11/1/04M-101 AAR Manual of Standards and Recommended Practices Wheels and Axles AXLES, CARBON STEEL, HEAT-TREATED Specification M-101 Adopted: 1914; Revised: 1996, 2004, 2005, 2007 IMPLEMENTED 01/07 1.0 SCOPE These specifications cover heat-treated axles of all sizes for passenger cars and freight cars to designs shown in Section G. These specifications also cover heat-treated locomotive axles. The grades of carbon steel axles are as follows: Grade F—Double normalized and tempered. (All freight axles over 6 1/2 in. nominal diameter at center shall be Grade F.) Grade G—Quenched and tempered. Grade H—Normalized, quenched, and tempered. Grades F, G, and H—Axles are used in heavy duty service on locomotives, cars, and other equipment. 2.0 QUALIFICATION AS MANUFACTURER Qualification as a manufacturer of axles for use in AAR interchange service must be in accordance with Appendix C of this specification. Qualification is effective until revoked for cause by the Committee. 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 Recommended Practices, Section J, Specification M-1003, “Specification for Quality Assurance.” 3.0 MANUFACTURE 3.1 Process The steel shall be made by any of the following processes: open hearth, electric furnace, or basic oxygen. 3.2 Discard A sufficient discard shall be made from each ingot to ensure freedom from piping and undue segregation. 3.3 Reduction Practice The axles may be made directly from the ingot or from blooms. The total reduction from ingot or strand-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 from center 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 furnaces. 4.2 Blooms shall be reheated for working in a manner that will prevent internal bursts and overheating. 4.3 After reduction, axles shall be slow-cooled in closed containers, covered conveyors, or in hoods. If axles (Grades F, G, and H) are heat-treated directly from reduction, they shall be slow-cooled following the final heat treatment. 4.4 Axles (Grades F, G, and H) that are heat-treated directly from reduction 1) shall be cooled below the transformation temperature or to approximately 1,000 °F before any reheating opera11/1/04 G [M-101] 1 11/1/04 AAR Manual of Standards and Recommended Practices Wheels and Axles M-101 tion; and 2) must not be permitted to cool below 500 °F without slow-cooling as defined in paragraph 4.3. Note: As the temperature of the axles approaches the minimum of 500 °F, a supplemental heat source may be necessary to ensure an effective slow-cooling cycle. 4.5 When properly vacuum-degassed steel is used, the slow-cooling requirements of paragraphs 4.1, 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 be accomplished by piling and covering the piled blooms or axles with insulating materials in lieu of using closed containers, hoods, furnaces, and covered conveyors. Covered piles must be capable of providing effective cooling rates in accordance with the manufacturer’s procedure or specification. 5.1 Axles for heat treatment shall be reheated gradually and uniformly to a suitable temperature to refine the grain structure. 5.2 Normalizing After being heated to a suitable temperature, the axles shall be withdrawn from the furnace and allowed 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 reasonably uniform cooling. 5.3 Double Normalizing The procedure shall consist of two separate normalizing treatments. The second treatment shall be performed at a lower temperature than the first treatment. A furnace charge thus treated is termed 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 F can be met. 5.4 Quenching After being heated to a suitable temperature, the axles shall be quenched in a suitable medium under reasonably uniform conditions. A furnace charge thus treated is termed a quenching charge. 5.5 Tempering Axles shall be reheated gradually to, and held at, a suitable temperature below the critical range and shall then be allowed to cool under suitable conditions. A furnace charge thus treated is termed a tempering charge. 5.6 Heat treatment may be performed in either batch-type furnaces or continuous furnaces. 6.0 STRAIGHTENING Straightening shall be done before machining and preferably at a temperature not lower than 950 °F. Straightening performed at temperatures lower than 950 °F shall be followed by stress relieving or an applicable heat treatment. G [M-101] 2 11/1/04 IMPLEMENTED 01/07 5.0 HEAT TREATMENT 1 Permissible variations for check analysis Elements Manganese Phosphorus Sulphur Silicon 11/1/04 Permissible Variations.020 G [M-101] 3 .15 Grades G and H Heat-Treated Max.59 — 0. manganese.030 0.11/1/04 M-101 AAR Manual of Standards and Recommended Practices Wheels and Axles 7.008 0.1. If drillings are taken.0. Over the Maximum Limit or Under the Minimum Limit Percentage 0. 0.0 CHECK ANALYSIS Analysis may be made by the purchaser from one axle representing each heat.045 0.15 Max — 0. The sample for these analyses shall be taken from one end of the test axle or full-size prolongation at a point midway between the center and surface. percentage Min.1 An analysis of each heat of steel shall be made by the manufacturer to determine the percentage of carbon. percentage Sulphur.60 — — 0.1. sulfur. 9. 0. the bloom or blooms that comprise a mix of the two consecutive heats shall be deemed to be outside the requirements of the specification unless additional chemical analyses prove compliance. they shall be obtained using a 5/8-in.050 — 8. percentage Silicon. If both ladle analyses are in compliance with the specification. and silicon. Table 9. percentage Phosphorus.90 0.0 CHEMICAL COMPOSITION The steel shall conform to the requirements for chemical composition shown in Table 7. 8. phosphorus. or turnings may be taken from a tensile test specimen. If the ladle analysis of one heat does not meet the requirements of the specification. The chemical composition thus determined shall be reported to the purchaser or purchaser’s representative and shall conform to the requirements of paragraph 7.2 Identification of Heats in Consecutive Strand Castings If more than one heat is consecutively strand cast at one time. percentage Manganese. that bloom may be given the heat number that comprises the larger portion of the bloom on either side of the mixed portion. subject to tolerances included in Table 9.-diameter drill. Alternatively.1 Chemical composition IMPLEMENTED 01/07 Grade F Carbon. Min. the heat number assigned to the cast product shall remain unchanged until all of the steel in the bloom is from the following heat.45 0.0.90 0.050 — — 0.60 0. The chemical composition thus determined shall conform to the requirements of paragraph 7. when all of the mixed portion of two consecutive heats is in one bloom.008 0. Table 7.045 — 0. ladle analyses shall be obtained of each heat.0 LADLE ANALYSIS 8. 11. “Standard Methods and Definitions for Mechanical Testing of Steel Products. 10.000 65.4 Tension tests from the prolongations shall have minimum tensile strength and yield point values 5% greater than shown in Table 10.2 Unless otherwise specified.000 75.000 85.5 The use of automated devices that determine the offset yield strength without the need for plotting a stress-strain curve are acceptable. Grade F tension tests from axle prolongations shall have 92.000 50. and H axles.1 shall be determined by the procedure described in ASTM A 370. G. 11.3 Tension test specimens shall conform to dimensions shown in Fig.1. 88. G.000 105.0 TENSION TEST SPECIMENS 11. the axis of the specimen shall be located at any point midway between the center and surface of the axle or full-sized prolongation and shall be parallel to the axis of the axle. 10.000 Yield Strength (psi) Min. G [M-101] 4 11/1/04 IMPLEMENTED 01/07 F (Double Normalized and Tempered) G (Quenched and Tempered) H (Normalized. Quenched.000 16 18 35 35 10. 22 Reduction of Area (percentage) Min.000 50.” The yield strength shall be determined using the 0. 11. and H axles shall conform to the requirements in Table 10. 11.1 Grades F. Table 10. C. A Class B2 or more accurate extensometer shall be used.5 Tension test specimens from axles shall be taken from the journal of the axle at the mid-radius.000 20 20 19 39 39 37 — 7 7 10 115. (percentage) Min.2% offset technique.0 TENSION TESTS 10. samples shall be taken from the mid-radius.3 The diameter of the test prolongation shall be at least equal to the as-formed diameter of the journal.6 Tests shall be made only after final heat treatment of Grades F.1 Tensile requirements for carbon steel heat-treated axles Grade Tensile Strength (psi) Min. and Tempered) Size (Solid Diameter or Thickness) (in.000 85.11/1/04 AAR Manual of Standards and Recommended Practices Wheels and Axles M-101 10. halfway between the surface and center. For tensile specimens removed from the prolongation.000 Elongation in 2 in.4 The tensile properties for all grades listed in Table 10. 10. 11. with the gauge dimension parallel to the axis of the axle. 10.500 psi minimum tensile strength and 52. For example. 37 — 4 7 4 7 10 90.1.1. with the gauge dimension parallel to the axis of the axle. halfway between the surface and center. 500 psi minimum yield point.0.2 The size classification shall be determined by the finished diameter of the journal.000 55.1 Tension test specimens shall be taken from the test prolongation or an axle in accordance with the provisions of paragraph 12.) Over Not Over — 8 . 50. 1 If the results of the mechanical tests of any lot do not conform to the requirements specified because a flaw developed in the test specimen during testing. or H axles does not conform to the requirements specified.2 Time of Inspection Inspection shall be made after axle ends are machined and centered. 15. a retest shall be allowed if the defect is not caused by ruptures.11/1/04 M-101 AAR Manual of Standards and Recommended Practices Wheels and Axles 12.1 Unless otherwise specified by the purchaser.0 RETEST 15. In the event that the mechanical properties of a test do not conform to the requirements specified.3 Test reports shall state prolongation sizing prior to test or the use of axles for test. the axles may be retreated. per heat.0 PROLONGATION FOR TEST 12. 11/1/04 G [M-101] 5 . The axles represented by this test shall be called a heat-treatment lot. prolongations shall be attached to at least 5% of the axles in each size classification of each heat in each heat-treating lot.2 If the result of the mechanical test of any lot of Grade F. but not more than three additional times. or flakes in the steel. 14. This section for microscopic test shall be cut from the large undistorted portion of the tension test specimen in such a way as will give a face transverse to the axis of the axle.1 A specimen.0 MICROSCOPIC TEST FOR HEAT-TREATED AXLES (GRADES F. IMPLEMENTED 01/07 13. shall be taken for microscopic test from the tension test specimen. 16. but each test shall represent no more than 70 axles. all of the axles from the heat-treatment lot are to be retreated in accordance with paragraph 15. 14. but prior to drilling the cap screw holes. The specimen shall be examined under a magnification of 100 diameters.2 of this specification.3 The entire specimen shall show a uniform.2 If axles with prolongations have been expended.2 One test per grade. 16. mechanical tests for grades and sizes shown in Table 10. and shall have a grain size of 5 or finer as measured in accordance with ASTM Standard Method E112. cracks. whether in batch-type or continuous furnaces. 12.1 shall be made from heat-treated axles as covered in paragraph 14. including the test axle. 13. latest version.1 For test purposes.0 NUMBER OF TESTS 14. 13.0 ULTRASONIC TESTING 16. and retests shall be made in accordance with paragraph 10. AND H) 13. 12. 15. it may be discarded and another specimen taken.1 Ultrasonic testing is required for all heat-treated axles. G. G.2 14. per size classification is required. fine-grained structure.2 The face shall be polished practically free from scratches and shall be etched to define the microstructure.0. representing each size classification of each heat in each heat-treatment lot. Each heat-treatment lot of axles shall be heat-treated together. then axles may be used for test procurement.3 If any test specimen fails because of mechanical condition of the testing apparatus. Other transducers of similar response capability as those described may be used. .1. applicants will forward their specifications to the AAR with their application under the provision of Appendix C. 17.5 A suitable couplant shall be used between the test surface of the axle and the transducer.0 TEST EQUIPMENT AND INSPECTION PERSONNEL REQUIREMENTS 17.2 Personnel Requirements for Ultrasonic Inspection 17.3 Records Each 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. 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 representative. test surface of the axle.2. the signal for each transducer in a multiple set shall be individually monitored.2. Recommended Practice SNT-TC-1A.1 All personnel engaged in ultrasonic operations will be qualified to NDT (nondestructive testing) Level I according to the qualification requirements as defined by the American Society for Nondestructive Testing.1.4 Ultrasonic test instrumentation shall be calibrated and certified annually or whenever repairs are made or parts replaced that may affect the performance of the instrument. 17. However.3 Single or multiple transducers may be used for scanning.3 Each manufacturer will employ the services of an individual who will be trained and qualified to meet the criteria for NDT Level III for ultrasonic testing as defined by the American Society for Nondestructive Testing. based on the requirements in paragraphs 17. Recommended Practice SNT-TC-1A.1.11/1/04 AAR Manual of Standards and Recommended Practices Wheels and Axles M-101 17. The transducer type is at the option of the axle manufacturer. 17.2 The instrument may use various transducers or piezoelectric elements ranging in size from 3/4-in.1. 17. broadband pass amplifier with the capability of operating transducers in the range of . When “equivalent” processes are used. 17.2 All personnel conducting inspection setups and machinery setups will be trained and qualified to meet the criteria for NDT Level II for ultrasonic testing as defined by the American Society for Nondestructive Testing.0 through 17. latest edition. square. to 1-in. and couplant shall be free of contaminants that would affect the quality of sound transmission.2.3.2.1 The ultrasonic transducer shall be operated at a 2 1/4 MHz frequency for both penetrability and discontinuity detection for heat-treated axles or equivalent such as ISO 9712 or other national standards that have similar testing and certification requirements and have been reviewed and deemed acceptable by the AAR. 17.4 MHz to 10 MHz. latest edition. latest edition. diameter or 1-in.1 Test Equipment The instrument or ultrasonic flaw detector shall be a pulse-echo-type.1. 17. G [M-101] 6 11/1/04 IMPLEMENTED 01/07 17. The transducer face. 17. Recommended Practice SNT-TC-1A. 2 Required size (flat-bottom holes) detectable at various distances from end faces Heat-treated axles Heat-treated axles Heat-treated axles Test Distance up to 15 in. Inspection certification records shall be maintained and shall indicate inspector. finish. rust.1 and adjustments shall be made to instrument controls to ensure compliance with the specifications.0 INSTRUMENT SENSITIVITY. 1/8 in. AND DISTANCE AMPLITUDE CORRECTION 18.–30 in.1 Instrument sensitivity setting Heat-treated axles Indication Amplitude [% Full Screen Height (FSH)] 20 18. an additional 6 dB minimum shall be added to the reference or sensitivity level for scanning purposes. 18. sensitivity shall be adjusted to produce an indication of the amplitude specified in Table 18. grit.2 Reference blocks shall be kept free of dirt. long.1). Periodic tests shall be made during production testing against the reference block described in paragraph 18. the instrument shall detect in heat-treated reference axles a flat-bottom hole of the size and distance specified in Table 18. to 125 µin. the amplitude of the indication from the end face opposite the transducer shall be monitored.4 Results of scanning of each axle shall be recorded by axle serial number. During the discontinuity inspection test. 11/1/04 G [M-101] 7 .3 At the sensitivity established in paragraph 18.2. to Mid-Length 3/8 in. 18.2.-deep.1.3).3 During scanning. 1-in. 18. All discontinuity evaluation shall be performed at the original recorded sensitivity level prior to final disposition. inspection date.2.AAR Manual of Standards and Recommended Practices Wheels and Axles 11/1/04 M-101 18. 18.1 Prior to testing the instrument.2. but also with respect to the effect on the back reflection amplitude (see paragraph 19.1 Scanning shall be performed from both end faces. The scanning shall include the maximum end face area obtainable by manual or automated inspection techniques. manufactured from a Grade F axle forging having a 1/8-in. 18. and surface finish. from the test end face of the axle section.-diameter. Test Distance Over 30 in.1. SCANNING. 1/4 in. paragraph 2.2. which shall have a surface finish not exceeding 125 µin. Records of results shall be maintained for at least 5 years.3 Distance Amplitude Correction The amplitude of an ultrasonic indication must be considered in relation to its distance from the testing surface to evaluate its significance.1.0. The amplitudes of all discontinuity indications shall be evaluated not only with respect to the distance from the test surface (see paragraph 18. This can be accomplished by an electronic device or by distance-amplitude curves (DAC) that are described in Appendix B. flat-bottom hole drilled perpendicular to and at a distance of 15 in.2 The end faces of the axles and the surface of the transducer shall be free of dirt or grit during testing. 18. Table 18. IMPLEMENTED 01/07 Table 18.1.1. Test Distance 15 in. or defacement and shall be inspected semiannually for compliance with a surface finish of 80 µin.2 Scanning 18.1.1 Instrument Sensitivity 18.1 below from a reference test block 16 in. 11/1/04 AAR Manual of Standards and Recommended Practices Wheels and Axles M-101 19. The machining shall be done in a workmanlike manner.0 RECALIBRATION Check the calibration of the instrument using the calibration block and technique previously established when any of the following occur: . and other accessories 20.0 REJECTION 19.4 Rough machined journals and wheel seats shall be 1/8 in. over on the diameters and shall have no more than 1/8 in. over the finished diameters and longitudinally 1/8 in.1 Axles shall be machined to a smooth machined finish between the wheel seats. the overall length shall range from 1/8 in. allowance longitudinally at each change of cross section. the rough machining shall be free from objectionable ridges and chatter marks. The wheel seats and journals shall be rough machined. if not specified in axle drawings provided by the purchaser. Journals.5 The smooth machined body shall be to the specified size.2. C. Part II. to 1/4 in.1 For other than the standard freight and passenger car axles referenced in this specification.3 The interpretation of injurious defects in axles shall comply with Appendix A.2 Finish The axles shall be free from injurious defects.” G [M-101] 8 11/1/04 IMPLEMENTED 01/07 20. with no more than 1/8 in.” 23. and wheel seats of axles supplied in finished form will comply with applicable provisions of the AAR Manual of Standards and Recommended Practices. 23. Section G. over the specified minimum length.2 Change in operators 20. C. 22. cables.2 Discontinuity Test The axle shall be rejected if the amplitude of any discontinuity indication exceeds the indication levels obtained from the flat-bottom holes listed in Table 18. dust guard seats.4 Loss of power or equipment malfunction 21.3. “Interpretation of Defects Considered Injurious in Axles. to 1/4 in. unless specified otherwise in Fig.0 WEIGHT The approximate weights of the passenger and freight car axles covered by this specification are shown in M-101.1 Longitudinal Penetration Axles that do not produce a 40% minimum full screen height (FSH) back reflection from the end face opposite the search unit shall be rejected or made acceptable by heat treatment.0 DIMENSIONS AND TOLERANCES 21. 21. 19.1 Every 4 hours of continuous use 20. 21. 21. of metal shall be allowed at each change of cross section for finish machining. considering the distance amplitude correction as described in paragraph 18. 21.3 20. “Wheel and Axle Manual. 23.3 For all axles ordered for finished end facing by the purchaser.5. standard tolerances and allowances will apply.0 WORKMANSHIP AND FINISH 23.2 Axle centers shall conform to Fig. to 1/4 in.3 Change in transducers. The manufacturer shall afford the inspector. shall be furnished at the time of shipment. 28. and Forgings.5. 25.0 MARKING Axles shall be legibly cold stamped with characters not less than 1/4 in. larger than those shown under dimension “I” in Fig. Such tests shall be made at the expense of the purchaser. to all parts of the manufacturer’s works that concern the manufacture of the material ordered. C. a manufacturer’s certification that the material was manufactured and tested in accordance with this specification.1 through C. 27.1 Any axle that fails to meet the requirements of these specifications will be rejected.1 Microscopic Tests The prolongation from the largest axle in each heat shall be sawed normal to the axis of the axle and shall then be split longitudinally. high in accordance with the AAR standard marking requirements shown in Fig.3. 26.0 CERTIFICATION Upon request of the purchaser in the contract or order. Tests and inspection for acceptance shall be made at the place of manufacture. together with a report of the test results. all reasonable facilities and necessary assistance to satisfy the inspector that the material is being furnished in accordance with these specifications. free of charge. C. 29. 11/1/04 G [M-101] 9 .11/1/04 M-101 AAR Manual of Standards and Recommended Practices Wheels and Axles 24.2 The purchaser may specify axle wheel seat diameters 1/8 in. If in this inspection defects are found that the manufacturer can remedy.” 29.2.0 INSPECTION IMPLEMENTED 01/07 25. Billets.2 The purchaser may make tests to cover the acceptance or rejection of the material in purchaser’s own laboratory or elsewhere. B. defects. and M-101. 30. 26. manufacturer may correct such defects.1 The inspector representing the purchaser shall have free entry. 29. 25.0 This specification includes Appendices A. at all times while the work on the contract of the purchaser is being performed. The transverse and the longitudinal face shall be etched for microscopic examination.0 REHEARING Samples of axles tested in accordance with these specifications that represent rejected material shall be held for 14 days from date of the test report. Details shall be agreed upon by the manufacturer and the purchaser. and conformity to the dimensions given on the order or drawing.2 Axles that show injurious defects subsequent to their original inspection and acceptance at the manufacturer’s works or elsewhere will be rejected and the manufacturer shall be notified. Figs. In case of dissatisfaction with the results of the tests. “Standard Method of Macroetch Testing Steel Bars.0 The following supplementary requirements shall apply only when specified by the purchaser.0 REJECTION 26. the manufacturer may request a hearing within that time. Reference shall be made to Specification ASTM E381.3 The inspector shall examine each axle in each heat for workmanship. C. C. Blooms. 25. 1 Must not extend into fillets. 5. that appear after the axles have been finish-machined and burnished or ground. The right of the purchaser is reserved to reject temporarily such axles and make final settlement on the basis of further negotiations between representatives of the manufacturer and the purchaser who are especially qualified to decide such questions. ghost lines. stringers. 7. 6. etc.2 All Other Axles Longitudinal discontinuities on the finished machined surface of wheel and gear seats. shadow marks. fine seams. It is therefore advisable to describe these conditions in more detail.2.2 Must not be over 1/2 in. long. shadow seams.2 Must not be over 3/4 in.1 Must not extend into the dust guard or body fillets. stringers.1 Must not extend within 1 1/2 in. stringer. variously described as actual seams.0 Ghost lines. G [M-101] 10 11/1/04 IMPLEMENTED 01/07 3.0 Any transverse or circumferential seams. or fine seam. regardless of their location..0 The interpretation of injurious defects as enumerated below is not to be considered as precluding other unforeseen or objectionable conditions not specifically listed. or fine seams are not considered injurious if they meet the following conditions: 6. 7. 1/4 in. tight seams.1.0 JOURNALS AND DUST GUARDS 6.2 Must not be over 2 in. .1. hairlines. 2. long individually in the journal or 1/2 in. or laps of indeterminate depth on the axle surfaces other than the discolorations listed in paragraph 4.1. in machined fillets is considered to be injurious and is cause for rejection without further conditioning. 7.0 The conditions that have been most difficult for inspectors to evaluate are light lines visible to the normal unaided eye. of either end of wheel or gear seat.1. are considered to be injurious and are cause for rejection without further machining. or other similar discolorations.. long must not exceed 2 in. 7.1. in any one end of axle. regardless of location. etc.0 WHEEL AND GEAR SEATS 7.1. long individually in the dust guard seat. are not considered injurious if they meet the following conditions: 7.0 Any longitudinal discontinuity.2. long individually.3 Total length of such imperfections over 1/4 in. surface imperfections. cracks. variously termed hairline. 6.3 Total length of such imperfections.11/1/04 APPENDIX A AAR Manual of Standards and Recommended Practices Wheels and Axles M-101 APPENDIX A INTERPRETATION OF DEFECTS CONSIDERED INJURIOUS IN AXLES 1.0. to 2 in. variously termed hairlines. 7.1 Freight Car Axles (Roller Bearing) Longitudinal seams in wheel seats of freight car axles are not considered injurious if they meet the following conditions: 7.1 Roller Bearing Axles Fine longitudinal discontinuities on the finished (burnished or ground) surfaces variously termed hairlines. 4. must not exceed 4 in. long individually. visible to the normal unaided eye that are not actual separations in the metal are not considered injurious. stringers. in any one end of axle. 6. 4 Axles containing longitudinal discontinuities in the body in excess of those described in paragraphs 8.2 Must not be over 1/2 in. provided the diameter is not reduced below the specified limit.1 Must not extend into fillets adjacent to wheel or gear seat.2. stringers. are not considered injurious if they meet the following conditions: 8. must not exceed 1 1/2 in. to 1/2 in. IMPLEMENTED 01/07 8. 8.3 Total length of such imperfections.3 above may be reconditioned by grinding or machining.1. in any one end of axle. in any 12 in. long individually. 1/4 in.1.0 AREAS BETWEEN WHEEL (AND GEAR) SEATS (BODY) 8.2 and 8. variously termed hairlines. 11/1/04 G [M-101] 11 . or fine seams. 8.1. long.1.3 Total length of such imperfections.1 Machined Bodies Longitudinal discontinuities on the finished surfaces.1. 1/4 in. 8.11/1/04 M-101 AAR Manual of Standards and Recommended Practices Wheels and Axles APPENDIX A 7.1. long. to 1/2 in. must not exceed 3 in. of body length. 3.25 MHz quartz transducer) G [M-101] 12 11/1/04 IMPLEMENTED 01/07 2. The relationship can be established by an electronic device or by curves. To compensate for this effect. B. it is possible to produce spurious indications. Fig. Because the distance-amplitude relationship is influenced primarily by the ultrasonic transducer and instrument. and 2) a 1 1/2-in.1. For example. A typical example is shown in Fig. indication from a #1 series “A” Alcoa block. It is not practical to define these indications in the specification. B.0 SPURIOUS ULTRASONIC INDICATIONS FROM CONTOUR VARIATIONS Because an axle varies in cross-section. B. . Type UM using a 1 1/8-in.1. 4.0 ALTERNATE REFERENCE STANDARDS Alternate references may be used to establish the test sensitivity if they are cross-referenced with the reference test block described in paragraph 18. it is necessary to relate this factor to the specific equipment used.1. but the competent operator or technician will recognize these spurious indications as responses from axle contours.1 Showing location of reference holes in axles Fig.11/1/04 APPENDIX B AAR Manual of Standards and Recommended Practices Wheels and Axles M-101 APPENDIX B DISTANCE AMPLITUDE CORRECTION 1. from the test surface.2 Typical distance-amplitude curve for heat-treated axle (as determined with a Sperry reflectoscope.-diameter. Appropriate distance-amplitude curves shall be developed. These must be recognized and are not reason for rejection. particularly at changes of cross-section. indication from an ASTM E-127 block #1-0300. a distance-amplitude relationship is employed.0 NEAR-FIELD RESOLUTION It should be recognized that detection of discontinuities near the test surface is limited by the ultrasonic test frequency. the following are alternate references for heat-treated axles that give equivalent sensitivity: 1) a 1-in. B. 2.0 DISTANCE-AMPLITUDE CORRECTION The amplitude of an ultrasonic indication from a given discontinuity size varies with its distance from the test surface. this is approximately 1 in.2 as related to the axle in Fig. In the case of heat-treated axles. the AAR must be notified no later than 2 weeks prior to reopening.0 Subsequent to the satisfactory completion of the tests and approval by the Committee of test results. and the cost will be borne by the applicant. 2. for testing by the AAR.0 After satisfactory review of the data submitted with the application. 4. 11/1/04 G [M-101] 13 . an AAR inspection will be arranged for the wheel shop. if an electronic copy is not provided.” should be included.” 8.0 Applications for approval are to be submitted to the AAR. However.0 All plants desiring to maintain their status as an AAR-approved manufacturer of axles for use in AAR interchange service must also have their steel suppliers and heat-treating subcontractors inspected if they do not use their own facility. 5. 6. Specification M-1003. an inspection of the facility is required prior to the delivery of any items for use in interchange service. This will consist of the applicant furnishing three axles.0 In the event that a facility ceases production for less than a year and has not received its scheduled annual inspection. 3. AAR prefers electronic submissions. These inspections will require that all costs be paid by the applicant. Upon the granting of AAR approval. the AAR.0 All plants desiring to maintain their status as an AAR-approved manufacturer of axles for use in AAR interchange service must be inspected as described in S-649. company marks to be stamped on the axle end face will be assigned. the AAR will inspect for proper equipment the plant where the axles are to be produced per S-649. Section G. In the event it is desired to deliver mounted wheel sets. “Specification for Quality Assurance.0 In the event a plant does not receive its annual inspection or ceases production of axles for AAR interchange service for more than 1 year. reserves the right to withhold or withdraw approval. at applicant’s expense.0 In addition to the foregoing. then applicant should provide 15 copies of the printed documentation. Part II. the Committee will authorize the applicant to contact the AAR for information concerning product testing. If mounted wheels are to be provided. “Wheel and Axle Manual. requalification will be required prior to delivery of any items for use in AAR interchange service. axle manufacturers must meet the requirements of the AAR Manual of Standards and Recommended Practices. Applicants should provide brochures and information that will provide a general description of the plant and the equipment to be used in the production of axles. in conjunction with the Committee.11/1/04 M-101 AAR Manual of Standards and Recommended Practices Wheels and Axles APPENDIX C APPENDIX C QUALIFICATION OF MANUFACTURER’S PLANT AS A PRODUCER OF AXLES FOR AAR INTERCHANGE SERVICE IMPLEMENTED 01/07 1. The costs of inspection are to be borne by the axle producer. 7. These inspections will be made in conjunction with the facility inspection. Section J. In the event that a facility fails to satisfy inspection or testing expense obligation. information indicating that equipment is available to comply with the wheel mounting requirements of the AAR Manual of Standards and Recommended Practices. All costs are to be paid by the applicant upon notification of the testing charges. In the event a plant ceases production of axles for AAR interchange service for more than 60 days and less than 1 year. 11/1/04 APPENDIX C AAR Manual of Standards and Recommended Practices Wheels and Axles M-101 IMPLEMENTED 01/07 NOTE: THE GAUGE LENGTH. 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. gauge length Paragraph 11. Fig. C. PARALLEL SECTION.3 G [M-101] 14 11/1/04 .1 Standard round tension test specimen with 2-in. AND FILLETS SHALL BE AS SHOWN. P.2 AAR standard marking requirements Paragraph 24.R. Poland Makrotek Mexico Standard Forged Products McKees Rocks.R.C Trenton Canada Chebarkul. Italy LugCentroKuZ Lugansk.11/1/04 IMPLEMENTED 01/07 M-101 AAR Manual of Standards and Recommended Practices Wheels and Axles APPENDIX C AAR STANDARD AXLE MARKINGS NOTES: 1. Czech Republic a/ No Longer in Production 4. Zaporozhye (DSS) Zaporozhye. Osaka. SERIAL NUMBER. Spain Brazil Dunkerque. All marks will be deeply and legibly stamped with characters not less than 1/4 in. Bethlehem Steel Corporation Construcciones y Auxiliar de Ferrocarriles (CAF) Cobrasma Valdunes (formerly Creusot-Loire) Baotou Chrzanow. W. Brazil S. but the locations on individual items may vary from that illustrated. England SSD Standard Steel LLC. HEAT IDENTIFICATION NUMBER General Notes: Refer to the latest mechanical division circular letter listing of AAR-approved axle manufacturers for current approval status. France Yelahanka. MONTH AND YEAR MADE 5. Shanxi Province.s. C. Manufacturers must finish one end of the axle for stamping. SMR S. Romania Scot Forge Clinton.A. C. Valdunes (formerly Creusot-Loire) WAP Rail Wheel Factory Indian Railways (Formerly Wheel and Axle Plant) Bonatrans a.0 11/1/04 G [M-101] 15 . Fig. Poland Johnstown. Russia Fairfield Works Gary Works Homestead Works Valenciennes. Wisconsin Standard Forgings Sumitomo Metal Industries LTD. Pennsylvania MWL Rodas & Eixos LTDA (Formerly Mafersa) Cacapavz. (Formerly Norinco Jinxi) Taiyuan. Bals. The above are the minimum marking requirements. (Formerly Lucchini Poland) Warsaw. LTD. LABORATORY ACCEPTANCE STAMP—FOR USE BY PURCHASER TO SIGNIFY ACCEPTANCE OF AXLES SO MARKED PRIOR TO SHIPMENT BY PRODUCER 2. (Formerly ZAD) ZB Burnham. United States Steel Corp. Japan British Steel Templebourough Works. Shanxi Province. Bagalore. TW plus a/ UF USS-Fa/ USS-Ga/ USS-Ha/ V Hawker Siddeley Ural Forge United States Steel Corp.o Gliwice. France Baotou Inner Mongolia PRC Jinxi Axle Company LTD.C DDAP/RAX Dneprderzhinsk. Ukraine Huta Gliwice-Osie Sp.A. 3. Pennsylvania Germiston. Sao Paulo. MANUFACTURER’S NAME OR BRAND BF BSa/ CAF CBa/ CF CHB CHT DDAP DSS HM JAW KWa/ L LCKZ LP MKa/ MRF MW RW SCOTa/ SFC or Sa/ SMI SPTa/ Bumar-Fablock S. high. Ukraine JSC Dneprospetsstal. England Taiyuan. Poland Standard Forged Products Johnstown. zo. All marks for freight car roller bearing axles must be located adjacent to the periphery of the centering hole. Ukraine Huta L. Quenched and Tempered 6. P. South Africa Trafford Park Works. GRADE OF AXLE F =Double Normalized and Tempered G =Quenched and Tempered H =Normalized. SW SWASAP Works Ta/ British Steel THM or TZ Taiyuan Heavy Machinery (Group) Co. United States Steel Corp. PA Beasain. India Bohumin. PA Klockner West Germany Lucchini Siderugica Spa (Formerly Temi) Lovere. RUNOUT ON JOURNAL SURFACE “G”.2B TAP 3-HOLES COUNTERSINK 1/8" LARGER THAN BOLT DIA.26. C. 1998. * THE L DIMENSION NEED NOT BE CORRECTED FOR LENGTH EACH TIME THE WHEEL SEATS ARE TURNED ON NEW AXLES MACHINE 3 in. 6. WORN DIA. JOURNAL FINISH MUST NOT EXCEED 63 µIN. MACHINE CHAMFER TO 250 µin. ± 1" OVERALL LENGTH BREAK SHARP CORNER 1"R 1 2 V +0 1" 16 O N 1"R + 01" 1 2 16 16 CL TO CL OF JOURNAL 3"R E E K I W AXLES SHALL BE MACHINED TO 250 µin. G Y H R J ° 120 120 ° M-101 . MAXIMUM PERMISSIBLE VARIATION IN JOURNAL DIAMETER AT ANY PLACE MUST NOT EXCEED . 7. THE TURNED FINISH MUST NOT EXCEED 125 µIN. MAX. NOTES: 1. T REMOVE SHARP CORNERS. MAXIMUM WHEN TOLERANCED. L* 3" ENLARGED SECTION SHOWING OPTIONAL RADIUS WHEN USING CONTOUR GRINDER 1" + 0 1" 4 4 ( * L)3'11 2" J D 0 1" + 8 C OVER SIZE DIA.015. DEPTH OF DRILLED HOLE MUST EQUAL V DIMENSION PLUS 7" MAXIMUM. “I” DIMENSION TOLERANCE IS +0. MAX. TO 8 R.006" TOTAL DIAL INDICATOR. FINISH TO 125 µIN. IF GROUND OR TURNED ONLY. MAXIMUM ALLOWABLE RUNOUT BETWEEN “G” AND “H” IS . FIG.AAR Manual of Standards and Recommended Practices Wheels and Axles 11/1/04 APPENDIX C NOTE: V DIMENSION DESIGNATES MINIMUM LENGTH OF FULL THREAD.015" TOTAL DIAL INDICATOR.C. 3. B X ENLARGED VIEW SHOWING CONDITION AT FILLET JOINING BODY PORTION OF AXLE TO INSIDE EDGE OF WHEEL SEAT.5 and Paragraph 29. DIMENSIONS “B” AND “N” ARE CONSIDERED ENGINEERING DATA FOR TRUCK DESIGN AND DO NOT NECESSARILY AGREE WITH AXLE MANUFACTURING TOLERANCES. Fig. 9. END CHAMFER IS 4° 15' 5/8" ±1/8". Revised 1984. 8. 5. REQUIRED FOR PRESS FIT OF ROLLER BEARING BACKING RING WHERE THE “H” DIAMETER IS TOLERANCED. 2.2 G [M-101] 16 11/1/04 IMPLEMENTED 01/07 120° STAMP IDENTIFICATION MARKS ON THIS SURFACE. MUST NOT EXCEED .N.001 INCH AND THERE SHALL BE NO ABRUPT CHANGES OR STEPS OVER THE LENGTH OF THE JOURNAL.015 –0.3 Axle for freight car roller bearing—raised wheel seat (page 1 of 2) Standard 1963. Effective March 1.008" TOTAL DIAL INDICATOR. 4. BETWEEN WHEEL SEATS 2" U ±161" M ±161" MATERIAL AAR SPECIFICATION M101 1" 1" 16 R.8 T U. WHEN ROTATED ON CENTERS. MAXIMUM ALLOWABLE RUNOUT BETWEEN “G” AND “I” IS . 5. MIN. BOLT DIA.. MAX. NEW DIA. THE "W" DIMENSION CANNOT EXCEED THE TOLERANCE LIMITS OF THE GAUGE SHOWN IN MSRP SECTION G-II. IF TURNED AND ROLLED.. FOR 7" × 12" JOURNALS. 5. 1985 Paragraph 21. 8 CHECK LOCATION WITH GAUGE SHOWN ON MSRP SECTION G-II Fig. RADIUS AT SPECIFIED DIMENSION L FOR ANY WHEEL SEAT DIA. AND THE ROLLED FINISH MUST NOT EXCEED 16 µIN. 003 8.294" 2 1/8" 67 1/8" 2 1/4" 1 1/8" – 7 69.1/4 1 1/4" + 0/. 6.1905 7.1905 7. 5.500 3.750 4.530 2 5/16" I 7 5/8" 3" max 5.500" 2 1/8" 1" – 8 1 1/8"–7 1 1/4" –7 1 1/8" – 7 66 1/8" 2 1/8" 1" – 8 7/8" – 9 T Fig. C.457 4.1915 7.397" max 7.11/1/04 SIZE OF JOURNAL 5 1/2 × 10 6 × 11 6 1/2 × 12 7 × 12 6 1/2 × 9 6×8 7×9 D E F G K L M 1 3/4" C E G H G [M-101] 17 4.000 9 1/2" 8 1/4" 8 3/4" 9 1/2" 8 3/4" 8 1/4" 5 7/8" K N 7 3/8" 8" 7 3/8" 8 9/16" 8" 88" 62 1/2" 79" 87.1/4 1 1/4" + 0/.1915 6 3/8" 7 9/16" min. 7.030 5 1/2" B DIMENSIONS 9.1905 D 5 15/16" 1 13/16" 7 5/8" 3" max 5.5040 7.853" 5 15/16" 6 7/16" 3.1/4 X — — 10° 4°15" 2°8" 2°8" 2°8" Y 11/1/04 CLASSIFICATION OF AXLE IMPLEMENTED 01/07 M-101 AAR Manual of Standards and Recommended Practices Wheels and Axles APPENDIX C .6905 7.293 3.1915 7.500" 85.20 5/8" ± 1/8 1 1/4" + 0/.532 min.086" 2" 69.530 7 5/8" 3" max 5.5030 7.002 8.931" 11 1/16" 11 3/4" 10 15/16" 10 1/6" W — — .000" 8.250" ± 0.207" 8.032 min. 5. 6.032 min.004 min.6905 7. 5.6915 7.6915 7.530 7 5/8" 3" 1 13/16" 7 5/8" 3" max 6.3 Axle for freight car roller bearing—raised wheel seat (page 2 of 2) 7 5/8" 3" max 6.156" 62 1/2" 79" 89 1/4" 62 1/2" 79" 89 5/8" 7 5/16" 6 7/16" 62 1/2" 78" 7 7/8" 8 9/16" 7 7/8" O 62 1/2" 77" 86 1/8" M 7 5/16" 6 7/16" 62 1/2" 78" 6 3/4" J 2 1/8" 1 15/16" 2 1/8" 2 5/16" 2 1/8" 1 15/16" 1 3/4" R 66 1/8" 66" U 2" 1 7/8" V 69.532 min.030 7 5/8" 3" max 6. 6.5" 62 1/2" 79" 87.532 min. 955 .008 7 3/16 6.850 .080 .636 . C.2500 4. TOLERANCE ON ALL DIMENSIONS TO BE 1/64 IN.) 2 3/8 2 5/8 2 7/8 3 1/2 2 7/8 2 5/8 2 7/8 E .2500 3. BREAK SHARP CORNERS.8750 4.695 7 3/16 6.0000 3.195 8 7.4 Pin-type gauge for cap screw holes in ends of roller bearing axles Standard 1979.955 1.) 3.749 .508 Amtrak Passenger Car Axles 6 1/2 5.850 0.6250 4.195 6 11/16 5.507 7 6. UNLESS OTHERWISE SPECIFIED.749 IMPLEMENTED 01/07 Class D E F G K L M Freight Car Axles B (in.8750 D (in.195 6 11/16 5. PARTS TO BE HARDENED AND SURFACES MARKED “G” ARE TO BE GROUND.) C 6 3/16 5. Revised 1982. GRADE 1045 OR EQUIVALENT.625 D E F 5 1/2 × 10 6 × 11 6 1/2 × 12 3.507 M-101 MATERIAL: ASTM A-576.) 5 1/2 × 10 6 × 11 6 1/2 × 12 7 × 12 6 1/2 × 9 6×8 7×9 A (in.740 .955 1 7/8 2 3/8 2 5/8 .007 7 1/2 6.11/1/04 APPENDIX C AAR Manual of Standards and Recommended Practices Wheels and Axles Size (in.695 7 3/16 6.5000 3.8750 4. Fig.5000 3. 1998 G [M-101] 18 11/1/04 . 1979 Paragraph 21. C. Fig.11/1/04 IMPLEMENTED 01/07 M-101 AAR Manual of Standards and Recommended Practices Wheels and Axles APPENDIX C NOTE: DEPTH OF COUNTERBORE IN ROUGH AXLE SHALL BE INCREASED FROM THAT SHOWN TO COMPENSATE FOR STOCK ALLOWED TO FACE AXLE.2 11/1/04 G [M-101] 19 . Revised 1966. WHEN SECONDHAND AXLES ARE RECENTERED. DIAMETER AND DEPTH MAY BE INCREASED SUFFICIENTLY TO PRODUCE AN ACCURATE 60º CENTER.5 Axle centering and gauge for axle center and lathe center Adopted 1944. APPENDIX C AAR Manual of Standards and Recommended Practices Wheels and Axles M-101 IMPLEMENTED 01/07 THIS PAGE LEFT BLANK INTENTIONALLY G [M-101] 20 11/1/04 . RAISED WHEEL SEAT AXLES Recommended Practice RP-622 Adopted: 1966.11/1/04 RP-622 AAR Manual of Standards and Recommended Practices Wheels and Axles WEIGHTS OF MACHINED-FINISH. Revised: 2007 Nominal Weight (lb) IMPLEMENTED 01/07 Classification of Axles Roller Bearing 11/1/04 Size of Journal (in.) Rough-Turned Journal and Wheel Seats Freight Car Passenger Car D 5 1/2 × 10 810 840 E 6 × 11 975 1005 F 6 1/2 × 12 1175 1220 G 7 × 12 1415 — K 6 1/2 × 9 1168 — L 6×8 900 — M 7×9 1325 — G [RP-622] 1 . AAR Manual of Standards and Recommended Practices Wheels and Axles RP-622 IMPLEMENTED 01/07 THIS PAGE LEFT BLANK INTENTIONALLY G [RP-622] 2 11/1/04 .