EN 13261:2003

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Railway applications - Wheelsets and bogies - Axles - Product requirementsApplications ferroviaires - Essieux montés et bogies - Essieux-axes - Prescriptions pour le produitBahnanwendungen - Radsätze und Drehgestelle - Radsatzwellen - Produktanforderungen45.040Materiali in deli za železniško tehnikoMaterials and components for railway engineeringICS:SIST EN 13261:2004enTa slovenski standard je istoveten z:EN 13261:200301-junij-2004SIST EN 13261:2004SLOVENSKI
STANDARD
EUROPEAN STANDARDNORME EUROPÉENNEEUROPÄISCHE NORMEN 13261September 2003ICS 45.040English versionRailway applications - Wheelsets and bogies - Axles - ProductrequirementsApplications ferroviaires - Essieux montés et bogies -Essieux-axes - Prescriptions pour le produitBahnanwendungen - Radsätze und Drehgestelle -Radsätze - ProduktanforderungenThis European Standard was approved by CEN on 14 February 2003.CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this EuropeanStandard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such nationalstandards may be obtained on application to the 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 translationunder the responsibility of a CEN member into its own language and notified to the Management Centre has the same status as the officialversions.CEN members are the national standards bodies of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece,Hungary, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Slovakia, Spain, Sweden, Switzerland and UnitedKingdom.EUROPEAN COMMITTEE FOR STANDARDIZATIONCOMITÉ EUROPÉEN DE NORMALISATIONEUROPÄISCHES KOMITEE FÜR NORMUNGManagement Centre: rue de Stassart, 36
B-1050 Brussels© 2003 CENAll rights of exploitation in any form and by any means reservedworldwide for CEN national Members.Ref. No. EN 13261:2003 E

Particular characteristics for axles of steel grade EA1T and EA4T.30 A.1 Chemical composition.30 A.2 Mechanical characteristics.30 A.3
Microstructure characteristics.31 Annex B (normative)
Standard wedge for measurement of permeability to ultrasound.32 B.1 Test piece.32 B.2 Tolerances of the wedge.32 B.3 Steel grade.32 Annex C (normative)
Method to assess resistance to impact of the coating.33 C.1 Principle.33 C.2 Test piece.33 C.3 Apparatus.33 C.4 Procedure.33 C.5 Expression of results.33 Annex D (normative)
Method to assess resistance to gritting of the coating.34 D.1 Principle.34 D.2 Test piece.34 D.3 Apparatus.34 D.4 Procedure.34 D.5 Expression of results.34 Annex E (normative)
Method to assess the resistance of the coating to specific
corrosive products.35 E.1 Principle.35 E.2 Test piece.35 E.3 Apparatus.35 E.4 Corrosive products.35 E.5 Procedure.35 E.6 Expression of results.36 Annex F (normative)
Method to assess the resistance of the coating to cyclic mechanical stresses.37 F.1 Purpose.37

Measurement of the hydrogen content in the steel for axles at the melting stage.39 G.1 Sampling.39 G.2 Analysis methods.39 G.3 Precautions.39 Annex H (informative)
Drawings of test pieces.40 Annex I (informative)
Product qualification.42 I.1 General.42 I.2 Requirements.42 I.3 Qualification procedure.43 I.4 Qualification certificate.44 I.5 Qualification file.45 Annex J (informative)
Product delivery.46 J.1 General.46 J.2 Delivery condition.47 J.3 Controls on each axle.47 J.4 Batch control.48 J.5 Quality plan.49 J.6 Allowable rectification.50 Bibliography.51

Annexes H, I and J are informative. This document contains a bibliography. According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Slovakia, 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 informative annex I);
c) definition of delivery conditions (see informative annex J). Here, a choice is given to the supplier of either:  a traditional delivery procedure with a control by batch sampling as in existing documents (see J.4), or  a delivery procedure using quality assurance concepts (see J.5).
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 (normative).
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) has an influence on them.
1) N for the normalized metallurgical condition T for the quenched and tempered metallurgical condition

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, 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).
ISO 643, Steels – Micrographic determination of the apparent grain size.
ISO 2409, Paints and varnishes – Cross-cut test.
ISO 2808, Paints and varnishes – Determination of film thickness.
ISO 4967, Steel – Determination of content of non-metallic inclusions – Micrographic method using standard diagrams.
ISO 5948, Railway rolling stock material – Ultrasonic acceptance testing.
ISO 6933:1986, Railway rolling stock material – Magnetic particle acceptance testing.
ISO 9227, Corrosion tests in artificial atmospheres – Salt spray tests.
ISO/TR 97692), Steel and iron – Review of available methods of analysis.
ISO 14284:1996, Steel and iron – Sampling and preparation of samples for the determination of chemical composition.
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.
2) See also CR10261
Table 1 C Si Mn Pa
Sab
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 oxygen cracking.
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.
3.2 Mechanical characteristics
3.2.1 Characteristics from tensile test
3.2.1.1 Values to be achieved
The 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 2.
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
ReH (N/mm2)a
Rm (N/mm2)
As %
≥ 320
550-650
≥ 22
a If no distinctive yield strength is present, the proof stress R0,2 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:
 as near as possible to the external surface for all the axles;  at mid-radius and in the centre of solid axles;

as shown in Figure 1 a) and b). Dimensions in millimetres.
Figure 1 a) — Solid axle
Figure 1 b) — Hollow axle
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 mid-distance between external and internal surfaces of hollow axles.
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
KU longitudinal (J)
KU transverse (J)
≥ 30 ≥ 25
3.2.2.2 Location of test pieces
The test pieces shall be taken from three levels in the largest axle section:
 as near as possible to the external surface for all the axles;  at mid-radius and in the centre of solid axles;  at mid-distance between external and internal surfaces, and near the internal surface of hollow axles, as shown in Figure 2 a) and b).
3.2.2.3 Test method
The test shall be carried out in accordance with EN 10045-1.

Figure 2 a) — Solid axle
Figure 2 b — Hollow axle
Key
1 Longitudinal test piece 2 Transverse test piece

3.2.3.1 General
Verification of the fatigue characteristics is essential in order to have a correctly dimensioned axle. The satisfactory performance of an axle in service depends upon these characteristics. The values defined in this subclause are used for the calculation of the maximum permissible stresses that are referred to in the design rules in EN 13103 and EN 13104.
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:
 for the material, tests are made on reduced test pieces, for which the shapes do not depend upon the product geometry,  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.
3.2.3.1.1
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:
 smooth surface test pieces (fatigue limit RfL ) and  notched test pieces (fatigue limit RfE )
3.2.3.1.2
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
Limit F1 F2 RfL RfE q = RfL/RfE Value ≥ 200 N/mm2 ≥ 80 N/mm2 ≥ 250 N/mm2 ≥ 170 N/mm2 ≤ 1,47

3.2.3.3 Fatigue test pieces
For F1 and F2 determination, the test piece areas where the cracks initiate shall have a similar geometry and surface roughness to those of the axle areas that have to be analysed. For F2 determination, the test piece surface shall have a 1 mm deep notch as shown in Figure 3a. All of these test pieces shall come from the same fabrication process as that for the axle.
For RfL and RfE determination, the test piece diameter is nominally 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 3b. These test pieces are located as near as possible to the surface of the axle body.
Dimensions in millimetres
Figure 3 a — Solid axle
Figure 3b — Hollow axle
Examples of full size and reduced test piece drawings are given in annex H (informative).
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 Microstructure characteristics
3.3.1 Values to be achieved
The microstructure shall be one of ferrite and perlite.
The grain size shall not be greater than that defined by the reference diagram V of ISO 643.
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 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 thick series inclusions to be obtained are given in Table 5. Thin series inclusions are not taken into account.
Table 5
Category 1 Category 2 Type of inclusions 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.

Figure 4
3.4.1.3 Test method
Cleanliness level determination shall be carried out in accordance with ISO 4967, 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. The whole axle shall be examined, except certain parts (fillets, grooves, etc.) after agreement between the customer and the supplier.
3.5 Permeability to ultrasound
3.5.1 General The permeability shall ensure the feasibility of ultrasonic testing during service and is verified by producing a record for the axle after a preliminary calibration of the testing apparatus.

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.
3.5.3. Test method
The ultrasonic permeability examination shall be performed by longitudinal checking of the axle according to method T of ISO 5948.
If the tests are not performed by an automated process, the measurement shall be performed 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 ∅ 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
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.
3.6.2 Values to be achieved
On the axle surface, residual stresses shall be less than or equal to +100 N/mm2.
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 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) of finished or ready to assemble parts is given in Table 7. The symbols are those defined in Figure 6.
Table 7 Designation Symbol (see Figure 6)
Surface roughnessa
Ra (µm)
Rough-machined Finished or ready for assembly End of the axle - axle end and chamfer - axle centre face (solid and hollow axle)
a See details R1 and R2
- -
6,3 3,2 Journal - journal diameter - stress relieving grooves
b c (detail V)
12,5
0,8 0,8
Abutment - abutment diameter
d
12,5
1,6 Wheelseat
- wheelseat diameter - lead in taper
e f (detail U)
12,5
0,8/1,6c
1,6
Body - inner transitional radii to wheelseat - axle body diameter - gearwheel, seat and brake disc seat diameter - bearing seat and
seal seat diameter - transitional radii between two seats
g (detail T)
l h j k (detail S)
-
12,5
12,5
1,6
3,2b
0,8/1,6c
0,8
1,6
Bore - bore diameter
m (detail R1)
3,2
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 or 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.

Figure 6 - Symbols
The mean roughness of the axle surfaces (Ra) in their delivery condition, given in Table 7, shall be measured with a roughness test apparatus.
In fillet radii, the roughness may evaluated by comparison with tactile and visual specimens agreed between the customer and the supplier.
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.
3.7.2.1 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.6).
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
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.

Table 8
Category 1 Category 2 Areas Maximum length of an isolated
defecta
Maximum cumulative length of isolated defects Maximum length of an isolated defect 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
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),  axial magnetization for transverse defect investigation (see Figure "b" of ISO 6933).
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 external surface is to be undertaken.
3.8 Geometrical and dimensional tolerances
Geometrical tolerances are given in Table 9. The symbols used are defined in Figure 8.
Dimensional tolerances are given in Table 10. The symbols used are defined in Figure 9.

Designation
Symbol (see Figure 8)
Geometrical tolerancesab
(mm)
Rough-machined Ready for assembly Journal and abutment Cylindricity Run out of the vertical face of the abutment relative to the reference Y-Z Run out of the abutment relative to the reference Y-Z n
0,015
0,03
0,03
Wheelseat Run out relative to the reference Y-Zc Cylindricity
p
1,5 0,1
0,03 0,015 Gearwheel seat Run out relative to the reference Y-Zc
Cylindricity
q
1,5 0,1
0,03 0,015 Motor bearing seats Run out relative to the reference Y-Zc
Cylindricity
r
1,5 0,1
0,02 0,015 Disc brake seat Run out relative to the reference Y-Zc
Cylindricity
s
0,15 0,1
0,03 0,015 Axle body Run out relative to the reference Y-Zc
t
0,5 d Bore Concentricity relative to the reference Y-Zc
u
0,5
Holes for fixing axle end caps Concentricity relative
to the reference Y-Zc
v
0,5
Machining centre run out relative to the reference Y-Zc W1 W2 (details, R1/R2)
0,02 0,03 a For parameters which do not have a tolerance in this table, the general tolerances of EN 22768-2 shall be applied. b
For old axle types with plain bearing journals, the requirements are in the standards that deal with these products. c Reference axis: the reference axis is taken from the axle journals, identified as Y-Z in Figure 8. d
0,3 mm for axle category 1 axles.

Figure 8 - Symbols
Designation Symbol (see Figure 9) Dimensional tolerances a (mm)
Rough-machined Ready for assembly Longitudinal sizes . Length of axleb
. Length of wheelseat (including collar) . Length over abutments (between reference planes) . Journal bearing seat length . Abutment length . Journal and abutment length . Depth of journal groove . Length of journal groove . Others seats Diameters . Diameter of journal . Wheelseat diameter . Diameter of seats of gear wheel, or brake disc, or plain seal spacer, or bearing seat for motor suspension or motor drive roller bearing seat . Abutment diameter . Diameter of body Sizes of other parts of axle Axle machining centres . Plain axles . Hollow axles Holes for fixing axle end caps . Drilling concentricity . Drilling depth . Thread depth . Variation between drilling and thread Lead in taper . Wheelseat conical length
. Wheelseat taper depth
Diameter of bore Stress relieving groove - journal Transitional radii – wheelseat/body
Stress relieving groove between the 2 seats
A B C
D E F See detail V G (detail V) M
H I J
Nc
P
See detail R2d
See detail R1d
See detail R1d
K (detail U) (detail U) O (detail R1) See detail V See detail T See detail S
+2/0 +2/0 +2/0
0/-2 0/-2 0/-4
+2/0 +2/0 +2/0
+2/0 +4/0
+1 0/-0,5 +0,5e
c +1/0 c
c 0/-1
c
c
+0,25
+2/0
See detail R2 See detail R1
0,5 +2/0 +2/0 ≥10
0/-3 +0,1 +1 c c c a For parameters that do not have a tolerance defined in this Table, the general tolerances of EN 22768-2 shall be applied. b Attention is drawn to the fact that compliance with tolerances over the total length "A" does not allow all the individual tolerances to be cumulatively applied to the particular dimensions. . c According to the requirements of the drawing or documents accompanying the order. d Other geometries may be proposed and defined in the order. e Other values may be agreed for special applications.

Key
1 Reference plane 2 Chamfer Figure 9 - Symbols

3.9 Protection against corrosion and against mechanical aggression
3.9.1 Final protection
3.9.1.1 General All axles in service shall be protected against corrosion for the areas where there are no fitted components. For some axles, it is necessary to have protection against mechanical aggression (impacts, gritting, etc.).
Four classes of protection are defined, according to the use of the axle and the maintenance policy that is applied to the axle:
 class 1: axles that are subject to atmospheric corrosion and to mechanical impacts;  class 2: axles that are subject to the action of specific corrosive products;  class 3: axles that are subject to atmospheric corrosion;  class 4: axles that are subject to atmospheric corrosion when the stresses calculated according to
EN 13103 and EN 13104 are less than 60 % of limit stresses.
The choice between these four classes shall be defined in the order unless other requirements are defined. Some areas of an axle protected by a class 1 or class 3 coating can be requested with a class 2 coating.
The protective coatings for each class are, as a minimum, defined by the following characteristics given in
Table 11.
Other characteristics may also be required in the order according to particular conditions of utilization of the axles. The tests shall be carried out 14 days after the application of the coating.
The bore surface of hollow axles shall be protected against corrosion using a product whose properties are specified by the customer and the supplier.
Table 11
Class 1 Class 2 Class 3 Class 4 Coating thickness X X X - Coating adhesion X X X - Resistance to impacts X - - - Resistance to gritting X X X - Resistance to salt spray X X X - Resistance to specific corrosive products - X - - Coating resistance to cyclic mechanical stresses X X X -

3.9.1.2 Coating thickness
3.9.1.2.1 Values to be achieved
Unless the order includes special requirements, the minimum coating thickness shall be that which was recorded and found satisfactory during the "axle" product qualification.
3.9.1.2.2
Test piece
The test piece shall be the axle covered with its coating.
3.9.1.3 Method of measurement
The measurement shall be carried out by the 6 Ba method of ISO 2808, provided that the thickness of the coating permits this. If not, it is to be agreed between the customer and the supplier.
3.9.1.3 Coating adhesion
3.9.1.3.1
General
The adhesion is a characteristic of all adhesive forces applied between the coating and the axle surface.
3.9.1.3.2
Characteristics to be achieved
For a coating with a maximum thickness of 250 µm, the appearance shall comply with classification 1 of
ISO 2409, after incisions and coating wrench tests.
For a coating thickness greater than 250 µm, the adhesion characteristic shall be agreed between the customer and the supplier.
3.9.1.3.3
Test piece
The test piece shall be the axle or an axle section covered with the coating to be evaluated.
3.9.1.3.4
Test method
For a coating with a maximum thickness of 250 µm, the test method shall be that recommended by ISO 2409.
For thicknesses greater than 250 µm, the test method shall be agreed between the customer and the supplier.
3.9.1.4 Resistance to impacts
3.9.1.4.1
General
This characteristic defines the ability of the coating to protect the axle from damage due to impacts from projectiles, e.g. ballast. This characteristic applies only to class 1.
3.9.1.4.2
Characteristics to be achieved
After the test defined in 3.9.1.4.4, no hole shall be found in the coating, nor shall there be any alteration to the test piece surface.
3.9.1.4.3
Test piece
The test piece shall be the axle or an axle section covered with the coating to be evaluated.

Test method
The test piece shall be tested by firing a projectile onto the protected surface in accordance with annex C (normative).
3.9.1.5 Resistance to gritting
3.9.1.5.1
General
This characteristic defines the ability of the coating to protect the axle from damage due to repeated sand or grit blasting.
3.9.1.5.2
Characteristics to be achieved
After the test defined in 3.9.1.5.4, the coating surface shall comply with:
 coating loss level 3 for the protection of classes 1 and 2,  coating loss level 4 for the protection of class 3 ,as described in annex D (normative)
3.9.1.5.3
Test piece
The test piece shall be the axle or an axle section covered with the coating to be evaluated.
3.9.1.5.4
Test method
The method to assess the resistance to gritting is given in annex D (normative).
3.9.1.6 Resistance to salt spray
3.9.1.6.1
General
This characteristic defines the ability of the axle surface, when protected by its coating, to resist corrosion accelerated by an artificial salt spray.
3.9.1.6.2
Characteristics to be achieved
After the test defined in 3.9.1.6.4, no corrosion shall be found under the coating, nor shall there be any corrosion present at a distance of more than 2 mm from the edges or from the incisions in the coating.
The length of the incision is divided into successive 10 mm sections.
The maximum width of the corrosion is noted for each of these sections.
The average of these measurements constitutes the increase in corrosion.
3.9.1.6.3
Test piece
The test piece shall consist of an axle section covered with the coating to be evaluated in which cross-shaped incisions (for coating thickness < 250 µm) or an aperture (for coating thickness > 250 µm) have been made (see Figures 10a and 10b).

Key
1 Generating line Figure 10
3.9.1.6.4
Test method
The assessment of resistance to salt spray is carried out in accordance with ISO 9227; the solution used is that of the NSS test of that standard.
3.9.1.7 Resistance to specific corrosive products
3.9.1.7.1
General
This characteristic, which only affects the class 2 coating, assesses its resistance to specific corrosive products that might affect it (corrosive environments, products transported, etc.).
3.9.1.7.2
Characteristics to be ac
...