material for rolling stocks

8/2/2019 Material for Rolling Stocks

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MATERIAL FOR

ROLLING STOCKS

- AN OVERVIEW


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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.


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Iron and Steel are the most commonly

used fabrication material


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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


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DEFICIENCIES IN THE PROPERTIES OFSTEEL


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Yes

More prone to general & other forms of corrosion.

Corrosion protection processes are costly and timeconsuming.

Higher strength with compromise in workability.


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DO WE HAVE ANY CHOICE?


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Yes.

Other metals like Aluminum, plastics etc which againhave different sets of limitations of fabricability, cost,strength, availability, recyclability, ecology


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VARIATIONS OF IRON & STEEL LIKE

STAINLESS STEEL


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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


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HOW IS IT POSSIBLE?


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INTERNATIONAL DATA


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INTERNATIONAL SCENARIO -

WAGON


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INTERNATIONAL SCENARIOCOACH

Basel Switzerland Grade : Ferritic 1.4589


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Grade 301L


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Grade 1.4003 & 304


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Grade 304


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Grade 301LN


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Railcars made of UNS S20100 or UNS S20153 alloys havelong-lasting strength and beauty


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NIROSTA 4003


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INDIAN EXPERIENCE

Unpainted Stainless Steel wagon IRS M44/97


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409M wagon under fabrication


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Stainless Steel wagon painted


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Stainless Steel wagons ready for service


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Stainless Steel coach DIN 5512 (IR-CK-201)


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METRO COACH (301L UNPAINTED)


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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.


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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


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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)


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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


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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


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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


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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


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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


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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


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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


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NUANCES OF

STAINLESS STEEL


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SELECTION OF RIGHT GRADEAND

PROCESS OF FABRICATION

PLAY AN IMPORTANT ROLE IN

GETTING VALUE FROMSTAINLESS STEELS


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STEEL IS MADE STAINLESS

BY ADDITION OF CHROMIUM(11%) NICKEL, MOLY ETC.


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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


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Water

And

oxygen

Mild

steel

Stain-less

Steel

Weakporous

rust

Strong

Imperve-

ous layer

BEHAVIOUR OF MILD STEEL AND STAINLESSSTEEL

IN NORMAL ATMOSPHERE


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- +

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


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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


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HAZHAZ


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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


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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


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Easy Identification of SS grades

Identifying SS from Chrome Plated Steel


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Identifying 304 & 316 grade SS


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Identifying 304 & 316


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Identifying different SS

430 grade SS

4 % Nickel SS

304 Grade SS

1 % Nickel SS2 % Nickel SS


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CLEANING OF SS WELDS


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Why Low Carbon in SS


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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


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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


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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


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SS USED ABROAD FOR RAILWAYAPPLICATIONS


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The effect of nickel price on the price difference between AL201HP alloy and Type 304 based on the Ni raw-materialsurcharge [2]


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Samples of UNS S20100 alloy and Type 304 following 100 hours

of exposure in a salt spray test [15]

UNS S20100 Type 304


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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.


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Dull Satin Finish for Painting


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AT HIGH TEMPERATURE STRENGTHUGINE F12


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Comparison of Moon Rock V/s Slip FreeFinishes for Floor Applications

P t M R k Fi i h Sli F Fi i h


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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


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Corrosion Comparison


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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)


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Under the Paint Corrosion

Carbon Steel 409M


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Why no Titanium in utility Ferritic StainlessSteel

Extract from Research paper of Mr.Vigor of

Metallurgy dept, GM USA


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S


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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


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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


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I AM REACHABLE

E-MAIL: [email protected]

MOBILE NUMBER: +91-9448674645(Bangalore)
mailto:[email protected]:[email protected]


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Thank You For Your Kind Attention

material for rolling stocks

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