dalitete — : 91-0522-2450189 (Direct) wren ewe tm staan 91-0522-2450115(DI0) segs arene site ear et serena, 22601 a vteafPax + 91-0522-2450189 Government of india Ministry of Railways 91-0522-2458500 Research Designs & Standards Organisation = chow 226011 No.QAM/CBC/Gen! Date 11/02/2013 To, All Coupler and Bogie Manufacturers, (As per mailing list) ‘Sub:- Foundry Practices - Quality Aspects During the inspection of officials to various foundries, it is observed that there is a scope to bring in uniformity in practices being followed to ensure quality castings. In addition to the infrastructure, the technical discipline in the foundry can help ensure consistency in quality. Attempt has been made to compile the good practices for implementation in the foundries. The copy of guidelines is attached. DA- As above Copy to: Director (I&L), RDSO, 7 i) New Annex Building, W. Rly., Ast floor, Churchgate, Mumbai-400 020 They are advised to make available the ii) 3, Koilaghat Street, Kolkata-700 001. ‘copy to inspector for ensuring implement- li) Behind Shankar Market, Near IRCOT, New Delhi ation by foundry manufacturers. iv) Lucknow :——==—— — — t—‘—sS 14 144 112 116 1A 118 Sub: Foundry practices - Quality Aspects Instructions exist for compliance during manufacturing of Bogies, Couplers and other Castings, However, in view of the issues highlighted time to time, 1S necessary that cata reas are to be given special emphasis. In view of this, the following guidelines are being issued for implementation by all concerned to ensure quality of S3eting (Bogie/Coupler assembly etc). Certain good practices being followed by a few foundry units are also indicated for benefits of others. system for Melting and Heat Treatment as well as Heat Clearance by RDSO inspecting official: General: Serial no of the cast product should have as-cast five digi unic’s casting serial umber (4 digit for small foundry) and continuous in calendar year for traceability of each product. ‘After melting, all castings against a particular heat should be processed for various stages in a lot and all ites of a particular heat should be alven heat treatment in a Tor und offered for heat clearance in a lot. To exercise control, a previ’ card for ‘each heat should be strictly followed for traceability of all items in. particular heat. Mixing of different heats as well as different grades in a Iot for heat treatment is not permitted; all tems of the particular heat should be given heat treatment in a lot and foundry unit may record the same in the process card for easy traceability. ‘Against the offered lot for heat clearance, one test coupon should be used by the foundry unit for intemal heat clearance and the respective sample should be preserved and record to be shown to ROSO inspecting official before offering the lot for heat clearance. Heat clearance will be carried out by RDSO's inspecting official a5 assigned for Teepective unit. After heat treatment, test coupon will be stamped by RDSO Teebecting official for further testing afier recording details of al serial numbers of heat. Minimum five test coupons in one heat or as prescribed in respecte specification aarr pe provided. One test coupon should be used by foundry unit fo internal test should pe prey second test coupon should be used for heat clearance by RDSO's: frepector and balance three test coupons should be preserved [o re-offer in case of tdspute or re-offer after re-heat treatment or preserved for future reference, if any. FIFO system should be adopted for heat clearance as wel 35 for further inspection by ROSO's inspector. To ensure this, FIFO system should be ‘established at various stages of manufacturing process. Heat clearance should preferably be done within a stage time after pouring of castings and castings should be used on FIFO basis. It roy ie ensured that casting pouring date should be after purchase order date of Zonal Railways. ‘The foundry unit should carry out the internal testing for chemical composition and physical test before offering the lot to RDSO's inspecting official for inspection. Foundry Practices — Quality Aspects Page 1 of 29———=————— SS ttttt—t—‘“S™S 119 ‘Tensile and impact test samples should be prepared in-house for traceability of heat Serna foundries have adopted a good system of traceability by Keeping the stamped particular at one end of impact sample which is ‘detached in presence of ROSO Trepecting official for impact test. Similarly other test sample such as Nil Ductility test ample and Joriney test samples should be prepared in-house. 4.1.10 product. 1AA1 Record of heat clearance should be maintained in @ hard bound register and RDSO's inspector should check heat clearance register before further inspection of Repair through welding of any casting should only be carried out as stipulated in specification, Prior approval of RDSO inspecting oficial should be taken before any Seng repair. After welding repair stress relieving to be ensured by stress relieving {H.7) af lower temperature, but after major repairing at Zane. 1 area normalizing feat treatment should be done. Records of weld repair shall be maintained. Welding repair is not permitted for HTEA grade casting and thus welded castings of HTEA grade will be rejected. Serial number and other marking of the cast product should be integral. In case of illegible marking, Coupler Components should be rejected at the initial stage by the respective foundry unit and should not be offered for RDSO inspection. For other Castings welding should not be done to make good deficient digit of the serial umber of castings and other marking without prior approval of RDSO inspecting Daiclel, Foundry unit should use Shell core for Si. No and other marking as per drawing, 413 The latest drawing issued by Design Directorate should be used for marking purpose. The following drawings shall be referred for marking purpose: SN. Descri Drawing no. 41) Side frame & Bolster for CASNUB 22 (HS, NLB, MOD I!) WD — 86038 — S/1 (Alt 5) or latest 2 | Side frame & bolster for Container Bogie Type - LCCF 20 (C) CONTR — 9404 — SI16 | Centre pivot assembly (Flat type) for HS bogie WD — 97049 — S/3 (Alt 6) or latest Centre pivot assembly (Flat type) for CONCOR bogie CONTR 9404-S/8 ‘Centre pivot assembly (Spherical type) WD — 85079 — S/2 (Alt 24 ) or latest ‘Wedge SFICIO13 Knuckle for CBC ‘SK-62724 item -2 Alt.23 Body for CBC ‘SK-62724 item -1 Alt.23 Yoke for CBC. ‘SK-62724 item -3 Alt.23 Lock for CBC ‘SK-62724 item -6 Alt.23 ‘Knuckle thrower for CBC. ‘SK-62724 item -9 Alt.23 =JaJele|sJolofa] | |e) Toggle, hook and connector for CBC ‘SK-62724 item -5,6 & 7 Alt.23 14.14 Quality control of non DM items (not inspected by ROSO/RITES) should be ensured with implementation of Test Certificate and Internal Testing at consignee’s end. Item Wise record should be maintained in hard bound register with Drawing No//Specification materials. All stores procured through RDSO inspection (such as springs, spring plank, wear plates, brake beam, side bearer, CP washer, EM pads, Foundry Practices — Quality Aspects Page 2 of 29———— <= i | 14.15 41.16 4a 441.18 14.19 1.1.20 14.21 1.1.22 14.23 1.1.24 ‘Type of Bogie Inner Outer ‘Snubber NLB 20.32 8 12 4 NLB 22.9 10 14 4 - | HS 20.32 12 a) 4 HS 22.9 14 14 4 Mod II 22.32 12 12 4 CONCOR 20.32 12 14 4 CONCOR 22 14 14 4 brake block etc) should be stocked under covered shed to avoid damage due to rusting and mis-handling. Destructed materials of DM ‘components should be kept with proper tag for six months. Back Stops should be supplied to Wagon Unit only with proper DM (RDSO inspection). No bake core should be used for all application of casting. Core box should be ae easS at weekly interval for large foundry and at 15 days interval for smal foundry. ‘After sectioning of the casting, wall thickness should be measured and if required orective measures should be taken on the basis of sectioning report Wall thickness should be measured with D -meter from offered lot @ 1 in 20 and if required corrective measures should be taken by foundry unit Pattern checking should be ensured as per provision in STR(after manufacturing of 500 castings) Mould box Bush condition should be checked at an interval of 15 days for large foundry and one month interval for small foundry and record is to be kept. Foundry unit should carry out 100% weighment of all castings. Record is to be kept Corrective measure is to be taken on the basis of weight record, ‘mall casting such as YPSP, Striker Casting, Back Stop, Wedge, Toggle, knuckle thrower ete, should be offered for heat clearance. Items passed in heat clearance aie urther dimensional check should only be ulilized for further assembly. Record is to be kept. Before offering the bogie for RDSO inspection, the following spring group should be ensured on the basis of colour code: Knocking of casting should be ensured after adequate cooling of castings (temperature should be less than 500° C). Foundry Practices - Quality Aspects Page 3 of 29—————<= Specification - 48 BD 08 (NTT) & 56 BD 07 (TT) > Drawing No.- SK62724 Alt-21 WD-81010-S-03 All.8 or latest. S.N. Remarks 1_| Date of Cast a 2_| Month/Year, Drawing No., Manufacturer Name etc 3__| SINo. of coupler component (Coupler Body, yoke, Knuckle) 4 _| Date of Heat Clearance./ Heat treatment Records, Graphs ete Visual & operational check — No cracks, hot tears, cold shot, & weld cracks and surface condition by ‘SCRATA & Marking as per drawing. Component should operate freely in assembled condition Critical Area Non critical Area Fig.-9 Fig.-9 5 | [A [Surface Roughness AS. AS B_| Surface Inclusion B2 B4 C | Gas Porosity C2, C3 D | Laps D1 D4 E | Scabs 2 2 E | Chaplets F2 F4 G | Thermal Dressing G2 G3 H_| Mechanical Dressing HS Ha J_[Welds 2 3 @ | Microstructure of Coupler, Yoke & Knuckle — Fine Tempered, Mertensite - As recorded in heat clearance Register. Physical & Chemical properties check from heat register & passed by 7 RDSO's Inspecting official Chemicai Composition Grade -E Grade -B. C-0.28-0.33, C-0.32 (Max) Mn-0.8-1.1 Mn-0.90 (Max) 74 || Si0.4.06 Si -0.60 (Max) $-0.03 (Max) $-0.03 (Max) P.0.03 (Max) P-0.03 (Max) Cr-0.5-0.8 Ni-0.5-0.6 Mo-0.15-0.25 Foundry Practices - Quality Aspects Page 22 of 29Description Mechanical Properties Grade -E UTS-627.473_Nimm? or 84.35 | UTS-482.652 Nimm? or 49.20 kgimm? kg/mm? YS-689 Nimm* or 70.30 kg/mm? | YS-261.927 Nimm?? or 26.70 EL%-14 kg/mm? RA%-30 EL%-24 RA%-30 Hardness test (BHN) — 5% or minimum 5: Coupler Body 241-317 | Yoke Knuckle 261-291 Follower 241-311 CBC Lock Grade -B 137-208 Proof Static tension test tem Frequency of [Load applied Permanent set testing max Coupler Body | One perlot | 317.5t 0.76 mm Yoke 340.2 0.76 mm. Knuckle 1815t [0.76 mm: ‘Minimum Ultimate Load. Ttem Frequency of testing | Load applied Coupler Body One in 6 months 408 t Yoke 408 t Knuckle 295t Destructive Test (Sectioning) Item Frequency of testing ‘Coupler Body [2 % should be subject to Yoke destructive test as per annexure Il Knuckle (Sheet 1,2 &3) of amendment 1 of Jan’2004, Foundry Practices — Quality AspectsDesc Remarks 12 Wall ~ thickness: Wail thickness dimension variation 6 mm upto not | +3mm to-0.8 mm including 11 mm 11 mm upto not | +#3mmto-24mm including 19 mm 19 mm upto not | +3 mm to-3 mm including 32 mm 32mm above 446 mm to-4 mm 13 Radiography Test Casting areas for evaluation shall be rated as to level of severity by comparing them with standard reference photographs for casting solidity. Location of Radiography examination as per sketches showing: Item Frequency of testin Coupler Body ‘5% of each lot. ‘Yoke Knuckle 14 Check for Interchangeability of components and dimensional accuracy. 15 Check for Coupler operation - Check for coupleribiity 16 Weight tem ‘Weight (in Kg) Coupler Body (TT) 178.16 ‘Coupler Body (NTT) ___| 165+5%-3% Yoke 100+#5%-3% Knuckle 30.545%-3% Lock 6.59 + 5% - 3% Lock iff ever hook 1.04 Knuckle thrower 2.54 7 Facture Toughness test (Nil ductility test) — as per ASTM E 208 at - 8706 é 18 Harden ability test (Jominy Test)- One test every month Carbon Percentage _[ Minimum Hardness. 0.28-0.30 33 RC 0.31-0.33 35RC. 19 Test Lugs = 25 mm Height, 25 mm width & 13 or 16 mm thickness. For all casting at four lugs shall be cast Foundry Practices ~ Quality Aspects Page 24 of 29SN. Description Remarks 20 Welding Repair Maximum depth of repaired area must not exceed 25 mm with a imum of 3.2 mm sound metal between edge of repair weld and the nearest casting wall All casting repaired by welding shall be re-heat treatment. ‘The welding materials used for the repair of defects in Grade E casing ~ E 12015, £12016, E 13015, E 13016, E 13018 or equivalent by M&CIRDSO. The welding materials used for the repair of defects in Grade B casing - E 7015, E 7016, E 7018, E 8015, E 8016 or equivalent by M&C/RDSO. 21 Painting — Only exposed surfaces of coupler & yoke shall be painted with Black quick drying paint in accordance with IRS- R6. Paint must not be applied to the inside of the coupler or internal fittings. Painting shall be done after completion of inspection. Foundry Practices — Quality Aspects Page 25 of 29Check points for inspection of Draft Gear Specification no: WD - 49 BD - 08 Drawing no. - WD - 81010 - S-03 Annexure - X SN. Description Remarks Date of Cast Month/Year, Drawing No., Manufacturer Name etc. Date of Heat Clearance. Heat treatment Records, Graphs etc Physical & Chemical properties check from heat register & passed by RDSO's Inspecting official ‘Chemical Composition C-0.30-0.35 Mn-0.7-1.0 Si-0.35-0.80 S-0.04 (Max) P-0.04 (Max) Al-0.03-0.08 ‘Mechanical Properties UTS-448 Nimm? or 45.71 kg/mm? YS-665 Nimm* or 66.8 kg/mm? EL%-10(min) RA%-25 min ‘Gauging & Dimension checking — Gauge & Dimension checking for individual casting — 5% or Min 10 Nos. Tup hammer Test Capacity test — ‘Consignee 5% RDSO inspecting official 1%. Hardness test (BHN) — 5% or minimum 5 (137-208) interchangeability of components and dimensional accura E % Performance test of DG should be carried out at six month interval as specified in para 12.1.5 of ‘specification 49-BD — 08. The following tests shall be under taken on one draft gear once in 6 months. ¥ Capacity test ¥ — Sturdiness test. ¥ Sticking Uniformity of action Foundry Practices ~ Quality Aspects Page 26 of 29Check points in connection with inspection of castings 1 Chemical composition of other castings (other than Bogie, Coupler & Draft Gear): Item i Chemical composition Striker Casting ‘AAR M ~ 201 Gr. B CAST STEEL IS: 1030 Gr. 27-54 Knuckle Thrower, |[_C% 0.32 MAX. Toggle, Hook — & || _Mn% 0.90 MAX 2 Connector ‘Si% 0.60 MAX. se S% 0.030 MAX. a P% 0.030 MAX Centre Pivot (Top & | Grade-C = Bottom) C 0.32 Max Mn 1.85 Max. 3 Si 1.50 Max 'S 0.04 Max P 0.04 Max ‘Wedge Grade: Manganese steel - IS 276 Gr! C (1.05-1.35) 4 Mn (11-14) Si (1.0 max) 'S (0.025 max) P (0.08 max i 2 Tensile Test as per ASTM standard A 370 or latest version: Grade Tensile Yield Strength | Elongation Reduction area Strength (Min) | (Min) (Min%) % N/Sqmm NSqmm. Eg .. 827.473 689.643 14 (in,51. mm) 30 B 500 300 = [20 (in'70mm) | 30 ‘ASTM standard A 370 or latest version z c 633.3 422.2 22 (in 70 mm) 45 AAR M-201 Minor 448 665 70 (in 51 mm) 25 ‘Wedge 600 300 24 (in__mm) Bend 150 18-276 Gr ‘Striker 449.0 267 24 (in__mm) 36 eastingng ‘AAR M201 Gr. B CAST STEEL IS : 1030 Gr. 27-64 Knuckle Thrower | 482.652 261.927 24 (in__mm) 36 ‘AARM-201 GR-B) Foundry Practices - Quality Aspects Page 27 of 29Impact Test: Grade E 27.7 J min at -40°C B 25 J min at -RT c B 21 J min at -18°C Minor 20.4 J min at -28 88°C Knuckle Thrower, Toggle, 2.07 Kg.m (-7°C) Connector Grain Size & Micro Structure: E Fine Tempered Martensite B Min 4 Ferrite & Pearlite c Fine Ferrite & Pearlite ‘Minor 68 ‘Tempered Martensite Striker Casting 6108 | Ferrite & Pearlite Knuckle Thrower, Toggle, Hook &|6to9 | Tempered Martensite Connector Hardness: Grade ae Hardness BHN E -Except Knuckle __| 241-311 E - Knuckle 261-291 B 137-208, c 179-241 Modified & Concor CPT ‘Above 300 Minor 217-285 Wedge 229 Max Striker Casting 137-208 Knuckle Thrower, Toggle, Hook & | 137-208 Connector Foundry Practices — Quality Aspects Page 28 of 29List of Bogie & Coupler Manufacturer Firm's name (M/s) Address. ‘AD Electro Steel Co Pvt. Lid Baltikuri (Surkimill), Kalitala, Howrah-711 113 Besco Ltd. 7B & C Poonam, 5/2 Russel Street, Kolkata 700 001 3° | Bhilai Engineering Corporation | Hathkhoj industrial Area, Bhilai, C.G Ltd. 4 | Braithwaite & Co. Ltd., Angus | PO: Angus, Dist: Hooghly, Pin: 712 221 Works 5 Brand Alloys Ltd. | NH-2 Delhi Road, Chatra, Serampore, Hooghly (we)-23. 6 | Burn Standard Co. Ltd/Howrah | 20-22, Nityadhan Mukherjee Road, Howrah — Works 714101 tine 7 | Chittaranjan Locomotive works, | Chittaranjan, Dist: Burdwan, West Bengal- 713 Stee! Foundry | 331 8 | Frontier Alloys Steels Ltd KM 25/5 & 6, Kalpi Road, Rania, Kanpur Dehat (uP) Additional Works: Jamni Wala Road, Jamboo Khala Tehsil Paonta Sahib, Dist: Sirmaur (HP) - 173025 9 |Hindusthan “Engineering _& | 27, Sir R'NKukherjee Road, Kolkata 700 001. Industries Ltd. 10 | Jupiter Alloys & Steel (India) | Shahgunj, Chinsurah, Dist: Hooghly — 712104, Ld West Bengal. i 11__| Orient Steel industries Ltd 2, Brabourne Road, Kolkata - 700001 12 | Raneka Industries Ltd. Plot no.15, 16, 17 Sector-3 (Sagore), Pithampur, Dist: Dhar (MP) Pin:454 775 13 | Rauseena Ltd. | Sikkim House, 4/1, Middleton Street, 4” floor, (Engineering Division) Kolkata 700 071 14 | Rine Engineering Pvt. Ltd. 73A,B&C HPSIDC Indl. Area, Baddi-173 205, Dist: Solan (HP)-173205 15 | Siena Engineering Pvt. Ltd. Plot no.18A-22 and S-3/3 , Sector-Ill Sagore Kutti Road, Pithampur, Dist: Dhar-454775 (MP) 16 _ | Simplex Casting Ltd Urla Industrial Estate, Raipur. 17 | Texmaco Rail & Engineering | Belgharia, 24 Parganas, Kolkata- 700 056. Ltd (Stee! Foundry), a 18 | Titagarh Wagons Ltd. 113, Park Street, Kolkata — 700 016. 19 [Titagarh Wagons Ltd. Heavy |PO: Hindmotor, Dist: Hooghly. Engineering Division Foundry Practices — Quality Aspects Page 29 of 29