/04 G [M-101] 13

IMP

LE

ME

NT

ED


Wheels and AxlesAPPENDIX C M-101

11/1/04Fig. C.1 Standard round tension test specimen with 2-in. gauge lengthParagraph 11.3

NOTE:THE GAUGE LENGTH, PARALLEL SECTION, AND FILLETS SHALL BE AS SHOWN, BUT THE ENDS

MAY BE OF ANY SHAPE TO FIT THE HOLDERS OF THE TESTING MACHINE IN SUCH A WAY THAT THE LOAD SHALL BE AXIAL.G [M-101] 14 11/1/04

IMP

LE

ME

NT

ED

01/



11/1/04Fig. C.2 AAR standard marking requirementsParagraph 24.0

AAR STANDARD AXLE MARKINGS

General Notes:Refer to the latest mechanical division circular letter listing of AAR-approved axle manufacturers for current approval status. All marks will be deeply and legibly stamped withcharacters not less than 1/4 in. high. All marks for freight car roller bearing axles must be located adjacent to the periphery of the centering hole. Manufacturers must finish oneend of the axle for stamping. The above are the minimum marking requirements, but the locations on individual items may vary from that illustrated.

NOTES:1. LABORATORY ACCEPTANCE STAMPFOR USE BY PURCHASER TO SIGNIFY

ACCEPTANCE OF AXLES SO MARKED PRIOR TO SHIPMENT BY PRODUCER2. SERIAL NUMBER.3. MANUFACTURERS NAME OR BRAND

4. MONTH AND YEAR MADE5. GRADE OF AXLE

6. HEAT IDENTIFICATION NUMBER

BF Bumar-Fablock S.A. Chrzanow. PolandBSa/ Bethlehem Steel Corporation Johnstown, PACAF Construcciones y Auxiliar de Ferrocarriles (CAF) Beasain, SpainCBa/ Cobrasma BrazilCF Valdunes (formerly Creusot-Loire) Dunkerque, FranceCHB Baotou Baotou Inner

Mongolia PRCCHT Jinxi Axle Company LTD. (Formerly Norinco Jinxi) Taiyuan, Shanxi

Province, P.R.CDDAP DDAP/RAX Dneprderzhinsk,

UkraineDSS JSC Dneprospetsstal, Zaporozhye (DSS) Zaporozhye,

UkraineHM Huta Gliwice-Osie Sp. zo.o Gliwice, PolandJAW Standard Forged Products Johnstown, PAKWa/ Klockner West GermanyL Lucchini Siderugica Spa (Formerly Temi) Lovere, ItalyLCKZ LugCentroKuZ Lugansk, UkraineLP Huta L. W. (Formerly Lucchini Poland) Warsaw, PolandMKa/ Makrotek MexicoMRF Standard Forged Products McKees Rocks,

PennsylvaniaMW MWL Rodas & Eixos LTDA (Formerly Mafersa) Cacapavz, Sao

Paulo, BrazilRW S. C. SMR S.A. Bals, RomaniaSCOTa/ Scot Forge Clinton, WisconsinSFC or Sa/ Standard Forgings SMI Sumitomo Metal Industries LTD. Osaka, JapanSPTa/ British Steel Templebourough

Works, England

SSD Standard Steel LLC. Burnham, Pennsylvania

SW SWASAP Works Germiston, South Africa

Ta/ British Steel Trafford Park Works, England

THM or TZ Taiyuan Heavy Machinery (Group) Co. LTD. Taiyuan, Shanxi Province, P.R.C

TW plus a/ Hawker Siddeley Trenton CanadaUF Ural Forge Chebarkul, RussiaUSS-Fa/ United States Steel Corp. Fairfield WorksUSS-Ga/ United States Steel Corp. Gary WorksUSS-Ha/ United States Steel Corp. Homestead WorksV Valdunes (formerly Creusot-Loire) Valenciennes,

FranceWAP Rail Wheel Factory Indian Railways (Formerly

Wheel and Axle Plant)Yelahanka, Bagalore, India

ZB Bonatrans a.s. (Formerly ZAD) Bohumin, Czech Republic

a/ No Longer in Production

F =Double Normalized and TemperedG =Quenched and TemperedH =Normalized, Quenched and Tempered11/1/04 G [M-101] 15

IMP

LE

ME

NT

ED



11/1/04Fig. C.3 Axle for freight car roller bearingraised wheel seat (page 1 of 2)Standard 1963; Revised 1984, 1998; Effective March 1, 1985

Paragraph 21.5 and Paragraph 29.2

!

"!

#$ %!

&' (

)

"*$+

,

-,%.(! # ,

,-

#"

,

/01#%%

%"$2

%"$2

%"$2 "!

!

$$%

#%$%

"*$+

& $%!#'%3

%!'"%

& $%!#'%3

%!'"%

%!4'%3

%!4'%3

%!4'%3

& $%!#'5

%!'5

%!'%3

678!'

(

%!'(

NOTES:1. I DIMENSION TOLERANCE IS +0.015 0.015.2. MAXIMUM ALLOWABLE RUNOUT BETWEEN G AND H IS .006" TOTAL DIAL INDICATOR.3. MAXIMUM ALLOWABLE RUNOUT BETWEEN G AND I IS .008" TOTAL DIAL INDICATOR.4. FOR 7" 12" JOURNALS, END CHAMFER IS 4 15' 5/8" 1/8".5. REQUIRED FOR PRESS FIT OF ROLLER BEARING BACKING RING WHERE THE H

DIAMETER IS TOLERANCED. FINISH TO 125 IN. MAXIMUM WHEN TOLERANCED.6. THE "W" DIMENSION CANNOT EXCEED THE TOLERANCE LIMITS OF THE GAUGE SHOWN IN

MSRP SECTION G-II, FIG. 5.26.7. RUNOUT ON JOURNAL SURFACE G, WHEN ROTATED ON CENTERS, MUST NOT EXCEED

.015" TOTAL DIAL INDICATOR.8. DIMENSIONS B AND N ARE CONSIDERED ENGINEERING DATA FOR TRUCK DESIGN AND

DO NOT NECESSARILY AGREE WITH AXLE MANUFACTURING TOLERANCES.9. JOURNAL FINISH MUST NOT EXCEED 63 IN., IF GROUND OR TURNED ONLY. IF TURNED

AND ROLLED, THE TURNED FINISH MUST NOT EXCEED 125 IN., AND THE ROLLED FINISH MUST NOT EXCEED 16 IN.

Fig. 5.8G [M-101] 16 11/1/04

IMP

LE

ME

NT

ED

01/



11/1/04CLAS

SIFI

-CA

TION

OF

AXL

ESI

ZE O

F JO

URNA

L

DIME

NSIO

NS

BC

DE

GH

IJ

KM

NO

RT

UV

WX

Y

D5 1

/2

105 1

/2"1 3

/4"7 5

/8"3"

max 5

.1915

min.

5.190

56 3

/8"7 9

/16"

6 3/4"

5 7/8"

62 1/

2"77

"86

1/8"

1 3/4"

7/8"

966

"1 7

/8"10

1/6"

1 1/4"

+ 0/-

1/4

28"

E6

115 1

5/16"

1 13/1

6"7 5

/8"3"

max 5

.6915

min.

5.690

57.0

327.0

308 1

/4"7 5

/16"

6 7/16

"62

1/2"

78"

88"

1 15/1

6"1"

8

66 1/

8"2"

10 15

/16"

1 1/4"

+ 0/-

1/4

28"

F6 1

/2

126 7

/16"

1 13/1

6"7 5

/8"3"

max 6

.1915

min.

6.190

57.5

327.5

308 3

/4"7 7

/8"7 3

/8"62

1/2"

79"

89 5/

8"2 1

/8"1 1

/8"

766

1/8"

2 1/8"

11 3/

4"1 1

/4"+

0/- 1/

42

8"

G7

125 1

5/16"

2 5/16

"7 5

/8"3"

max 7

.004

min.

7.003

8.002

8.000

9 1/2"

8 9/16

"8"

62 1/

2"79

"89

1/4"

2 5/16

"1 1

/4" 7

67 1/

8"2 1

/4"11

1/16

"5/8

"

1/84

15"

K6 1

/2

94.8

53"

3.397

"7 5

/8"3"

max 6

.1915

min.

6.190

57.5

327.5

308 3

/4"7 7

/8"7 3

/8"62

1/2"

79"

87.15

6"2 1

/8"1 1

/8"7

69.29

4"2 1

/8"8.9

31"

.250"

0.2

010

L6

84.4

573.2

937 5

/8"3"

max 5

.6915

min.

5.690

57.0

327.0

308 1

/4"7 5

/16"

6 7/16

"62

1/2"

78"

85.5"

1 15/1

6"1"

8

69.08

6"2"

8.207

"

M7

94.7

503.5

007 5

/8"3"

max 6

.5040

min.

6.503

07.5

327.5

309 1

/2"8 9

/16"

8"62

1/2"

79"

87.50

0"2 1

/8"1 1

/8"

769

.500"

2 1/8"

9.000

"

Fig.

C.3

Axle

for f

reig

ht ca

r rol

ler b

earin

gra

ised

whee

l sea

t (pa

ge 2

of 2)11/1/04 G [M-101] 17

IMP

LE

ME

NT

ED



11/1/04Fig. C.4 Pin-type gauge for cap screw holes in ends of roller bearing axlesStandard 1979; Revised 1982, 1998

Freight Car AxlesClass Size (in.) A (in.) B (in.) C D (in.) E

D 5 1/2 10 3.5000 6 3/16 5.195 2 3/8 .740E 6 11 3.8750 6 11/16 5.695 2 5/8 .850F 6 1/2 12 4.2500 7 3/16 6.195 2 7/8 .955G 7 12 4.6250 8 7.008 3 1/2 1.080K 6 1/2 9 4.2500 7 3/16 6.195 2 7/8 .955L 6 8 3.8750 6 11/16 5.695 2 5/8 .850M 7 9 4.625 7 3/16 6.508 2 7/8 0.955

Amtrak Passenger Car AxlesD 5 1/2 10 3.0000 6 1/2 5.507 1 7/8 .636E 6 11 3.5000 7 6.007 2 3/8 .749F 6 1/2 12 3.8750 7 1/2 6.507 2 5/8 .749

MATERIAL: ASTM A-576, GRADE 1045 OR EQUIVALENT. PARTS TO BE HARDENED AND SURFACES MARKED G ARE TO BE GROUND. BREAK SHARP CORNERS. TOLER-ANCE ON ALL DIMENSIONS TO BE 1/64 IN. UNLESS OTHERWISE SPECIFIED.G [M-101] 18 11/1/04

IMP

LE

ME

NT

ED

01/



11/1/04Fig. C.5 Axle centering and gauge for axle center and lathe centerAdopted 1944; Revised 1966, 1979

Paragraph 21.2

NOTE:DEPTH OF COUNTERBORE IN ROUGH AXLE SHALL BE INCREASED FROM THAT SHOWN TO COMPENSATE FOR STOCK ALLOWED TO FACE AXLE. WHEN SECONDHAND

AXLES ARE RECENTERED, DIAMETER AND DEPTH MAY BE INCREASED SUFFICIENTLY TO PRODUCE AN ACCURATE 60 CENTER.11/1/04 G [M-101] 19

IMP

LE

ME

NT

ED


Wheels and AxlesAPPENDIX C M-101THIS PAGE LEFT BLANK INTENTIONALLYG [M-101] 20 11/1/04

IMP

LE

ME

NT

ED

01/


Wheels and AxlesRP-62211/1/04WEIGHTS OF MACHINED-FINISH, RAISED WHEEL SEAT AXLES

Recommended PracticeRP-622

Adopted: 1966; Revised: 2007

Classificationof Axles

Size of Journal(in.)

Nominal Weight (lb)Rough-Turned Journal and

Wheel SeatsFreight Car Passenger Car

RollerBearing

D 5 1/2 10 810 840E 6 11 975 1005F 6 1/2 12 1175 1220G 7 12 1415 K 6 1/2 9 1168 L 6 8 900 M 7 9 1325 11/1/04 G [RP-622] 1

IMP

LE

ME

NT

ED


Wheels and AxlesRP-622THIS PAGE LEFT BLANK INTENTIONALLYG [RP-622] 2 11/1/04

Norma AAR M101 Axle 2007

Documents

Transcript of Norma AAR M101 Axle 2007