EN 13261:2009+A1:2010

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Bahnanwendungen - Radsätze und Drehgestelle - Radsatzwellen - ProduktanforderungenApplications ferroviaires - Essieux montés et bogies - Essieux-axes - Prescriptions pour le produitRailway applications - Wheelsets and bogies - Axles - Product requirements45.040Materiali in deli za železniško tehnikoMaterials and components for railway engineeringICS:Ta slovenski standard je istoveten z:EN 13261:2009+A1:2010SIST EN 13261:2009+A1:2010en,fr,de01-december-2010SIST EN 13261:2009+A1:2010SLOVENSKI
STANDARD
EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM
EN 13261:2009+A1
October 2010 ICS 45.040 Supersedes EN 13261:2009English Version
Railway applications - Wheelsets and bogies - Axles - Product requirements
Applications ferroviaires - Essieux montés et bogies - Essieux-axes - Prescriptions pour le produit
Bahnanwendungen - Radsätze und Drehgestelle - Radsatzwellen - Produktanforderungen This European Standard was approved by CEN on 29 November 2008 and includes Amendment 1 approved by CEN on 14 September 2010.
CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the CEN Management Centre or to any CEN member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the CEN Management Centre has the same status as the official versions.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre:
Avenue Marnix 17,
B-1000 Brussels © 2010 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members. Ref. No. EN 13261:2009+A1:2010: ESIST EN 13261:2009+A1:2010

Particular characteristics for axles of steel grade EA1T and EA4T . 33 A.1 Chemical composition . 33 A.2 Mechanical characteristics . 33 A.2.1 Characteristics from tensile test . 33 A.2.2 Impact test characteristics . 33 A.2.3 Fatigue characteristics . 34 A.3 Metallographic characteristics . 34 Annex B (normative)
Standard wedge for measurement of permeability to ultrasound . 35 B.1 Test piece . 35 B.2 Tolerances of the wedge . 35 B.3 Steel grade . 35 SIST EN 13261:2009+A1:2010

Method to assess resistance to impact of the coating . 36 C.1 Principle. 36 C.2 Test piece . 36 C.3 Apparatus . 36 C.4 Procedure . 36 C.5 Expression of results . 36 Annex D (normative)
Method to assess resistance to gritting of the coating . 37 D.1 Principle. 37 D.2 Test piece . 37 D.3 Apparatus . 37 D.4 Procedure . 37 D.5 Expression of results . 37 Annex E (normative)
Method to assess the resistance of the coating to specific corrosive products . 38 E.1 Principle. 38 E.2 Test piece . 38 E.3 Apparatus . 38 E.4 Corrosive products . 38 E.5 Procedure . 38 E.6 Expression of results . 39 Annex F (normative)
Method to assess the resistance of the coating to cyclic mechanical stresses . 40 F.1 Purpose . 40 F.2 Principle. 40 F.3 Test piece . 40 F.4 Apparatus . 40 F.5 Procedure . 40 F.6 Expression of results . 41 Annex G (normative)
Measurement of the hydrogen content in the steel for axles at the melting stage . 42 G.1 Sampling. 42 G.2 Analysis methods . 42 G.3 Precautions . 42 Annex H (informative)
Drawings of test pieces . 43 Annex I (informative)
Product qualification . 45 I.1 Introduction . 45 I.2 General . 45 I.3 Requirements . 45 I.3.1 Requirements to be met by the supplier . 45 I.3.2 Requirements to be met by the product . 46 I.4 Qualification procedure . 46 I.4.1 General . 46 I.4.2 Documentation required . 46 I.4.3 Evaluation of the manufacturing plant and of the production processes . 47 I.4.4 Laboratory tests . 47 I.5 Qualification certificate . 47 I.5.1 Condition of validity . 47 I.5.2 Modification and extension . 48 I.5.3 Transference . 48 I.5.4 Lapsed certification . 48 I.5.5 Cancellation . 48 I.6 Qualification file . 48 Annex J (informative)
Product delivery . 49 J.1 Introduction . 49 J.2 General . 49 J.3 Delivery condition . 50 SIST EN 13261:2009+A1:2010

!Relationship between this
European
Standard and the Essential Requirements
of EU Directive 2008/57/EC"""" . 54 Bibliography . 57
This document comprises amendment 1 adopted by CEN on 2010-09-14. This document supersedes EN 13261:2009. The start and end of the text added or modified by the amendment is indicated in the text by the !" marks. !This document has been prepared under a mandate given to CEN/CENELEC/ETSI by the European Commission and the European Free Trade Association, and supports essential requirements of EU Directive 2008/57/EC." !For relationship with EU Directive 2008/57/EC, see informative Annex ZA, which is an integral part of this document." According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and the United Kingdom.
Product qualification was sometimes mentioned, but the procedures and the characteristics that had to be verified for the qualification were not given.
This standard addresses these issues by:
a) definition of all axle characteristics; these are verified either during qualification or delivery of the product (see clause 3); b) definition of qualification procedures (see Annex I); c) definition of delivery conditions (see Annex J); here, a choice is given to the supplier of either: 1) a traditional delivery procedure with a control by batch sampling as in existing documents (see J.5),
or; 2) a delivery procedure using quality assurance concepts (see J.6). SIST EN 13261:2009+A1:2010

1 Scope This European Standard specifies the characteristics of axles for use on European networks.
It defines characteristics of forged or rolled solid and hollow axles, made from vacuum-degassed steel grade EA1N1 that is the most commonly used grade on European networks. For hollow axles, this standard applies only to those that are manufactured by machining of a hole in a forged or rolled solid axle
In addition, the particular characteristics for axles in grade EA1T1 and EA4T1 are given in Annex A.
Two categories of axle are defined, category 1 and category 2. Generally, category 1 is chosen when the operational speed is higher than 200 km/h.
This standard is applicable to axles that are designed in accordance with the requirements of EN 13103 and EN 13104.
NOTE Different values for some characteristics may be agreed if a particular process of fabrication (e.g. cold rolling, shot peening, shot peening, steel cleanliness, reduction ratio, improved material properties from melting and heat treatment processes, etc.) has an influence on them. 2 Normative references The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 10002-1, Metallic materials — Tensile testing — Part 1: Method of test at ambient temperature
EN 10045-1, Metallic materials — Charpy impact test — Part 1: Test method
EN 13103, Railway applications — Wheelsets and bogies — Non-powered axles — Design method
EN 13104, Railway applications — Wheelsets and bogies — Powered axles — Design method
EN 13260, Railway applications — Wheelsets and bogies — Wheelsets — Product requirements
EN 20898-2:1993, Mechanical properties of fasteners — Part 2: Nuts with specified proof load values — Coarse thread (ISO 898-2:1992)
EN 22768-1, General tolerances — Part 1: Tolerances for linear and angular dimensions without individual tolerance indications (ISO 2768-1:1989)
EN 22768-2, General tolerances — Part 2: Geometrical tolerances for features without individual tolerance indications (ISO 2768-2:1989)
EN ISO 643:2003, Steels — Micrographic determination of the apparent grain size (ISO 643:2003)
EN ISO 2409:2007, Paints and varnishes — Cross-cut test (ISO 2409:2007)
N for a normalized metallurgical condition
T for a quenched and tempered metallurgical condition SIST EN 13261:2009+A1:2010

EN ISO 2808:2007, Paints and varnishes — Determination of film thickness (ISO 2808:2007)
EN ISO 9227:2006, Corrosion tests in artificial atmospheres — Salt spray tests (ISO 9227:2006)
EN ISO 14284:2002, Steel and iron — Sampling and preparation of samples for the determination of chemical composition (ISO 14284:1996)
ISO 4967:1998, Steel — Determination of content of non-metallic inclusions — Micrographic method using standard diagrams
ISO 5948:1994, Railway rolling stock material — Ultrasonic acceptance testing
ISO 6933:1986, Railway rolling stock material — Magnetic particle acceptance testing . ISO/TR 97692
Steel and iron — Review of available methods of analysis. 3 Product definition 3.1 Chemical composition 3.1.1 Values to be achieved The maximum percentage contents of the various elements are given in Table 1. Table 1 —
Limit values by product analysis (%)
C Si Mn P a S ab Cr Cu Mo Ni V 0,40 0,50 1,20 0,020 0,020 0,30 0,30 0,08 0,30 0,06 a A maximum content of 0,025 % may be agreed at the time of enquiry and the order. b A minimum sulfur content may be agreed at the time of enquiry and the order according to the steelmaking process, in order to safeguard against hydrogen embrittlement.
3.1.2 Location of sample The test sample shall be taken at mid-radius of solid axles or at mid-distance between external and internal surfaces of hollow axles.
3.1.3 Chemical analysis The chemical composition analysis shall be performed according to the methods and definitions described in ISO/TR 9769.
See also CEN/TR 10261. SIST EN 13261:2009+A1:2010

The values to be achieved near the external surface shall be greater than or equal to 0,95 times the values measured at mid-radius of solid axles or at the mid-distance between external and internal surfaces of hollow axles.
The values to be achieved in the centre of solid axles or near the internal surface of hollow axles shall be greater than or equal to 0,8 times the values measured at mid-radius or at mid-distance between external and internal surfaces. Table 2 —
Values to be achieved at mid-radius of solid axles or at mid-distance between external and internal surfaces of hollow axles
ReH(N/mm²)a Rm (N/mm²) A5% ≥ 320 550-650 ≥ 22 a If no distinctive yield strength is present, the proof stress Rp0,2 shall be determined.
3.2.1.2 Location of test pieces The test pieces shall be taken from three levels in the largest axle section:
1) as near as possible to the external surface for all the axles; 2) at mid-radius and in the centre of solid axles;
3) at mid-distance between external and internal surfaces, and near the internal surface of hollow axles as shown in Figure 1 a) and b).
1a) — Solid axle
1b) — Hollow axle Figure 1 — Location of test pieces 3.2.1.3 Test method The test shall be carried out in accordance with EN 10002-1. The test piece diameter shall be at least 10 mm in the machined-down portion. The gauge length shall be five times the diameter.
3.2.2 Impact test characteristics 3.2.2.1 Values to be achieved Impact test characteristics shall be determined at 20 °C in the longitudinal and the transverse directions. Values to be achieved at mid-radius of solid axles, or at mid-distance between external and internal surfaces of hollow axles, are given in Table 3.
Near the surface, they shall be greater than or equal to 0,95 times the values measured at mid-radius or at SIST EN 13261:2009+A1:2010

In the centre of solid axles or near the internal surface of hollow axles, they shall be greater than 0,8 times the values measured at mid-radius or at mid-distance between external and internal surfaces.
For each level (surface, mid-radius, centre), the average value of the 3 test pieces (see 3.2.2.2) is defined in Table 3.
No individual value shall be less than 70 % of the values in Table 3.
Table 3 — Values to be achieved at mid-radius or at mid-distance between external and internal surfaces of hollow axles KU longitudinal (J) KU transverse (J) ≥
30 ≥ 20
3.2.2.2 Location of test pieces The test pieces shall be taken from three levels in the largest axle section:
1) as near as possible to the external surface for all the axles; 2) at mid-radius and in the centre of solid axles; 3) at mid-distance between external and internal surfaces, and near the internal surface of hollow axles as shown in Figure 2a) and 2b). 3.2.2.3 Test method The test shall be carried out in accordance with EN 10045-1.
Figure 2a) — Solid axle
Figure 2b) — Hollow axle Key
1 longitudinal test piece
2 transverse test piece Figure 2 — Location of test pieces SIST EN 13261:2009+A1:2010

It is necessary to estimate the fatigue limits in the following two areas, in order to predict the behaviour of the axle under in-service stresses:
1) for the material, tests are made on reduced test pieces, for which the shapes do not depend upon the product geometry; 2) for the product, tests are made on full size test pieces, for which the dimensions and manufacture are similar to the final product and its associated permissible fabrication defects. 3.2.3.1.2 Fatigue limits on reduced test pieces The fatigue limits defined with reduced test pieces are used to verify that the notch effect of the material used for the fabrication of the axle is in accordance with the security coefficient "S" defined in design standards
EN 13103 and EN 13104. They are determined from:
 unnotched surface test pieces (fatigue limit RfL );  notched test pieces (fatigue limit RfE). 3.2.3.1.3 Fatigue limits on full size test pieces The limits determined on full size test pieces are used to verify that the axle fatigue characteristics are in accordance with those that are used to calculate the maximum permissible stresses referred to in design standards EN 13103 and EN 13104.
These fatigue limits apply to different axle areas. Only the fatigue limits applying to the axle body are taken into account in this standard. The limits applying to the wheelset depend mostly on the assembly and are referred to in EN 13260.
It is necessary to define two fatigue limits:
 on the body surface, limit F1;  on the bore surface in the case of a hollow axle, limit F2.
3.2.3.2 Values to be achieved The values to be achieved are given in Table 4.
Table 4 — Fatigue limit values Limit F1 F2 RfL RfE q=RfL/RfE Value ≥ 200 N/mm² ≥ 80 N/mm² ≥ 250 N/mm² ≥ 170 N/mm² ≤ 1,47
For RfL and RfE determination, the test piece diameter is around 10 mm in the area where the crack initiates. The roughness (Ra) of the test piece for RfL determination is less than or equal to 0,4 µm. The notch for RfE determination is shown in Figure 3a. These test pieces are located as near as possible to the surface of the axle body.
Dimensions in millimetres
3 a)
— Notch for determination of RfE
3 b)
— Notch for determination of F2
Figure 3 — Fatigue test piece notches Examples of drawings of full-size and reduced dimension test pieces are given in Annex H. 3.2.3.4
Test method The tests shall be performed with machines that induce rotating bending stresses in the area where it is required to initiate a fatigue crack.
For each limit, F1 and F2, it shall be verified that for three test pieces there is no crack after 107 cycles of load that generates a surface stress level equal to F1 and F2. The values of the stresses are calculated by classical beam theory where it may be applied. If not, the stresses shall be measured by strain gauges in the areas where the fatigue cracks initiate.
RfL and RfE shall be determined for 107 cycles for a non-fracture probability of 50 %, which requires the use of at least 15 test pieces for each limit and a statistical method for the interpretation of the results.
3.3.2 Location of the test piece The test pieces shall be taken from the largest axle section in a 200 mm2 plane, perpendicular to arrow F, at mid-radius of solid axles, or at mid-distance between external and internal surface of hollow axles, as shown in Figure 4. 3.3.3 Test method Tests shall be performed in accordance with EN ISO 643. 3.4 Material cleanliness 3.4.1 Micrographic cleanliness 3.4.1.1 Cleanliness level to be achieved The level of cleanliness shall be measured by micrographic examination as defined in 3.4.1.2 and 3.4.1.3. The maximum values of inclusions to be obtained are given in Table 5.
Table 5 — Maximum values of inclusions in thin and thick series Type of inclusions Category 1 Category 2
Thick series (maximum)
Thin series (maximum)
Thick series (maximum)
Thin series (maximum)
A (Sulfur) 1,5 1,5 1,5 2 B (Aluminate) 1 1,5 1,5 2 C (Silicate) 1 1,5 1,5 2 D (Globular oxide) 1 1,5 1,5 2 B + C + D 2 3 3 4
3.4.1.2 Location of the micrographic sample The examination field is given in Figure 4.
The examination shall be made in a 200 mm² plane, perpendicular to arrow F, at mid-radius of the solid axles, or at mid-distance between external and internal surface of hollow axles. The test pieces shall be taken from the largest axle section. SIST EN 13261:2009+A1:2010

Figure 4 — Location of sample for micrographic examination 3.4.1.3
Test method Cleanliness level determination shall be carried out in accordance with ISO 4967:1998, method A.
3.4.2 Internal integrity 3.4.2.1 General Internal integrity shall be determined by ultrasonic examination. Standard defects shall be flat bottom holes at different depths.
3.4.2.2 Level to be achieved The axles shall have no internal defects that give echo magnitudes equal to or greater than those obtained for a standard defect situated at the same depth. The diameter of this standard defect shall be 3 mm. No attenuation of the back echo higher than 4 dB due to non-homogenates or internal defects shall be accepted.
3.4.2.3 Test piece The examination shall be made on the axle itself after heat treatment and in the delivery condition before the final protection is applied.
3.4.2.4 Method of examination The axle internal integrity is verified by ultrasonic diametral examination according to method Da of
ISO 5948:1994. The whole axle shall be examined, except certain parts (fillets, grooves, etc.) after agreement between the customer and the supplier.
3.5.2 Level to be achieved The echo obtained on the axles being checked shall have an amplitude equal to or greater than 50 % of full screen height, after preliminary calibration of the apparatus on the standard wedge described in Annex B. The height of the background noise shall be less than 10 % of the screen height.
3.5.3 Test piece The test piece to be examined shall be the axle, after full heat treatment.
The condition of the journal ends, at the moment of inspection, shall be the same as that required for delivery, without protection.
3.5.4 Test method The ultrasonic permeability examination shall be performed by longitudinal checking of the axle according to method T of ISO 5948:1994.
If the tests are not performed by an automated process, the measurement shall be performed at a minimum of 6 points, equally distributed around the axle journal section.
The probes used are the piezoelectric type, transmitter and receiver, in quartz or barium titrate BaTi with round or rectangular sections (between 80 mm2 and 450 mm2). Their frequency and the height of the echo obtained in front of the flat bottom of diameter 1 mm are described in Table 6 for each category of axle. The noise during the calibration shall not exceed 5 % of the full screen height.
For this test, the instrument shall operate with narrow frequency bands centred on the nominal frequencies "Fn" so that the band is between Fn - 20% and Fn + 20%, for an attenuation of 3 dB in relation to the frequency signal Fn.
Table 6 — Calibration for permeability examination
Category 1 Category 2 Frequency Fn 5 MHz 2 MHz to 3 MHz Conditions for calibration (% of full screen height) 90 % 40 %
For other types of probes, an agreement between the customer and the supplier is required in order to define the calibration and results to be achieved.
3.6 Residual stresses 3.6.1 General The different fabrication phases shall not create residual stresses that can cause in-service deformations of axles or facilitate fatigue crack initiation.
The difference between residual stress values measured at two different points 2 mm under the surface shall be ≤ 40 N/mm2.
3.6.3 Test piece and position of measurement points The test piece shall be the axle in the delivery condition. The position of measurement points is given in Figure 5.
Dimensions in millimetres
Sections 1 and 2
Section 3 Figure 5 — Position of measurement points
3.6.4 Measurement method The measurements shall be made either with strain gauges or by X-ray diffraction. The method shall be agreed between the customer and the supplier.
3.7 Surface characteristics 3.7.1 Surface finish 3.7.1.1 Characteristics to be achieved The axle surface shall not show any other marks than those stipulated in this standard.
The surface roughness (Ra) is given in Table 7. The symbols are those defined in Figure 6.
Surface roughness a Ra (µm) Designation Symbol
(see Figure 6) Rough-machined Finished or ready for assembly End of the axle - axle end and chamfer
a
-
6,3 - axle centre face (solid and hollow axle) See details R1 and R2 -
3,2 Journal -
journal diameter
b
12,5
0,8 - stress relieving grooves c (detail V)
0,8 Abutment - abutment diameter
d
12,5
1,6 Wheelseat - wheelseat diameter
e
12,5
Minimum 0,8 Maximum 1,6 c - lead in taper f (detail U)
1,6 Body - inner transitional radii to wheelseat
g (detail T)
-
1,6 - axle body diameter l
3,2 b - gearwheel, seat and brake disc seat diameter h 12,5 Minimum 0,8 Maximum 1,6 c - bearing seat and seal seat diameter j 12,5 0,8 - transitional radii between two seats k (detail S)
1,6 Bore - bore diameter
m (detail R1)
3,2 c a For old axle types with plain bearing journals, the requirements are in the standards that deal with these products. b 6,3 may be agreed if fatigue limits F1
and F2 defined in 3.2.3.2 and the sensitivity required for the in-service ultrasonic control are achieved. c In-service Non-Destructive Examination may require smaller values of surface finish, e. g. Ra 2 µm for the bore. SIST EN 13261:2009+A1:2010

Figure 6 — Symbols for surface finish SIST EN 13261:2009+A1:2010

3.7.2 Surface integrity 3.7.2.1 General Surface integrity of the axles shall be determined by a magnetic particle test for the external surfaces and by an ultrasonic examination or an equivalent method, agreed between the customer and the supplier, for the bore surface of hollow axles.
3.7.2.2 Level to be achieved On the external surface of the axle:
 transverse defects are not permissible;  longitudinal defects are acceptable outside z0 zones (see Figure 7), provided they are within the limits given in Table 8 (see also J.7). A defect shall be considered as a longitudinal defect if its inclination with the axle centreline is less than 10°.
Dimensions in millimetres
Figure 7 —
Zones On the bore surface of the hollow axles, transverse defects are permitted if they are no more than 0,5 mm deep and if there is not more than one per metre of axle length.
Category 1 Category 2
Zones
Maximum length of an isolated defecta
Maximum cumulative length of isolated defects
Maximum length of an isolated defecta
Maximum cumulative length of isolated defects
z0 z1 z2 z3 0 ≤ 6 mm ≤ 6 mm ≤ 6 mm 0 ≤ 6 mm ≤ 15 mm ≤ 15 mm 0 ≤ 6 mm ≤ 6 mm ≤ 10 mm 0 ≤ 6 mm ≤ 15 mm ≤ 30 mm a Defects are to be considered as isolated when the space between two of them, located on the same circumferential line, is more than 10 mm.
3.7.2.3 Test piece The test piece shall be the axle itself, after heat treatment, in the finish-machined condition defined by the purchase order and before the application of the protection.
3.7.2.4 Methods of examination 3.7.2.4.1 External surface of the axle The general conditions of the magnetic particle test are given in ISO 6933, except for:
 the surface magnetic flux, which shall be greater than 4 mT;  the lighting energy of ultra-violet light, which shall be greater than 15 W/m². The magnetization methods are those described in ISO 6933:
 circumferential magnetization for longitudinal defect investigation (see Figure "a" of ISO 6933:1986);  axial magnetization for transverse defect investigation (see Figure "b" of ISO 6933:1986). 3.7.2.4.2 Bore surface of the axle The method shall be agreed between the customer and the supplier. Unless otherwise specified, 45°-incidence ultrasonic examination from the
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