2013731372830003031_41.doc

Product Type and Name: AAR AxleProcess Document: AAR Axle Ultrasonic Detection Procedure

Prepared by Reviewed by workshop Quality Metrology Standard Approved by

Name yuhaijun liren wangchun liduanjin

Date 2 0 1 1 - 1 2 - 0 6 2 0 1 1 - 1 2 - 0 7 2 0 1 1 - 1 2 - 0 7 2 0 1 1 - 1 2 - 0 7

Process Document No. GY(11)TY-024

Process Document Product Type and Name Part No. Part Name Document No. Document Name Page:

Record sheet AAR Axle General purpose Axle AAR Axle Ultrasonic Detection Procedure Version: A Version Contents of document preparation and revision Revised by Procedure Modification Notice No. Date

A Preparation yuhaijun / Dec 7, 2011

Seq.No. Document No. Document Name Version No. Seq.No. Equipment No. Equipment Name Version


Record sheet AAR Axle General purpose Axle AAR Axle Ultrasonic Detection Procedure Version: A No.

1 AAR M-101Axles, Carbon Steel, Heat-

treated2011 1 Kw-4c

Digit ultrasonic flaw detecto

r

2 DJW61-66-000 Brazil Axle 7″×12″ A 2 2.25P20Z Straight probe

3 3 TS-1W Standard reference block

4 4 No.1, No.2, No.3 Axle reference block

5 5

6 6

7 7

8 8

9 9

10 10

11 11

12 12

13 13

14 14

15 15

16 16

17 17

18 18


Record sheet AAR Axle General purpose Axle AAR Axle Ultrasonic Detection Procedure Version: A

1 Applicable Scope

1.1 This document is applicable for ultrasonic flaw detection of axles manufactured according to AAR Specification M-101, Axles, carbon steel, heat-treated,

and specifies acceptance conditions.

2 Normative references

2.1 AAR Specification M-101, Axles, carbon steel, heat-treated

2.2 GB/T 9445 NDT personnel qualification and certification

2.3 JB /T 10061 General-purpose specification for type-A pulse-echo ultrasonic flaw detector

2.4 JB /T 10062 Testing methods for performance of probes used in ultrasonic flaw detection

3 Personnel requirements

3.1 Personnel engaged in ultrasonic inspections must have a high school, technical school or secondary and higher education and have eyesight (including

corrected eyesight) of 1.0 or above and be not color- blind. He or she shall be familiar with the relevant regulations or rules and technical requirements of

rolling stock , and love his or her NDT work.

3.2 Personnel engaged in ultrasonic inspection operations must have attended the special ultrasonic testing training organized by Railway Ministry NDT

personnel qualification and certification committee, and achieved NDT Level Ⅱor above ultrasonic testing certificate issued by the committee

3.3 Personnel engaged in new axle ultrasonic inspection operations must master relevant basic knowledge, and master and strictly carry out all the

regulations and requirements specified in this process procedure.

4 Environment requirements

4.1 Axle ultrasonic inspection shall be performed in a separate designated UT zone.

4.2 UT work room shall be far away from casting, forging, welding, and damp and dust locations.

4.3 UT work room shall be spacious and bright, and room temperature shall be kept at 10℃-30℃.

5 UT equipment and requirements

5.1 Ultrasonic flaw detector utilized in the UDT process shall have the following performances

5.1.1 Horizontal linearity error ≤2%.

5.1.2 Vertical linearity error ≤6%.

5.1.3 Frequency band 0.4--10MHz.

5.1.4 Surplus sensitivity ≥46dB.

5.1.5 Detecting depth≥3m.

5.1.6 Attenuator volume≥80dB.

5.1.7 Resolution capability (longitudinal wave, in longitudinal direction)≥26dB.



5.1.8 Other detector performances shall conform to the requirements of JB/T10061-1999.

5.2 Probe

5.2.1 2.25P20Z longitudinal wave straight probe shall be applied.

5.2.2 Included angle between main sound beam of straight probe and its normal line shall be ≤1°.

5.2.3 Sound pressure distribution of the probe sound field shall not have obvious double peak in all directions.

5.2.4 Other detector performances and test methods shall conform to the requirements of JB/T10062-1999.

5.3 Reference block

5.3.1 Test block includes standard reference block and axle reference block: TS-1W is used as standard reference block , No.1, No.2 and No.3 test block are

used as axle reference block. Detailed is given in Appendix B.

5.4 Couplant

5.4.1 Couplants are machine oil, glycerin, water or chemistry adhesive, etc.

5.4.2 The couplant used in adjusting reference block must be the same used during axle testing.

5.5 The ultrasonic flaw detector which new purchase or first put to use after overhauling ，needs the verification department to verify, and issue the qualified

verification certificate，the ultrasonic flaw detector which is not qualified or verification extended will not be put into use。6 Detection process

6.1 Time of inspection

6.1.1 Axial - anytime during production following axle end facing and center drilling, but before drilling cap screw holes. The axle end face roughness must be

Ra3.2 or better.

6.1.2 Radial - anytime during production following initial rough turn. The axle surface roughness must be Ra12.5 or better.

6.1.3 When axial testing, the surfaces to be scanned are the two axle end faces, and when radial testing, the surfaces to be scanned are the axle entire outer

cylindrical surface (except for parts of arcs).

6.2 When detecting, the probe shall scan axle along the saw-teeth path , and scanning speed is not more than 150mm/s, and coverage rate is not less than

10%.

6.3 Before each inspection beginning, daily performance calibration shall be made, and validated by supervisor, and the record - Daily performance

calibration record of ultrasonic detection machine shall be filled in.

6.3.1 The time which continuous use the apparatus to detect is over 4 hours, must be performed daily performance verification again.

6.3.2 Every time replace the system operator must be performed daily performance verification again.

6.3.3 Every time replace the probe, cable, or other system hardware or accessories, must be performed daily performance verification again.

6.3.4 The ultrasonic flaw detector malfunctions or improperly operates, must be performed daily performance verification again before starting detecting again.



6.4 At the end of each quarter, workshop shall be responsible to call together related personnel from Process Development Department and Quality

Assurance Department, and to invite acceptance rep, to perform the quarterly performance calibration of ultrasonic detection machine, and the record -

Quarterly performance calibration record of Ultrasonic detection machine shall be filled in. Requirement is that record must be filled in while calibration is

performing. Calibration flow: measuring horizontal linearity → measuring vertical linearity → measuring dynamic range → measuring surplus sensitivity.

6.5 Detection sensibility

6.5.1 The calibration of measuring distance

6.5.1.1 TS-1W reference block shall be utilized, and machine oil be used as couplant. Adjust the instrument to align the 1st and 10th backface reflection

fronts with the 0.8 big grid and the 8th big grid on the monitor respectively, at the meantime, each big grid on the monitor represents 300mm of the axle actual

length.

6.5.2 Determination of axial testing penetration transparency sensitivity and axial quantitative defect sensitivity.

6.5.2.1 Place probe on the detection face of No.1 axle reference block, and adjust reflected wave from φ3.2mm flat-bottom hole to 20% full screen height, and

this wave height is determined as the sensitivity of axial penetration transparency and axial defect detection.

6.5.3 Determination of radial detection sensitivity

6.5.3.1 Place probe on the wheel seat of trailer axle or the gear seat of power axle, adjust reflected wave from backface to 80% full screen height, and this

wave height is determined as the sensitivity of radial detection.

6.6 Scanning process

6.6.1 Axial penetration transparency: Place probe on axle end face, move probe along saw-teeth path to observe the change of backface wave, the zone that

probe moves shall be the entire axle end face.

6.6.2 Axial defect: increase wave height gain 6dB, and place probe on axle end face, move probe along saw-teeth path, observe the change of defect wave

and backface wave.

6.6.3 Radial defect: increase wave height gain 6dB, and place probe on axle outer cylindrical surface, scan the entire length of the axle radially through the

diameter along one line only.

7 Quality standard

7.1 Judgment of penetration transparency performance : All the axle end face zone shall be detection zone, within the detection zone, when the returned

wave from backface exceeds 40% wave height, axle is judged qualified, when equal or below 40% wave height, axle disqualified.

7.2 Judgment of axial defect: Judgment basis shall be Appendix A DAC curve for axial testing. If reflected flaw wave height exceeds DAC curve in Appendix

A, lower flaw wave height 6dB, at the meantime, if flaw wave height exceeds DAC curve at the corresponding zone, axle is judged disqualified.

7.3 Judgment of radial defect: when flaw detected, lower bottom wave 6dB, at the meantime, when bottom wave height is less than or equal to 16% height,

axle is judged disqualified.



8 UT marking

8.1 Axles that have passed the UT inspection shall be stamped with the character "R" between axle serial number and axle grade stamp.

9 Ultrasonic detection records

9.1 After detection, records shall be made, and detection reports issued. this requires clear and tidy writing, and no writing modification.

9.2 For all the new axles that having been performed ultrasonic flaw detection, Railway Wagon Wheel & Axle (Wheelset, Axle, Wheel) Ultrasonic (Magnetic

Particle) Inspection Record shall be filled in. For axles that have been confirmed disqualified and defect existing, Railway Wagon Wheel & Axle (Wheelset,

Axle, Wheel) Ultrasonic (Magnetic Particle) Inspection Defects Record shall also be filled in, and related detailed information be recorded.

9.3 The flaw detection records are kept for 15 years.

10 The disposal of disqualified flaw detection axles

10.1 The disqualified axles which are found during the flaw detection, fill in 《 railway wagon wheel ( wheel, axle, wheelset ) ultrasonic wave( magnetic powder)

flaw detection found defective record card 》 by the inspector， detailed record the relevant information of the defects ， after confirmation by the

inspector，judge the disposal result by the inspector.

Appendix A DAC curve for AAR axle axial testing



Appendix B



B.1 Type and dimension of TS-1W standard reference block

Type and dimension of TS-1W standard reference block

B.2 Type and dimension of No.1, No.2 and No.3 axle reference block



No.1 axle reference block

2013731372830003031_41.doc

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