AAR Coupling System And Truck Castings Committee TTCI/AAR
Casting Specificationsand Quality AssuranceTMAAR Coupling System and Truck Castings Committee TTCI/AAR
Casting Specificationsand Quality AssurancePresented by:Association of American RailroadsCoupling System and Truck Casting CommitteeandTruck Manufacturers Engineering CommitteeMARTS 2005 Technical ConferenceSeptember 20, 2005TMAAR Coupling System and Truck Castings Committee TTCI/AAR
Casting Specificationsand Quality Assurance Panel Introductions, Today’s Discussion, Formation of TMCSTCC -- CackovicWhy is this Effort so Important? -- IdenWhat has been Improved in the Specifications (to date) M-201 -- Clark M-202/203 -- Moseng M-210/211 progress -- StephensOther Improvements CSTCC Meetings - Participation in Foundry Audits –Cackovic Technical Checklists for QA Audits -- CackovicFuture Initiatives -- RFID -- MosengQuestions and AnswersAAR Coupling System and Truck Castings Committee TTCI/AAR
TMAAR Coupling System and Truck Castings Committee TTCI/AAR
Casting Specificationsand Quality Assurance AAR Coupling System and Truck Castings CommitteeMike Iden, Union Pacific Railroad Company Daniel Moseng, Jr. BNSF Railway Chuck Stevens, CSX Transportation Tim Ward, NS Corporation (absent) AAR Staff David L. Cackovic, Transportation Technology Center TMEC Mickey Clark, ASF TMAAR Coupling System and Truck Castings Committee TTCI/AAR
Origin of EEC & CSTCC efforts In 2002 the AAR was made aware of several derailmentscaused by broken truck bolsters. The AAR EquipmentEngineering Committee began an investigation, and atremendous effort ensued. The bolsters were failing due to a combination of inclusions,hot tears and improper heatheat-treating. Testing showed thatthere was at least 100,000 miles between initial and completefailure. The AAR EEC targeted over 24,000 cars for inspection andbolster replacement. The research in Pueblo led to amanaged, safe plan of inspection and replacement program,an effort which is still underway under the directmanagement of the AAR in Washington, DC. CSTCC formed 3Q’04, first activity November 10, 2004.TMAAR Coupling System and Truck Castings Committee TTCI/AAR
TMAAR Coupling System and Truck Castings Committee TTCI/AAR
Radiographic Sensitivity (Contrast and DefinitionDemonstrated by Three Shot Radiographic TechniqueTMAAR Coupling System and Truck Castings Committee TTCI/AAR
TMAAR Coupling System and Truck Castings Committee TTCI/AAR
Why is This Effort so Criticalto the Industry?EXAMPLE:Safety derailment prevention, hazmat shipments Operating velocity Customer service Industry success castings mfrs.,car builders/owners/maintainers, railroads,shippers and the public TMAAR Coupling System and Truck Castings Committee TTCI/AAR
TMAAR Coupling System and Truck Castings Committee TTCI/AAR
M-201 Steel Castings -- Improvements Section 3 – RecordsAdded requirement for heat treatment records Added requirement for traceability from individualcasting serial numbers to chemical, mechanical and heattreat records Reduced record retention period from 15 yrs to 3 yrs. Section 5 – Heat Treatment Added Draft Sill End Castings Added requirement that manufacturers must documentinspector qualifications and inspection proceduresregarding the removal and inspection of test lugs. Theseare used to verify that individual castings have beenheat treated. TMAAR Coupling System and Truck Castings Committee TTCI/AAR
M-201 Steel Castings -- Improvements Section 6 – Chemical Properties and TestsAdded a requirement to monitor “tramp” elements whichcan effect impact properties and weldability. A carbonequivalency formula and acceptance criteria wereadded. This formula considers carbon, manganese,silicon, chrome, molybdenum, vanadium, nickel andcopper content of cast steels. Section 7 – Mechanical Properties and Tests Added requirement that results of mechanical tests mustbe found to be in compliance prior to shipment offinished castings. Added requirement that a hardness test shall becompleted for each heat either from a casting or a testcoupon. TMAAR Coupling System and Truck Castings Committee TTCI/AAR
M-201 Steel Castings -- Improvements Section 12 – Weld Repair TMAdded requirement that manufacturer’s must havespecific procedures for weld repairs to castings. Theseprocedures must include restrictions to the amount ofweld repair allowed in critical and nonnon-critical areas.Added E9015, E9016 and E9018 weld wire for Grade EcastingsAAR Coupling System and Truck Castings Committee TTCI/AAR
TMAAR Coupling System and Truck Castings Committee TTCI/AAR
M-202 Truck Bolster and MM-203 SideFrame Tests -- Improvements Added test loading scenarios for 286K bolsters and side TMframes.Updated design requirements to utilize best practice moderntechniques.Increased the number of bolsters required to be testeddynamically.A detailed record of crack growth is to be maintained for alltests for later analysis.Clarification of what constitutes a failure for a side frame indynamic test.Test reports to include: Metal thickness readings related to drawings. Internal solidity assessment. Chemistry, Mechanical properties including impact. Radiographs of spring seat and bottom tension member.AAR Coupling System and Truck Castings Committee TTCI/AAR
M-210 Truck Bolster and Side FramePurchase and Acceptance -- Improvements Will soon go out for comment with: TMStrengthened purchaser and AAR rights toenter and inspect foundries at any time.Restricted time allowed when notmanufacturing AAR approved castings to nomore than 90 days.Clarified approval requirements and durations.Added B Steel per MM-201.Tied the metallurgical properties requirementsto MM-201Added the requirement for statistical samplingtechniques to be applied to gaging, andmaintained in auditable form.AAR Coupling System and Truck Castings Committee TTCI/AAR
M-210 Truck Bolster and Side FramePurchase and Acceptance -- Improvements Will soon go out for comment with: TMRequired auditable, written weld repair procedures to bemaintained.Added American Welding Society requirements forwelder qualification.Replaced superficial finishing requirements section with4 ½ pages of detail, including SCRATA surface conditionrequirements.Requires product distribution information to be sentquarterly to the AAR for archiving.Outlines required process control plan requirement forcritical foundry processes.Has placeholder for possible future foundry NDTrequirements based on AAR research.AAR Coupling System and Truck Castings Committee TTCI/AAR
M-211 Coupler and Yoke Purchaseand Acceptance – Improvements in Process Considering adding: TMArticulated connectors.Best practice, modern design techniques,including FEA.Revised definitions for design groups.Auditable: Critical process control plans. Gaging statistics.Requires product distribution information to besent quarterly to the AAR for archiving.AAR Coupling System and Truck Castings Committee TTCI/AAR
TMAAR Coupling System and Truck Castings Committee TTCI/AAR
Casting Specifications OtherImprovements Other Improvements CSTCC Meetings - Participation in Foundry AuditsCoordination with Quality Assurance Committee TechnicalChecklistsfor QA AuditsTMAAR Coupling System and Truck Castings Committee TTCI/AAR
Casting Specifications OtherImprovements – Technical Checklists All quality systems require that you“document what you do” All Quality system audits then comparewhat you have documented with what isbeing done M-1003 is the North American InterchangeRailway System Quality Specification andthe only quality system that requiresreference to AAR criteria within the qualityprogramTMAAR Coupling System and Truck Castings Committee TTCI/AAR
Casting Specifications OtherImprovements – Technical Checklists Quality audits are conducted with achecklist. To maintain consistency between audits. To ensure all requirements are met. M-1003 uses the Quality AssuranceSystem Evaluation (QASE) Checklist.TMAAR Coupling System and Truck Castings Committee TTCI/AAR
Casting Specifications OtherImprovements – Technical Checklists In addition to the QASE – M-1003 requiresthe use of “supplemental audit checklists”if appropriate. Supplemental Audit Checklists give anauditor additional information to look forconcerning specific requirements based ontechnical requirements. Supplemental checklists are used inconjunction with the QASE and do notreplace technical inspectionsTMAAR Coupling System and Truck Castings Committee TTCI/AAR
Casting Specifications OtherImprovements – Technical Checklists M-101, Axles M-201,CastingsM-210, Side Frames and Bolsters M-211, Couplers M-601,M-618, M-619, M-620, Hoses M-921, Cushioning Devices M-1002, Tank Cars S-2034, Freight Cars TMAAR Coupling System and Truck Castings Committee TTCI/AAR
Casting Specificationsand Quality Assurance – Future Initiatives NDT research at TTC to determinefeasibility for inin-foundry use. Failure database development. Load spectra testing by TTCI and others insupport of the Freight Car Fatigue TaskForce, which is made up of AAR membersand industry associations including ARCIand TMEC. RFID tags for castings.TMAAR Coupling System and Truck Castings Committee TTCI/AAR
Casting Specificationsand Quality Assurance – RFID TagsTMAAR Coupling System and Truck Castings Committee TTCI/AAR
Casting Specificationsand Quality Assurance Questions ?TMAAR Coupling System and Truck Castings Committee TTCI/AAR
TM AAR Coupling System and Truck Castings Committee Clarified approval requirements and durations. Added B Steel per MAdded B Steel per M-201. 201. Tied the metallurgical properties requirements to Mto M--201 201 Added the requirement for statistical sampling techniques to be applied to gaging, and maintained in auditable form.
1-A: Design of an AAR Prone Concrete Mix for Large Scale Testing 1-B: AAR Expansion; Effect of Reinforcement, Specimen Type, and Temperature 1-C: Effect of AAR on Shear Strength of Panels 2: Diagnosis & Prognosis of AAR in Existing Structures 3-a: Risk Based Assessment of the Effect of AAR on Shear Walls Strength
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Evaluation and Review (MeTER) software, which is the primary component of MTES, to produce immediately reviewable AAR data. The full MMLT AAR system consists of two subsystems: the data capture system and the AAR station (see Figures 1 and 2). The data capture system consists of one Velodyne HDL-64 LiDAR unit mounted on a tripod, two Axis Pan-Tilt-
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