Download - Material for Rolling Stocks
-
8/2/2019 Material for Rolling Stocks
1/82
MATERIAL FOR
ROLLING STOCKS
- AN OVERVIEW
-
8/2/2019 Material for Rolling Stocks
2/82
ABOUT ME
I am known as Ananthanarayanan. A graduate in Mechanical Engineering in year 1969
from Kerala University. After 2 years of plant training, started the work in the
Stainless Steel fabrication shop at Atomic Energy,
Mumbai. Joined Steel Authority of India in the year 1980 at their
Stainless project at Salem. Was attached to the Product Development and
Application Department. Took Voluntary retirement in the year 2002. Now enjoying retired life combined with Independent
Technical Consulting in the area of Stainless Steel.
-
8/2/2019 Material for Rolling Stocks
3/82
Iron and Steel are the most commonly
used fabrication material
-
8/2/2019 Material for Rolling Stocks
4/82
Why because
Abundantly available
Lower cost
Easy to fabricate, cast and forge
Good strength
Easy for ameliorating the properties by addingalloying elements and heat treatment
Recyclable & eco friendly
-
8/2/2019 Material for Rolling Stocks
5/82
DEFICIENCIES IN THE PROPERTIES OFSTEEL
-
8/2/2019 Material for Rolling Stocks
6/82
Yes
More prone to general & other forms of corrosion.
Corrosion protection processes are costly and timeconsuming.
Higher strength with compromise in workability.
-
8/2/2019 Material for Rolling Stocks
7/82
DO WE HAVE ANY CHOICE?
-
8/2/2019 Material for Rolling Stocks
8/82
Yes.
Other metals like Aluminum, plastics etc which againhave different sets of limitations of fabricability, cost,strength, availability, recyclability, ecology
-
8/2/2019 Material for Rolling Stocks
9/82
VARIATIONS OF IRON & STEEL LIKE
STAINLESS STEEL
-
8/2/2019 Material for Rolling Stocks
10/82
ADVANTAGES OF SS
While normal steel is Ferritic with body centeredcubic structure, SS is available in both BCC
(Ferritic) & FCC (Austenitic) structures. Austenitics are cold work hardenable (Higher
strength without compromising workability)
General corrosion resistance.
Fabricable, recyclable, indigenously available,eco friendly
Costly per kg, but cheap
-
8/2/2019 Material for Rolling Stocks
11/82
HOW IS IT POSSIBLE?
-
8/2/2019 Material for Rolling Stocks
12/82
INTERNATIONAL DATA
-
8/2/2019 Material for Rolling Stocks
13/82
INTERNATIONAL SCENARIO -
WAGON
-
8/2/2019 Material for Rolling Stocks
14/82
-
8/2/2019 Material for Rolling Stocks
15/82
INTERNATIONAL SCENARIOCOACH
Basel Switzerland Grade : Ferritic 1.4589
-
8/2/2019 Material for Rolling Stocks
16/82
Grade 301L
-
8/2/2019 Material for Rolling Stocks
17/82
Grade 1.4003 & 304
-
8/2/2019 Material for Rolling Stocks
18/82
Grade 304
-
8/2/2019 Material for Rolling Stocks
19/82
Grade 301LN
-
8/2/2019 Material for Rolling Stocks
20/82
Railcars made of UNS S20100 or UNS S20153 alloys havelong-lasting strength and beauty
-
8/2/2019 Material for Rolling Stocks
21/82
NIROSTA 4003
-
8/2/2019 Material for Rolling Stocks
22/82
INDIAN EXPERIENCE
Unpainted Stainless Steel wagon IRS M44/97
-
8/2/2019 Material for Rolling Stocks
23/82
409M wagon under fabrication
-
8/2/2019 Material for Rolling Stocks
24/82
Stainless Steel wagon painted
-
8/2/2019 Material for Rolling Stocks
25/82
Stainless Steel wagons ready for service
-
8/2/2019 Material for Rolling Stocks
26/82
Stainless Steel coach DIN 5512 (IR-CK-201)
-
8/2/2019 Material for Rolling Stocks
27/82
METRO COACH (301L UNPAINTED)
-
8/2/2019 Material for Rolling Stocks
28/82
SS IN INDIAN RAILWAYS
1965 Toilet pan, wash basin in SS 304 1984-85 Trough floor in SS 301
1990 Toilet inlays in SS 304
1990
LHB Coach in SS in DIN 5512
1.4003 1995 Internal furnishings in SS 304
1997 IRS M 44/97 specs for wagons
1998 Box N wagon in SS - 44/77
2000 CK-201 specs of SS for coaches
2000 44/97 used for structural in ICF designedcoaches.
-
8/2/2019 Material for Rolling Stocks
29/82
ALL SS COACHES
2003 Unpainted metro coaches in SS 301L byBEML.
2010 Unpainted EMU Coach by BEML.
2010 SLIP FREE SS flooring in EMU Coaches
-
8/2/2019 Material for Rolling Stocks
30/82
History of Ferritic SS for Wagons/Coach
1980s developed in South Africa and UK as 3 CR12 gradeutility SS for coal/ore transportation. (low carbon, 11% Cr andTitanium)
1990s Modified 3 CR12 for better toughness (low carbon, 11%Cr, 0.3 minimum Ni, Ti removed)
DIN 5512 of German Spec for railway SS specify this grade forfreight wagons and passenger coach as 1.4003
LHB specifies DIN 5512 (1.4003) for new coach design in India.LHB approves Indian manufacturer.
1997 IR specifies 44/97 (containing Ti max for trial wagons) 2000 ASTM spec UNS 40977 for Utility Ferritic SS (low
carbon, 11% Cr, minimum Ni, no Ti) 2001 IR specifies in CK 201 utility Ferritic matching 1.4003 2005 Internationally EN 1.4003 and UNS 40977 specifications
followed for utility grade Ferritic SS (Low carbon, 11% Cr, 0.3 minNi and NO Ti)
-
8/2/2019 Material for Rolling Stocks
31/82
Railway Coach Shells are made offollowing
Stainless Steel Grades
409 M 301L 201L
(Nickel Free) (Nickel 6-8%) (Nickel 4-5%)
&
The Surface Treatment Depends on the Stainless Steel GradesSelected for the Shell Components
-
8/2/2019 Material for Rolling Stocks
32/82
Basic Difference Between The ThreeGrades of Stainless Steel
Cheaper than301LCostlierCheapest ofthe ThreeCost
Very GoodVery GoodVery GoodWeldability
NoNoYesFor aesthetics
SurfaceProtection
GoodGoodFairGeneralCorrosion
Resistance
Very GoodVery GoodOKDuctility(Workability)
Yes(Cold Workable)
NoHigher StrengthLevels
NoNoYesFerroMagnetism
201L301L409MProperty
-
8/2/2019 Material for Rolling Stocks
33/82
Chemical Composition Utility Ferritic SS
Element%
X2CrNi12(1.4003)EN 10088 - 2ASTM S40977
DIN 5512 Part 3X2Cr11
IR CK 201X2CrNi12(409M)2002
IRSM 44/97
CarbonManganesePhosphorousSulphurSiliconChromium
NickelNitrogenTitanium
0.03 max1.50 max0.04 max0.015 max1.0 max10.5 12.5
0.3 1.00.03 maxNil
0.03 max0.5 1.50.04 max0.015 max1.0 max10.5 12.5
0.3 1.00.03 maxNil
0.03 max0.5 1.50.04 max0.03 max1.0 max10.5 12.5
0.3 1.00.03 maxNil
0.03 max0.8 - 1.50.03 max0.03 max1.0 max10.8 12.5
1.5 maxNil0.75 max
-
8/2/2019 Material for Rolling Stocks
34/82
Mechanical Properties Utility Ferritic SS
Property X2CrNi12(1.4003) EN 10088 - 2ASTM S40977
DIN 5512 Part3 X2Cr11
IR CK 201X2CrNi12(409M)2002
IRSM44/97
Yield
Strength(MPa)
TensileStrength(MPa)
PercentageElongation
280/320
450 - 650
20
320
450 - 600
18 - 20
320
450 650
20
350 - 450
500
25
-
8/2/2019 Material for Rolling Stocks
35/82
Chemical Composition Austenitic SS
Element%
304 (1.4301) 301L(1.4318)
201L(1.4371)
Carbon
ManganesePhosphorousSulphurSiliconChromiumNickel
Nitrogen
Titanium
0.07 max
2.0 max0.045 max0.03 (0.015) max0.75 (1) max17.5 19.58 10.5
0.10 (0.11 Max)
Nil
0.03 max
2.0 max0.045 max0.03 (0.015) max1 max16 18 (16.5 18.5)6 8
0.20 (0.1 0.2) max
Nil
0.03 max
5.5
7.5(6 - 8)0.045 max0.03 max (0.015)0.75 max (1)16 18 (16 - 17)3.5 5.5
0.25 max (0.15 0.2)Nil
-
8/2/2019 Material for Rolling Stocks
36/82
Mechanical Properties (annealed
condition) Austenitic SS
Grade Tensile Yield ElongationStrength Strength %MPa MPa
--------------------------------------------------------------------------------------------201L 655 260 40.0
301L 550 220 45.0
304 515 205 40.0
-
8/2/2019 Material for Rolling Stocks
37/82
Mechanical Properties Strain Hardened
Austenitic SS 301L & 201L
Temper UTS min.MPa
YSmin. MPa
Elongationmin. %
Low Tensile LT(2B Finish)
700 340 45
Special TensileST
760 415 35
Medium TensileMT
830 550 25
High Tensile HT 1,000 750 20
-
8/2/2019 Material for Rolling Stocks
38/82
NUANCES OF
STAINLESS STEEL
-
8/2/2019 Material for Rolling Stocks
39/82
SELECTION OF RIGHT GRADEAND
PROCESS OF FABRICATION
PLAY AN IMPORTANT ROLE IN
GETTING VALUE FROMSTAINLESS STEELS
-
8/2/2019 Material for Rolling Stocks
40/82
STEEL IS MADE STAINLESS
BY ADDITION OF CHROMIUM(11%) NICKEL, MOLY ETC.
-
8/2/2019 Material for Rolling Stocks
41/82
WHEN IN CONTACTWITH ATMOSPHERE
CHROMIUM FORMS IRON-FORMSPASSIVE CHROMIUM RUST-IRON OXIDEOXIDE
STAINLESS STEEL CARBON STEELRESISTS CORROSION RUSTS &CORRODESBY FORMING CHROMIUM BY FORMING IRON
OXIDE LAYER OXIDE LAYERON SURFACE ON SURFACE
-
8/2/2019 Material for Rolling Stocks
42/82
Water
And
oxygen
Mild
steel
Stain-less
Steel
Weakporous
rust
Strong
Imperve-
ous layer
BEHAVIOUR OF MILD STEEL AND STAINLESSSTEEL
IN NORMAL ATMOSPHERE
-
8/2/2019 Material for Rolling Stocks
43/82
- +
GALVANIC CORROSION
ANODE CATHODE
NEED * DIFFERENT METALS* ELECTROLYTIC CONTACT
THE METAL
WHICH IS - LESS NOBLE- LESS PASSIVE- MORE ACTIVE
- LESS NOBLE- LESS PASSIVE- MORE ACTIVE0
GALVANIC SERIESGOLDMONELSTAINLESS TYPE 316
STAINLESS TYPE 304STAINLESS 430SILVERALUMINIUM BRONZECOPPERBRASSCAST IRONCARBON STEEL
ZINCMAGNESIUM
BECOMES
THE ANODE THE CATHODE
- CORRODES ATINCREASED RATE
- IS PROTECTED
- CORRODES LEASTOR NIL
EFFECT OF COLD WORK ON MECHANICAL
-
8/2/2019 Material for Rolling Stocks
44/82
EFFECT OF COLD WORK ON MECHANICALPROPERTIES OF 301/304 STAINLESS STEEL
COLD WORK, PERCENT
20 40 60
0
40
80
5
200
400
600
800
1000
1200
1400TENSILE STRENGTH
YIELD STRENGTH
ELONGATION
-
8/2/2019 Material for Rolling Stocks
45/82
HAZHAZ
-
8/2/2019 Material for Rolling Stocks
46/82
SCHEMATIC ILLUSTRATION OF SENSITIZATION WITHIN THE HAZ, WITH ASSOCIATEDCHROME CARBIDE PRECIPITATION AND CHROMIUM DEPLETION AT THE GRAINBOUNDARIES.
WELD
DEPOSIT
PARENT
METAL
SENSITIZED REGION
CORROSION ALONG AND AROUND THEGRAIN BOUNDARIES
GRAINS ACTUALLY DISSOLVEDOUT
SCHEMATIC ILLUSTRATION OF SENSITIZATION WITHIN THE HAZ, WITH ASSOCIATEDCHROME CARBIDE PRECIPITATION AND CHROMIUM DEPLETION AT THE GRAINBOUNDARIES.
WELD
DEPOSIT
PARENT
METAL
SENSITIZED REGION
CORROSION ALONG AND AROUND THEGRAIN BOUNDARIES
GRAINS ACTUALLY DISSOLVEDOUT
SCHAEFFLER-DE LONG DIAGRAM SHOWINGTHE FERRITE CONTENT OF THE WELD METAL
-
8/2/2019 Material for Rolling Stocks
47/82
1 X
3
25
5
0 10 20 30
10
30
M+FF+M
M
M +A
A = AUSTENITE
CHORIMIUM EQUIVALENT (%Cr+%Mo+1.5 x %Si+0.5 x %Nb)
THE FERRITE CONTENT OF THE WELD METAL
20
15
25
5 15 25
F = FERRITE
M = MARTENSITE
CARBON STEEL
M+A+F 100% F
40% F
A+F
4
- WELD METALX - SHEET & PLATE
X
-
8/2/2019 Material for Rolling Stocks
48/82
Easy Identification of SS grades
Identifying SS from Chrome Plated Steel
-
8/2/2019 Material for Rolling Stocks
49/82
Identifying 304 & 316 grade SS
-
8/2/2019 Material for Rolling Stocks
50/82
Identifying 304 & 316
-
8/2/2019 Material for Rolling Stocks
51/82
Identifying different SS
430 grade SS
4 % Nickel SS
304 Grade SS
1 % Nickel SS2 % Nickel SS
-
8/2/2019 Material for Rolling Stocks
52/82
CLEANING OF SS WELDS
-
8/2/2019 Material for Rolling Stocks
53/82
-
8/2/2019 Material for Rolling Stocks
54/82
-
8/2/2019 Material for Rolling Stocks
55/82
-
8/2/2019 Material for Rolling Stocks
56/82
-
8/2/2019 Material for Rolling Stocks
57/82
Why Low Carbon in SS
-
8/2/2019 Material for Rolling Stocks
58/82
AT LOWER CARBON CONTENTS IT TAKES LONGERFOR THE MATERIAL TO BE SUSCEPTIBLE TO
INTERGRANULAR CORROSION
0.2 0.5 1.0 5 10 50 100 1000500
600
700
800
900
TIME, MIN
TEMPERATUREC
1h 10h
C=0.08
C=0.06
C=0.05C=0.03
C=0.02
SCHEMATIC ILLUSTRATION OF THE THREE ZONES OF
-
8/2/2019 Material for Rolling Stocks
59/82
SCHEMATIC ILLUSTRATION OF THE THREE ZONES OFWELDING AND THE RELATED CONFINED AREA OF HIGH
TEMPERATURE
WELD METAL
HEAT AFFECTED ZONE
PARENT METAL(UNAFFECTED)
WELD ZONE
TEMPERATURE(C)
ROOM TEMPERATURE
MELTING POINT
-
8/2/2019 Material for Rolling Stocks
60/82
EFFECT OF CHROMIUM CONTENT ON CORROSION RATE
% CHROMIUM
0 2 4 6 8 10 12 14 16
0.025
0.050
0.075
0.100
0125
0.150
0.175
0.200
CORROSI
ON
RATE
mmpy
-
8/2/2019 Material for Rolling Stocks
61/82
SS USED ABROAD FOR RAILWAYAPPLICATIONS
-
8/2/2019 Material for Rolling Stocks
62/82
The effect of nickel price on the price difference between AL201HP alloy and Type 304 based on the Ni raw-materialsurcharge [2]
-
8/2/2019 Material for Rolling Stocks
63/82
Samples of UNS S20100 alloy and Type 304 following 100 hours
of exposure in a salt spray test [15]
UNS S20100 Type 304
-
8/2/2019 Material for Rolling Stocks
64/82
From NIROSTA 4003
Type 4003 provides good corrosion resistance, excellent abrasionresistance, hence does not need coating or painting systems to beapplied for performance reasons. For aesthetic reasons it may bedesirable in some applications to apply paint, especially as type
4003 will tend to discolor in corrosive conditions. Type 4003 hasexceptional under-paint corrosion resistance and will continue toresist corrosion even where the paint coat has been damaged.
Normal preparation is required such as ensuring a clean surfacefree of grease and other contamination. A primer coat is
recommended for cold roll material due to its smoother surface, buthot rolled 1D finish material may be suitably painted in a single coat.
-
8/2/2019 Material for Rolling Stocks
65/82
Dull Satin Finish for Painting
-
8/2/2019 Material for Rolling Stocks
66/82
AT HIGH TEMPERATURE STRENGTHUGINE F12
-
8/2/2019 Material for Rolling Stocks
67/82
Comparison of Moon Rock V/s Slip FreeFinishes for Floor Applications
P t M R k Fi i h Sli F Fi i h
-
8/2/2019 Material for Rolling Stocks
68/82
Parameter Moon Rock Finish Slip Free Finish
Grade SS 430 SS 304/ SS 430
Type 2 dimensional 3 dimensional
Rigidity Low 250 Mpa (passed through oneetched and one plain roll)
High 375 Mpa (passed thru male/female deepengraved rolls)
Relief Low 270 N/mm (depth is around 0.15mm)
High 400 N/mm(depth is around 1.5 mmminimum) Over the relief thickness will bearound 2.5mm
Slippage High possibility (top surface is plainwith ditches at low level )
Least slippage (contoured Surface with upsand downs) Test procedure attached
Hardness Lower Vickers 185 (lesser reduction inpass) Wear Resistance low
Higher Vickers 275 (more reduction due tomale /female system ) Wear Resistance High
Process ofmaking
Rolled with oil (oil surface possible) Dry process rolling
Suggestedthickness
2.5 mm 1.25MM /1.6 mm
Weight. per unitarea 16 Kg / Sq.Mtr 10 Kg / Sq. Mtr
Cleanability Difficult (dirt accumulates in ditches) Easy and self cleaning (easy flow pattern forwater)
InternationalPractice
Not for flooring Best used in flooring
Cost Rs.103 / Kg and Rs1648 / Sq. Mtr Rs. 100 / Kg andRs. 1000 / Sq. Mtr
-
8/2/2019 Material for Rolling Stocks
69/82
Corrosion Comparison
-
8/2/2019 Material for Rolling Stocks
70/82
3CR12 South Africa
HYFAB 3/12 United Kingdom
1.4003 Germany
F 12 N France
YUS 410W Japan
S41003 USA
GRADES SIMILAR TO 409M (IRS)
-
8/2/2019 Material for Rolling Stocks
71/82
Under the Paint Corrosion
Carbon Steel 409M
-
8/2/2019 Material for Rolling Stocks
72/82
Why no Titanium in utility Ferritic StainlessSteel
Extract from Research paper of Mr.Vigor of
Metallurgy dept, GM USA
-
8/2/2019 Material for Rolling Stocks
73/82
-
8/2/2019 Material for Rolling Stocks
74/82
-
8/2/2019 Material for Rolling Stocks
75/82
-
8/2/2019 Material for Rolling Stocks
76/82
-
8/2/2019 Material for Rolling Stocks
77/82
-
8/2/2019 Material for Rolling Stocks
78/82
S
-
8/2/2019 Material for Rolling Stocks
79/82
Summary
I suggest Change 301 to 301L for all trough floors of coaches (Improves
weldability and corrosion resistance
Modify IRS M44 in line with CK 201 to meet International standards
For LHB coach use 301L for trough floor and roof
Can avoid painting for wagons (if required one primer coat)
Avoid heating 4003 panels as it reduces the strength Use dull satin finish 2F for external panel for better paintability and avoid
sand blasting
Design inner structural members with 201L for metro coaches and use201L for exterior panel of metro coach with/without painting
Design tank wagons with 201L to reduce weight. Use double side embossed slip free finish for flooring and reduce weight
Use Stretch forming process for making structural members to avoidwrinkles
Use more of spot welding for fixing structural to panel
-
8/2/2019 Material for Rolling Stocks
80/82
WHAT NEXT
Unpainted normal SS coaches (301L panel,1.4003 structural)
Painted normal SS coaches with weightreduction (1.4003 panels, 201L structurals)
Painted Cost effective Metro coaches (1.4003panels, 201L structurals)
Tank wagons (Thickness reduction andunpainted) 201L
-
8/2/2019 Material for Rolling Stocks
81/82
I AM REACHABLE
E-MAIL: [email protected]
MOBILE NUMBER: +91-9448674645(Bangalore)
mailto:[email protected]:[email protected] -
8/2/2019 Material for Rolling Stocks
82/82
Thank You For Your Kind Attention