CODE OF PROCEDURES FOR ULTRASONIC TESTING

OF
AXLES AND WHEEL OF LARGE TRACK MACHINES
 REFERENCES
S.NO. MACHINE POSITION REPORT/DRAWING RDSO DATE OF
MODEL OF AXLE REFERRED LETTER ISSUE
NO.
1. Unimat 08- Axle UD62.4901 SP TM/HM/7 15/22.01.2008
275 1668/1676
2. UNIMAT 08- Axle WN02-120.184.1SP TM/HM/7 15/22.01.2008
275-3S, 1668/1676
DGS-62N,
09-3X and
UNIMAT
COMPACT
M
3. RM80, FRM Axle 64.02.2249 TM/HM/7 15/22.01.2008
80 and RM
76
4. CSM (09-32) Driving axle UD 62.3301 SP TM/HM/7 15/22.01.2008
and 1668/1676
DUOMATIC
(08-32)
5. Track --- RDSO report no.IRS R- TM/HM/7 02/06.6.2006
Machine 34-2003 Vol.III
Wheels

6. UTV90TT Powered M/s. Phooltas. TM/HM/7 26/28.02.2007

(Phooltas) axle Vol.III

7. CSM (09- Satellite or CPOH Drg. No. C-1411 TM/HM/7 07.2.2003

32) Driving CSM
Bogie axle
8. DUOMATIC Driving axleIRTMTC Drg. No. D- TM/HM/7 07.2.2003
1402 DUO-R1
9. UNIMAT Front driving CPOH Drg. No. UNI- TM/HM/7 07.2.2003
axle 1402
10. UNIMAT Rear driving CPOH Drg. No. UNI- TM/HM/7 07.2.2003
axle 1401
11. CSM (09-32) Running IRTMTC Drg. No. C- TM/HM/7 07.2.2003
axle 1406 CSM
 CONTENT

S.NO. MACHINE MODEL POSITION OF AXLE PAGE NO.

1. Unimat 08-275 Axle 1-10

2. UNIMAT 08-275-3S, DGS-62N, 09- Axle 11-20

3X and UNIMAT COMPACT M

3. RM80, FRM 80 and RM 76 Axle 21-30

4. CSM (09-32) and DUOMATIC (08- Driving axle 31-39

32)

5. Track Machine Wheels --- 40-46

6. UTV90TT (Phooltas) Powered axle 47-61

7. CSM (09-32) Satellite or Driving Bogie 62-75

axle
8. DUOMATIC Driving axle 62-75

9. UNIMAT Front driving axle 62-75

10. UNIMAT Rear driving axle 62-75

11. CSM (09-32) Running axle 62-75

CODE OF PROCEDURE OF ULTRASONIC TESTING OF TRACK
MACHINE UD62.4901 SP. 1668/1676 AXLE FOR 08-275 OF M/s PLASSER
INDIA Pvt. Ltd. IN SERVICE (TENTATIVE).

1. SCOPE : To ensure safety and reliability of rolling stocks, axles are

required to be examined periodically for presence of cracks. This
code stipulates the testing procedure, calibration method and
sensitivity setting for detection of cracks in Track Machine
UD62.4901 SP. 1668/1676 Axle for 08-275 of M/s Plasser India Pvt.
Ltd. in service.

2. NORMATED REFERENCES: The following RDSO / IS standards contain

provisions, which through reference in this text constitute provisions of
this code of procedure. At the time of publication, the editions
indicated were valid.

Specification No. Title

RDSO specification No. Technical specification for battery cum-

mains operated ultrasonic flaw detector
M&C/NDT/104/2000 having memory calibration and 100 mm X
(Rev.1) April 2005 80 mm screen.
or

RDSO specification Portable digital ultrasonic flaw detector with

No.M&C/NDT/125/2004 A-scan storage.

RDSO specification No. Soft grease

WD-17-MISC-92

IS:1628-1986 Axle oil

Reaffirmed in Feb.1996

IS: 1875-1992 Carbon steel billets, blooms, slabs and bars

for forging.

IS:12666-1988 Methods for performance assessment of

ultrasonic flaw detection equipment.
Reaffirmed in 1993

Page 1 of 75
3. PROCEDURE OF EXAMINATION:

3.1 Equipment and accessories to be employed:

3.1.1 Equipment: Ultrasonic flaw detector approved by RDSO, Lucknow to

RDSO specification No.M&C/NDT/104/2000 (Rev.1) April 2005 or
No. M&C/NDT/125/2004 or any other ultrasonic flaw detector
meeting RDSO specification No. M&C/NDT/104/2000 (Rev.1) April
2005 or No. M&C/NDT/125/2004.

3.1.2 Accessories : Far end scanning : Normal probe of 2.5 MHz, 20/25mm dia.,
Lead zirconate titanate or crystal of similar characteristics.

Near end low angle scanning : Normal probe of 2.5 MHz, 15/20 mm
dia., Lead zirconate titanate or crystal of similar characteristics with
perspex wedge capable of producing ultrasonic wave at 17.5o angle or
angle probe of 17.50 .

High angle scanning : Normal probe of 2.5 MHz, 20/25 mm dia.,

Lead zirconate titanate or crystal of similar characteristics with perspex
wedge capable of producing ultrasonic wave at 37 o angle or angle
probe of 370 having dia. of curvature 140 +200 mm .

3.1.3 Couplant: Soft grease or axle oil (medium) to RDSO specification No. WD-
17- MISC-92 or IS :1628 (86) Reaffirmed in Feb. 96 .

3.1.4 Standard bar : 50mm dia. x 500 mm long and 50mm dia. X 182 mm long
steel bar to designation 45C8 of IS:1875 –1992 rolled/forged and
normalized having grain size No.5 or finer to ASTM/E-10-39T.

3.2 Personnel engaged in testing: Testing of Axles shall be done only by trained
and certified personnel having valid RDSO certificate. Under no
circumstances testing shall be carried out by any other personnel not
meeting this requirement.

3.3 Scanning techniques :

3 .3.1 Far end scanning : This technique shall be used for testing the full length
of the axle from gear end as well from free end .

The time scale shall be calibrated to 250mm per main scale division of
compression wave. The normal probe of 2.5 MHz having 20/25 mm
dia shall be placed on the clean axle end faces with suitable couplant.
The probe shall be given slight rotary movement for proper acoustic
coupling while proving from ‘X’ end & ‘Y’ end. The expected signals
have been shown in Annexure.

Page 2 of 75
3.3.2 Examination by Trace Delay Technique: This technique shall be
employed to examine the axle in part of 500 mm each. This
technique may be utilized for confirmation of the findings during
Far End scanning.

The expected signals have been shown in Annexure.

3.3.3 Near End - Low Angle Scanning: This technique is used for examination
of fatigue cracks in the raised seat inner fillet area, which remains
unscanned during far end scanning.

The time scale shall be calibrated to 100 mm per main scale

division for compression wave. The normal probe of 2.5 MHz having
15/20 mm dia shall be placed on the clean axle end faces with suitable
couplant. The probe shall be given slight rotary movement for proper
acoustic coupling while probing from ‘X’ end & ‘Y’ end. The expected
signals have been shown in Annexure.

3.3.4 High Angle Scanning : This technique may be employed for

confirmation of the findings during Near End Low Angle
Scanning.

The time scale shall be calibrated to 50 mm per main scale division

for shear wave with the help of 50 mm dia. X 182 mm long steel
bar (since 5 X 182 = 910 mm longitudinal wave is equivalent to 5 X
100 mm = 500 mm of shear wave).
The time scale shall be calibrated to 50mm per main scale division of
shear wave. The normal probe of 2.5 MHz having 20/25 mm dia shall
be placed on the body of the axle at a distance of 120 mm from wheel
seat inner fillet with suitable couplant directing the central beam
towards wheel seat inner fillet. The probe shall be given slight rotary
movement for proper acoustic coupling. The expected signals have
been shown in Annexure.

3.3.5 Scale expansion: The analysis of oscillogram pattern having closely placed
echoes may be simplified by expanding the relevant part of the
pattern. This can be done with the scale expansion control provided
in the machine.

4. IMPORTANT NOTE :

1. Prior to ultrasonic testing it may be ensured that the axle end faces are
smooth for achieving proper acoustic coupling. If required, the end
faces of the Axle should be properly smoothened by filing /emery
finishing for achieving proper acoustic coupling.
Page 3 of 75
 2. In low angle and high angle scanning the onset of the signal in relation
to the initial pulse is a function of the thickness of the perspex wedge
at the probe index marking and the velocity of the ultrasonic wave in
the perspex.

3. If the thickness of the perspex wedge at the probe index marking is

more than the one used for the preparation of this code, the onset of
the signal is likely to shift towards right side of the standard position of
the signal.

4. It may be ensured that, calibration and sensitivity setting shall be

carried out before ultrasonic testing of the axles.

5. Various characteristics of the equipment and probes may be checked as

per IS-12666 at least once a month.

5. CRITERIA FOR ACCEPTANCE :

(a) Axle found to produce flaw signal other than those standard signals as
shown in the relevant trace patterns during scanning by Far End and
Near End Low Angle Scanning techniques shall be withdrawn from
service. Further confirmation of the defect may be carried out by Trace
Delay & high angle scanning.

(b) Axle found to produce signals as per the standard signals as given in
the Annexure should be declared satisfactory.

(c) During service, few standard signals may disappear due to change in
the geometrical configuration of axle. This aspect may be kept in view.

6. MAGNETIC PARTICLE TESTING:

Axles found defective during ultrasonic examination described above
should be subjected to magnetic particle examination after removal of
the wheels, bearings etc. as the case may be. Record of magnetic
particle examination and observations made shall be maintained in the
register.

7. RECORDING OF TEST DETAILS:

Ultrasonic personnel conducting the test shall maintain a register
indicating the complete details of axle identification, technique
employed, observation made , code of procedure followed and his
remarks. He should also record his observations on visual examination
of the axles.

Page 4 of 75
 Annexure-I

Theoretical calculations and relative positions of signals of axle of Tie

Tamping Machine UD62.4901 SP 1668/1676 axle for 08-275 of Plasser India
Pvt. Ltd. (Tentative).

(A) FAR END SCANNING : 1 Main Scale Div. = 250 mm (compression wave)

Probe: 20/25, 2.5 MHz

From ‘X’ End:

Sl DETAILS Distance Signal Echo

No. (mm) (Div.)

1. Direct reflection from axle end. 2162 8.6

2. Direct reflection from journal fillet 2021 8.0

3. Delayed reflection from fillet at a distance of 1942 7.8

1669 mm from probing end

4. Delayed reflection from fillet at a distance of 1819 7.3

1669 mm from probing end

5. Delayed reflection from fillet at a distance of 1669 6.7

1669 mm from probing end

6. Delayed reflection from wheel seat inner fillet 594 2.4

7. Delayed reflection from wheel seat inner fillet 471 1.9

8. Delayed reflection from wheel seat inner fillet 321 1.3

Page 5 of 75
From ‘Y’ End Side:

SL. Details Distance Signal Echo

No. (mm) (Div.)

1. Direct reflection from axle end 2162 8.6

2. Direct reflection from journal fillet 2021 8.0

3. Delayed reflection from fillet at a distance of 1227 4.9

954 mm from probing end

4. Delayed reflection from fillet at a distance of 1104 4.4

954 mm from probing end

5. Delayed reflection from fillet at a distance of 954 3.8

954 mm from probing end

6. Delayed reflection from wheel seat inner fillet 594 2.4

7. Delayed reflection from wheel seat inner fillet 471 1.9

8. Delayed reflection from wheel seat inner fillet 321 1.3

(B) TRACE DELAY SCANNING:

From ‘X’ End: ( 1 main scale div. = 50 mm)

0-500 mm:

S.NO. DETAILS DISTANCE SIGNAL

(mm (divn.)

1. Direct reflection from wheel seat inner fillet 321 6.4

2. Delayed reflection from wheel seat inner fillet 471 9.4

Page 6 of 75
500 mm- 1000 mm
S. NO. DETAILS DISTANCE SIGNAL

(mm (divn.)

1. Delayed reflection from wheel seat inner fillet 94 1.9

1000mm - 1500 mm NIL

1500mm - 2000 mm:

S.NO. DETAILS DISTANCE SIGNAL

(mm (divn.)

1. Direct reflection from fillet at a distance of 169 3.4

1669 mm from probing end

2. Delayed reflection from fillet at a distance of 319 6.4

1669 mm from probing end

3. Delayed reflection from fillet at a distance of 442 8.8

1669 mm from probing end

2000mm - 2500 mm:

S.NO. DETAILS DISTANCE SIGNAL

(mm) (divn.)

1. Direct reflection from journal fillet 21 0.4

2. Direct reflection from axle end 162 3.2

From ‘Y’ End: ( 1 main scale div. = 50 mm)

0-500 mm:

S.NO. DETAILS DISTANCE SIGNAL

(mm (divn.)

1. Direct reflection from wheel seat inner fillet 321 6.4

2. Delayed reflection from wheel seat inner fillet 471 9.4

Page 7 of 75
500 mm - 1000 mm:
S. NO. DETAILS DISTANCE SIGNAL

(mm (divn.)

1. Delayed reflection from wheel seat inner fillet 94 1.9

2. Direct reflection from fillet at a distance of 954 454 9.1

mm from probing end

1000mm - 1500 mm:

DETAILS DISTANCE SIGNAL

S. (mm (divn.)
NO.

1. Delayed reflection from fillet at a distance of 954 104 2.1

mm from probing end

3. Delayed reflection from fillet at a distance of 954 227 4.5

mm from probing end

1500mm - 2000 mm : NIL

2000mm - 2500 mm:

S.NO. DETAILS DISTANCE SIGNAL

(mm) (divn.)

1. Direct reflection from journal fillet 21 0.4

2. Direct reflection from axle end 162 3.2

Page 8 of 75
(C) NEAR END LOW ANGLE SCANNING 1 Main Scale Div. = 50mm

(Compressive Wave)

Probe : 15/20mm, 2.5 MHz

FROM ’X’ & ‘Y’ END SIDE :

S.NO. Details Distance Signal Echo

(mm (div.)

1. Direct reflection from wheel seat inner fillet. 340 6.8

(Wedge : 17.5, Central beam at 36mm from

edge of axle)

HIGH ANGLE SCANNING: 1 Main Scale Div. = 50 mm (Shear wave)

Probe: 20/25mm. , 2.5 MHz

From ‘X’ & ‘Y’ END SIDE :

S.NO. Details Distance Signal Echo

(mm) (div.)

1. Direct reflection from gear seat inner fillet. 194 3.9

(Wedge : 37 with dia. of curvature 140mm,

Stand off distance 120 mm from wheel seat
inner fillet.)

Page 9 of 75
Page 10 of 75
CODE OF PROCEDURE OF ULTRASONIC TESTING OF TRACK
MACHINE WN02-120.184.1 SP 1. 1668/1676 AXLE FOR 08-275 3S, DGS-62,
09-3X & UNIMAT COMPACT M OF M/s PLASSER INDIA Pvt. Ltd. IN
SERVICE (TENTATIVE).
1. SCOPE : To ensure safety and reliability of rolling stocks, axles are
required to be examined periodically for presence of cracks. This
code stipulates the testing procedure, calibration method and
sensitivity setting for detection of cracks in Track Machine WN02-
120.184.1 SP1. 1668/1676 AXLE FOR 08-275 3S, DGS-62, 09-3X &
UNIMAT COMPACT M of M/s Plasser India Pvt. Ltd. in service.

2. NORMATED REFERENCES: The following RDSO / IS standards contain

provisions, which through reference in this text constitute provisions of
this code of procedure. At the time of publication, the editions
indicated were valid.

Specification No. Title

RDSO specification No. Technical specification for battery cum-

mains operated ultrasonic flaw detector
M&C/NDT/104/2000 having memory calibration and 100 mm X
(Rev.1) April 2005 80 mm screen.
or
RDSO specification Portable digital ultrasonic flaw detector with
No.M&C/NDT/125/2004 A-scan storage.

RDSO specification No. Soft grease

WD-17-MISC-92

IS:1628-1986 Axle oil

Reaffirmed in Feb.1996

IS: 1875-1992 Carbon steel billets, blooms, slabs and bars

for forging.

IS:12666-1988 Methods for performance assessment of

ultrasonic flaw detection equipment.
Reaffirmed in 1993

Page 11 of 75
3. PROCEDURE OF EXAMINATION:

3.1 Equipment and accessories to be employed:

3.1.1 Equipment: Ultrasonic flaw detector approved by RDSO, Lucknow to

RDSO specification No.M&C/NDT/104/2000 (Rev.1) April 2005 or
No. M&C/NDT/125/2004 or any other ultrasonic flaw detector
meeting RDSO specification No. M&C/NDT/104/2000 (Rev.1) April
2005 or No. M&C/NDT/125/2004.

3.1.2 Accessories : Far end scanning : Normal probe of 2.5 MHz, 20/25mm dia.,
Lead zirconate titanate or crystal of similar characteristics.

Near end low angle scanning : Normal probe of 2.5 MHz, 15/20 mm
dia., Lead zirconate titanate or crystal of similar characteristics with
perspex wedge capable of producing ultrasonic wave at 17.5o angle or
angle probe of 17.50 .

High angle scanning : Normal probe of 2.5 MHz, 20/25 mm dia.,

Lead zirconate titanate or crystal of similar characteristics with perspex
wedge capable of producing ultrasonic wave at 37 o angle or angle
probe of 370 having dia. of curvature 160 + 200 mm .

3.1.3 Couplant: Soft grease or axle oil (medium) to RDSO specification No. WD-
17- MISC-92 or IS :1628 (86) Reaffirmed in Feb. 96 .

3.1.4 Standard bar : 50mm dia. x 500 mm long and 50mm dia. X 182 mm long
steel bar to designation 45C8 of IS:1875 –1992 rolled/forged and
normalized having grain size No.5 or finer to ASTM/E-10-39T.

3.2 Personnel engaged in testing: Testing of Axles shall be done only by trained
and certified personnel having valid RDSO certificate. Under no
circumstances testing shall be carried out by any other personnel not
meeting this requirement.

3.3 Scanning techniques :

3 .3.1 Far end scanning : This technique shall be used for testing the full
length of the axle from gear end as well from free end .
The time scale shall be calibrated to 250mm per main scale division of
compression wave. The normal probe of 2.5 MHz having 20/25 mm
dia shall be placed on the clean axle end faces with suitable couplant.
The probe shall be given slight rotary movement for proper acoustic
coupling while proving from ‘X’ end & ‘Y’ end. The expected signals
have been shown in Annexure.
Page 12 of 75
3.3.2 Examination by Trace Delay Technique: This technique shall be
employed to examine the axle in part of 500 mm each. This technique
may be utilized for confirmation of the findings during Far End
scanning.
The expected signals have been shown in Annexure.
3.3.3 Near End - Low Angle Scanning: This technique is used for
examination of fatigue cracks in the raised seat inner fillet area, which
remains unscanned during far end scanning.

The time scale shall be calibrated to 100 mm per main scale division
of compression wave. The normal probe of 2.5 MHz having 15/20 mm
dia shall be placed on the clean axle end faces with suitable couplant. The
probe shall be given slight rotary movement for proper acoustic coupling
while probing from ‘X’ end & ‘Y’ end. The expected signals have been
shown in Annexure.

3.3.4 High Angle Scanning : This technique may be employed for

confirmation of the findings during Near End Low Angle Scanning.

The time scale shall be calibrated to 50 mm per main scale division for
shear wave with the help of 50 mm dia. X 182 mm long steel bar (since
5 X 182 = 910 mm longitudinal wave is equivalent to 5 X 100 mm = 500
mm of shear wave).

The time scale shall be calibrated to 50mm per main scale division of shear
wave. The normal probe of 2.5 MHz having 20/25 mm dia shall be placed
on the body of the axle at a distance of 130 mm from wheel seat inner fillet
with suitable couplant directing the central beam towards wheel seat inner
fillet. The probe shall be given slight rotary movement for proper acoustic
coupling. The expected signals have been shown in Annexure.

3.3.5 Scale expansion: The analysis of oscillogram pattern having closely placed
echoes may be simplified by expanding the relevant part of the
pattern. This can be done with the scale expansion control
provided in the machine.

4. IMPORTANT NOTE :

1. Prior to ultrasonic testing it may be ensured that the axle end faces are
smooth for achieving proper acoustic coupling. If required, the end faces of
the Axle should be properly smoothened by filing /emery finishing for
achieving proper acoustic coupling.

2. In low angle and high angle scanning the onset of the signal in relation to
the initial pulse is a function of the thickness of the perspex wedge at the
probe index marking and the velocity of the ultrasonic wave in the perspex.
Page 13 of 75
 3. If the thickness of the perspex wedge at the probe index marking is
more than the one used for the preparation of this code, the onset of
the signal is likely to shift towards right side of the standard position of
the signal.

4. It may be ensured that, calibration and sensitivity setting shall be carried

out before ultrasonic testing of the axles.

5. Various characteristics of the equipment and probes may be checked as

per IS-12666 at least once a month.

5. CRITERIA FOR ACCEPTANCE:

(a) Axle found to produce flaw signal other than those standard signals as
shown in the relevant trace patterns during scanning by Far End and
Near End Low Angle Scanning techniques shall be withdrawn from
service. Further confirmation of the defect may be carried out by Trace
Delay & high angle scanning.

(b) Axle found to produce signals as per the standard signals as given in
the Annexure should be declared satisfactory.

(c) During service, few standard signals may disappear due to change in the
geometrical configuration of axle. This aspect may be kept in view.

6. MAGNETIC PARTICLE TESTING:

Axles found defective during ultrasonic examination described above

should be subjected to magnetic particle examination after removal of
the wheels, bearings etc. as the case may be. Record of magnetic
particle examination and observations made shall be maintained in the
register.

7. RECORDING OF TEST DETAILS:

Ultrasonic personnel conducting the test shall maintain a register

indicating the complete details of axle identification, technique
employed, observation made , code of procedure followed and his
remarks. He should also record his observations on visual examination
of the axles.

Page 14 of 75
 Annexure-I

Theoretical calculations and relative positions of signals of axle of Track

Machine WN 02-120.184.1 SP1. 1668/1676 for 08-275 3S, DGS-62, 09-3X &
UNIMAT COMPACT M of Plasser India Pvt. Ltd. (Tentative).

(A) FAR END SCANNING : 1 Main Scale Div. = 250 mm (compression wave)

Probe: 20/25mm, 2.5 MHz

From ‘X’ End Side:

SL . DETAILS Distance Signal Echo

No. (mm) (Div.)

1. Direct reflection from axle end. 2162 8.6

2. Direct reflection from journal fillet 2021 8.0

3. Delayed reflection from fillet at a distance of 1525 6.1

1212 mm from probing end

4. Delayed reflection from fillet at a distance of 1384 5.5

1212 mm from probing end

5. *Delayed reflection from fillet at a distance 1212 4.8

of 1212 mm from probing end

6. Delayed reflection from wheel seat inner fillet 634.5 2.5

7. Delayed reflection from wheel seat inner fillet 493.5 2.0

8. Direct reflection from wheel seat inner fillet 321.5 1.3

Page 15 of 75
From ‘Y’ End Side:
SL. Details Distance Signal Echo

No. (mm) (Div.)

1. Direct reflection from axle end 2162 8.6

2. Direct reflection from journal fillet 2021 8.0

3. Delayed reflection from fillet at a distance of 1741 7.0

1428 mm from probing end

4. Delayed reflection from fillet at a distance of 1600 6.4

1428 mm from probing end

5. Direct reflection from fillet at a distance of 1428 5.7

1428 mm from probing end

6. Delayed reflection from wheel seat inner fillet 634.5 2.5

7. Delayed reflection from wheel seat inner fillet 493.5 2.0

8. Direct reflection from wheel seat inner fillet 321.5 1.3

(B) TRACE DELAY SCANNING:

From ‘X’ End: ( 1 main scale div. = 50 mm)

0-500 mm:

S.NO. DETAILS DISTANCE SIGNAL

(mm) (divn.)

1. Direct reflection from wheel seat inner fillet 321.5 6.4

2. Delayed reflection from wheel seat inner fillet 493.5 9.9

500 mm- 1000 mm

S. NO. Details Distance Signal

(mm) (divn.)

1. Delayed reflection from wheel seat inner fillet 134.5 2.7

Page 16 of 75
1000mm - 1500 mm:

S. NO. Details Distance Signal

(mm) (divn.)

1. Direct reflection from fillet at a distance of 212 4.2

1212 mm from probing end

2. Delayed reflection from fillet at a distance of 384 7.7

1212 mm from probing end

1500mm - 2000 mm:

S. NO. Details Distance Signal

(mm) (divn.)

1. Delayed reflection from fillet at a distance of 25 0.5

1212 mm from probing end

2000mm - 2500 mm:

S. NO. Details Distance Signal

(mm) (divn.)

1. Direct reflection from journal fillet 21 0.4

2. Direct reflection from axle end 162 3.2

Page 17 of 75
From ‘Y’ End: ( 1 main scale div. = 50 mm)

0-500 mm:

S. NO. Details Distance Signal

(mm (divn.)

1. Direct reflection from wheel seat inner fillet 321 6.4

2. Delayed reflection from wheel seat inner fillet 471 9.4

500 mm - 1000 mm:

S. NO. Details Distance Signal

(mm) (divn.)

1. Delayed reflection from wheel seat inner fillet 134.5 2.7

1000mm - 1500 mm:

S. Details Distance Signal

NO.
(mm)
(divn.)

1. Direct reflection from fillet at a distance of 428 8.6

1428 mm from probing end

1500mm - 2000 mm :

S. Details Distance Signal

NO.
(mm) (divn.)

1. Delayed reflection from fillet at a distance of 100 2.0

1428 mm from probing end

2. Delayed reflection from fillet at a distance of 241 4.8

1428 mm from probing end

Page 18 of 75
2000mm - 2500 mm:

S.NO. Details Distance Signal

(mm) (divn.)

1. Direct reflection from journal fillet 21 0.4

2. Direct reflection from axle end 162 3.2

(C) NEAR END LOW ANGLE SCANNING 1 Main Scale Div. = 50mm

(Compressive Wave)

Probe : 15/20mm, 2.5 MHz

FROM ’X’ & ‘Y’ END SIDE :

S.NO. Details Distance Signal Echo

(mm (div.)

1. Direct reflection from wheel seat inner fillet. 344 6.9

(Wedge : 17.5, Central beam at 38 mm from

edge of the axle)

HIGH ANGLE SCANNING: 1 Main Scale Div. = 50 mm (Shear wave)

Probe: 20/25mm. , 2.5 MHz, Wedge 37

From ‘X’ & ‘Y’ END SIDE :

S.NO. Details Distance Signal Echo

(mm) (div.)

1. Direct reflection from wheel seat inner fillet. 224 4.5

(Wedge : 37 with dia. of curvature 160mm,

Stand off distance 130 mm from wheel seat
inner fillet.)
Page 19 of 75
Page 20 of 75
CODE OF PROCEDURE OF ULTRASONIC TESTING OF TRACK
MACHINE 64.02.2249 AXLE FOR RM 80. FRM 80 & RM 76 OF M/s
PLASSER INDIA Pvt. Ltd. IN SERVICE (TENTATIVE).

1. SCOPE : To ensure safety and reliability of rolling stocks, axles are

required to be examined periodically for presence of cracks. This
code stipulates the testing procedure, calibration method and
sensitivity setting for detection of cracks in Track Machine
64.02.2249 Axle for RM 80. FRM 80 & RM 76 OF M/s Plasser India
Pvt. Ltd. in service.

2. NORMATED REFERENCES: The following RDSO / IS standards contain

provisions, which through reference in this text constitute provisions of
this code of procedure. At the time of publication, the editions
indicated were valid.

Specification No. Title

RDSO specification No. Technical specification for battery cum-

mains operated ultrasonic flaw detector
M&C/NDT/104/2000 having memory calibration and 100 mm X
(Rev.1) April 2005 80 mm screen.
or

RDSO specification Portable digital ultrasonic flaw detector with

No.M&C/NDT/125/2004 A-scan storage.

RDSO specification No. Soft grease

WD-17-MISC-92

IS:1628-1986 Axle oil

Reaffirmed in Feb.1996

IS: 1875-1992 Carbon steel billets, blooms, slabs and bars

for forging.

IS:12666-1988 Methods for performance assessment of

ultrasonic flaw detection equipment.
Reaffirmed in 1993

Page 21 of 75
3. PROCEDURE OF EXAMINATION:

3.1 Equipment and accessories to be employed:

3.1.1 Equipment: Ultrasonic flaw detector approved by RDSO, Lucknow to

RDSO specification No.M&C/NDT/104/2000 (Rev.1) April 2005 or
No. M&C/NDT/125/2004 or any other ultrasonic flaw detector
meeting RDSO specification No. M&C/NDT/104/2000 (Rev.1) April
2005 or No. M&C/NDT/125/2004.

3.1.2 Accessories : Far end scanning : Normal probe of 2.5 MHz, 20/25mm dia.,
Lead zirconate titanate or crystal of similar characteristics.

Near end low angle scanning : Normal probe of 2.5 MHz, 15/20 mm
dia., Lead zirconate titanate or crystal of similar characteristics with
perspex wedge capable of producing ultrasonic wave at 17.5o angle or
angle probe of 17.50 .

High angle scanning : Normal probe of 2.5 MHz, 20/25 mm dia.,

Lead zirconate titanate or crystal of similar characteristics with perspex
wedge capable of producing ultrasonic wave at 37 o angle or angle
probe of 370 having dia. of curvature 155 + 200 mm .

3.1.3 Couplant: Soft grease or axle oil (medium) to RDSO specification No. WD-
17- MISC-92 or IS :1628 (86) Reaffirmed in Feb. 96 .

3.1.4 Standard bar : 50mm dia. x 500 mm long and 50mm dia. X 182 mm long
steel bar to designation 45C8 of IS:1875 –1992 rolled/forged and
normalized having grain size No.5 or finer to ASTM/E-10-39T.

3.2 Personnel engaged in testing: Testing of Axles shall be done only by trained
and certified personnel having valid RDSO certificate. Under no
circumstances testing shall be carried out by any other personnel not
meeting this requirement.

3.3 Scanning techniques :

3 .3.1 Far end scanning : This technique shall be used for testing the full
length of the axle from gear end as well from free end .
The time scale shall be calibrated to 250mm per main scale division of
compression wave. The normal probe of 2.5 MHz having 20/25 mm
dia shall be placed on the clean axle end faces with suitable couplant.
The probe shall be given slight rotary movement for proper acoustic
coupling while proving from ‘X’ end & ‘Y’ end. The expected signals
have been shown in Annexure.

Page 22 of 75
3.3.2 Examination by Trace Delay Technique: This technique shall be
employed to examine the axle in part of 500 mm each. This technique
may be utilized for confirmation of the findings during Far End
scanning.

The expected signals have been shown in Annexure.

3.3.3 Near End - Low Angle Scanning: This technique is used for
examination of fatigue cracks in the raised seat inner fillet area,
which remains unscanned during far end scanning.

The time scale shall be calibrated to 100 mm per main scale

division of compression wave. The normal probe of 2.5 MHz having
15/20 mm dia shall be placed on the clean axle end faces with suitable
couplant. The probe shall be given slight rotary movement for proper
acoustic coupling while probing from ‘X’ end & ‘Y’ end. The expected
signals have been shown in Annexure.

3.3.4 High Angle Scanning : This technique may be employed for

confirmation of the findings during Near End Low Angle
Scanning.

The time scale shall be calibrated to 50 mm per main scale division

for shear wave with the help of 50 mm dia. X 182 mm long steel
bar (since 5 X 182 = 910 mm longitudinal wave is equivalent to 5 X
100 mm = 500 mm of shear wave).
The time scale shall be calibrated to 50mm per main scale division of
shear wave. The normal probe of 2.5 MHz having 20/25 mm dia shall
be placed on the body of the axle at a distance of 132 mm from wheel
seat inner fillet with suitable couplant directing the central beam
towards wheel seat inner fillet. The probe shall be given slight rotary
movement for proper acoustic coupling. The expected signals have
been shown in Annexure.

3.3.5 Scale expansion: The analysis of oscillogram pattern having closely placed
echoes may be simplified by expanding the relevant part of the
pattern. This can be done with the scale expansion control
provided in the machine.

4. IMPORTANT NOTE :

1. Prior to ultrasonic testing it may be ensured that the axle end faces are
smooth for achieving proper acoustic coupling. If required, the end
faces of the Axle should be properly smoothened by filing /emery
finishing for achieving proper acoustic coupling.

Page 23 of 75
 2. In low angle and high angle scanning the onset of the signal in relation
to the initial pulse is a function of the thickness of the perspex wedge
at the probe index marking and the velocity of the ultrasonic wave in
the perspex.

3. If the thickness of the perspex wedge at the probe index marking is more
than the one used for the preparation of this code, the onset of the
signal is likely to shift towards right side of the standard position of the
signal.

4. It may be ensured that, calibration and sensitivity setting shall be carried

out before ultrasonic testing of the axles.

5. Various characteristics of the equipment and probes may be checked as

per IS-12666 at least once a month.

5. CRITERIA FOR ACCEPTANCE:

(a) Axle found to produce flaw signal other than those standard signals as
shown in the relevant trace patterns during scanning by Far End and
Near End Low Angle Scanning techniques shall be withdrawn from
service. Further confirmation of the defect may be carried out by Trace
Delay & high angle scanning.

(b) Axle found to produce signals as per the standard signals as given in
the Annexure should be declared satisfactory.

(c) During service, few standard signals may disappear due to change in the
geometrical configuration of axle. This aspect may be kept in view.

6. MAGNETIC PARTICLE TESTING:

Axles found defective during ultrasonic examination described above
should be subjected to magnetic particle examination after removal of
the wheels, bearings etc. as the case may be. Record of magnetic
particle examination and observations made shall be maintained in the
register.

7. RECORDING OF TEST DETAILS:

Ultrasonic personnel conducting the test shall maintain a register

indicating the complete details of axle identification, technique
employed, observation made , code of procedure followed and his
remarks. He should also record his observations on visual examination
of the axles.
Page 24 of 75
 Annexure-I

Theoretical calculations and relative positions of signals of axle of Track

Machine 64.02.2249 axle for RM80. FRM80 & RM 76 M/s Plasser India Pvt.
Ltd. (Tentative).

(A) FAR END SCANNING : 1 Main Scale Div. = 250 mm (compression wave)

Probe: 20/25mm, 2.5 MHz

From ‘X’ End Side:

SL . Details Distance Signal Echo

No. (mm) (Div.)

1. Direct reflection from axle end. 2211 8.8

2. Direct reflection from journal fillet 2098 8.4

3. Direct reflection from wheel seat outer fillet 2032.5 8.1

4. Delayed reflection from fillet at a distance of 1682 6.7

1377.5 mm from probing end

5. Delayed reflection from fillet at a distance of 1545 6.2

1377.5mm from probing end

6. Direct reflection from fillet at a distance of 1377.5 5.5

1377.5mm from probing end

7. Delayed reflection from wheel seat inner fillet 662 2.6

8. Delayed reflection from wheel seat inner fillet 525 2.1

9. Direct reflection from wheel seat inner fillet 357.5 1.4

Page 25 of 75
From ‘Y’ End Side:

SL. Details Distance Signal Echo

No. (mm) (Div.)

1. Direct reflection from axle end 2211 8.8

2. Direct reflection from journal fillet 2098 8.4

3. Direct reflection from wheel seat outer fillet 2032.5 8.1

4. Delayed reflection from fillet at a distance of 1879 7.5

1574.5 mm from probing end

5. Delayed reflection from fillet at a distance of 1742 7.0

1574.5 mm from probing end

6. Direct reflection from fillet at a distance of 1574.5 6.3

1574.5mm from probing end

7. Delayed reflection from wheel seat inner fillet 662 2.6

8. Delayed reflection from wheel seat inner fillet 525 2.1

9. Direct reflection from wheel seat inner fillet 357.5 1.4

(B) TRACE DELAY SCANNING:

From ‘X’ End: ( 1 main scale div. = 50 mm)

0-500 mm:

S. NO. Details Distance Signal

(mm) (divn.)

1. Direct reflection from wheel seat inner fillet 357.5 7.2

500 mm- 1000 mm

S. NO. Details Distance Signal

(mm) (divn.)

1. Delayed reflection from wheel seat inner fillet 25 0.5

2. Delayed reflection from wheel seat inner fillet 162 3.2

Page 26 of 75
1000mm - 1500 mm:

S. NO. Details Distance Signal

(mm) (divn.)

1. Direct reflection from fillet at a distance of 377.5 7.6

1377.5mm from probing end

1500mm - 2000 mm:

S. NO. Details Distance Signal

(mm) (divn.)

1. Delayed reflection from fillet at a distance of 45 0.9

1377.5 mm from probing end

2. Delayed reflection from fillet at a distance of 182 3.6

1377.5 mm from probing end

2000mm - 2500 mm:

S. NO. Details Distance Signal

(mm) (divn.)

1. Direct reflection from wheel seat outer fillet 32.5 0.7

2. Direct reflection from journal fillet 98 2.0

3. Direct reflection from axle end 211 4.2

Page 27 of 75
From ‘Y’ End: ( 1 main scale div. = 50 mm)

0-500 mm:

S. NO. Details Distance Signal

(mm (divn.)

1. Direct reflection from wheel seat inner fillet 357.5 7.2

500 mm - 1000 mm:

S. NO. Details Distance Signal

(mm) (divn.)

1. Delayed reflection from wheel seat inner fillet 25 0.5

2. Delayed reflection from wheel seat inner fillet 162 3.2

1000mm - 1500 mm: NIL

1500mm - 2000 mm :

S. Details Distance Signal

NO.
(mm) (divn.)

1. Direct reflection from fillet at a distance of 74.5 0.9

1574.5 mm from probing end

2. Delayed reflection from fillet at a distance of 242 4.8

1574.5 mm from probing end

3. Delayed reflection from fillet at a distance of 379 7.0

1574.5 mm from probing end

Page 28 of 75
2000mm - 2500 mm:

S.NO. Details Distance Signal

(mm) (divn.)

1. Direct reflection from wheel seat outer fillet 32.5 0.7

2. Direct reflection from journal fillet 98 2.0

3. Direct reflection from axle end 211 4.2

(C) NEAR END LOW ANGLE SCANNING 1 Main Scale Div. = 50mm

(Compressive Wave)

Probe : 15/20mm, 2.5 MHz

FROM ’X’ & ‘Y’ END SIDE :

S.NO. Details Distance Signal Echo

(mm) (div.)

1. Direct reflection from wheel seat inner fillet. 380 7.6

(Wedge : 17.5, Central beam at 28 mm from

edge of the axle)

HIGH ANGLE SCANNING: 1 Main Scale Div. = 50 mm (Shear wave)

Probe: 20/25mm. , 2.5 MHz

From ‘X’ & ‘Y’ END SIDE :

S.NO. Details Distance Signal Echo

(mm) (div.)

1. Direct reflection from wheel seat inner fillet. 216 4.3

(Wedge : 37 with dia. of curvature 155mm,

Stand off distance 132 mm from wheel seat
inner fillet.)
Page 29 of 75
Page 30 of 75
CODE OF PROCEDURE OF ULTRASONIC TESTING OF TRACK
MACHINE UD62.3301 SP 1668/1676 (DRIVING) AXLE FOR 09-32 CSM &
08-32 DUOMATIC OF M/s PLASSER INDIA Pvt. Ltd. IN SERVICE
(TENTATIVE).

1. SCOPE : To ensure safety and reliability of rolling stocks, axles are

required to be examined periodically for presence of cracks. This
code stipulates the testing procedure, calibration method and
sensitivity setting for detection of cracks in Track Machine
UD62.3301 SP 1668/1676 (Driving) Axle for 09-32 CSM & 08-32
Duomatic of M/s PLASSER INDIA Pvt. Ltd. in service.

2. NORMATED REFERENCES: The following RDSO / IS standards contain

provisions, which through reference in this text constitute provisions of
this code of procedure. At the time of publication, the editions
indicated were valid.

Specification No. Title

RDSO specification No. Technical specification for battery cum-

mains operated ultrasonic flaw detector
M&C/NDT/104/2000 having memory calibration and 100 mm X
(Rev.1) April 2005 80 mm screen.
or

RDSO specification Portable digital ultrasonic flaw detector with

No.M&C/NDT/125/2004 A-scan storage.

RDSO specification No. Soft grease

WD-17-MISC-92

IS:1628-1986 Axle oil

Reaffirmed in Feb.1996

IS: 1875-1992 Carbon steel billets, blooms, slabs and bars

for forging.

IS:12666-1988 Methods for performance assessment of

ultrasonic flaw detection equipment.
Reaffirmed in 1993

Page 31 of 75
3. PROCEDURE OF EXAMINATION:

3.1 Equipment and accessories to be employed:

3.1.1 Equipment: Ultrasonic flaw detector approved by RDSO, Lucknow to

RDSO specification No.M&C/NDT/104/2000 (Rev.1) April 2005 or
No. M&C/NDT/125/2004 or any other ultrasonic flaw detector
meeting RDSO specification No. M&C/NDT/104/2000 (Rev.1) April
2005 or No. M&C/NDT/125/2004.

3.1.2 Accessories : Far end scanning : Normal probe of 2.5 MHz, 20/25mm dia.,
Lead zirconate titanate or crystal of similar characteristics.

Near end low angle scanning : Normal probe of 2.5 MHz, 15/20 mm
dia., Lead zirconate titanate or crystal of similar characteristics with
perspex wedge capable of producing ultrasonic wave at 17.5o angle or
angle probe of 17.50 .

High angle scanning : Normal probe of 2.5 MHz, 20/25 mm dia.,

Lead zirconate titanate or crystal of similar characteristics with perspex
wedge capable of producing ultrasonic wave at 37 o angle or angle
probe of 370 having dia. of curvature 144 + 200 mm .

3.1.3 Couplant: Soft grease or axle oil (medium) to RDSO specification No. WD-
17- MISC-92 or IS :1628 (86) Reaffirmed in Feb. 96 .

3.1.4 Standard bar : 50mm dia. x 500 mm long and 50mm dia. X 182 mm long
steel bar to designation 45C8 of IS:1875 –1992 rolled/forged and
normalized having grain size No.5 or finer to ASTM/E-10-39T.

3.2 Personnel engaged in testing: Testing of Axles shall be done only by trained
and certified personnel having valid RDSO certificate. Under no
circumstances testing shall be carried out by any other personnel not
meeting this requirement.

3.3 Scanning techniques :

3.3.1 Far end scanning : This technique shall be used for testing the full length
of the axle from gear end as well from free end .
The time scale shall be calibrated to 250mm per main scale division of
compression wave. The normal probe of 2.5 MHz having 20/25 mm dia shall
be placed on the clean axle end faces with suitable couplant. The probe shall
be given slight rotary movement for proper acoustic coupling while proving
from ‘X’ end & ‘Y’ end. The expected signals have been shown in Annexure.

Page 32 of 75
3.3.2 Examination by Trace Delay Technique: This technique shall be
employed to examine the axle in part of 500 mm each. This
technique may be utilized for confirmation of the findings during
Far End scanning.
The expected signals have been shown in Annexure.
3.3.3 Near End - Low Angle Scanning: This technique is used for
examination of fatigue cracks in the raised seat inner fillet area,
which remains unscanned during far end scanning.

The time scale shall be calibrated to 100 mm per main scale

division

of compression wave. The normal probe of 2.5 MHz having 15/20

mm dia shall be placed on the clean axle end faces with suitable
couplant. The probe shall be given slight rotary movement for proper
acoustic coupling while probing from ‘X’ end & ‘Y’ end. The expected
signals have been shown in Annexure.

3.3.4 High Angle Scanning : This technique may be employed for

confirmation of the findings during Near End Low Angle
Scanning.

The time scale shall be calibrated to 50 mm per main scale division

for shear wave with the help of 50 mm dia. X 182 mm long steel bar
(since 5 X 182 = 910 mm longitudinal wave is equivalent to 5 X 100
mm = 500 mm of shear wave).
The time scale shall be calibrated to 50mm per main scale division of
shear wave. The normal probe of 2.5 MHz having 20/25 mm dia shall be
placed on the body of the axle at a distance of 132 mm from wheel seat
inner fillet with suitable couplant directing the central beam towards
wheel seat inner fillet. The probe shall be given slight rotary movement
for proper acoustic coupling. The expected signals have been shown in
Annexure.

3.3.5 Scale expansion: The analysis of oscillogram pattern having closely placed
echoes may be simplified by expanding the relevant part of the
pattern. This can be done with the scale expansion control provided
in the machine.

4. IMPORTANT NOTE :

1. Prior to ultrasonic testing it may be ensured that the axle end faces are
smooth for achieving proper acoustic coupling. If required, the end
faces of the Axle should be properly smoothened by filing /emery
finishing for achieving proper acoustic coupling.
Page 33 of 75
 2. In low angle and high angle scanning the onset of the signal in relation
to the initial pulse is a function of the thickness of the perspex wedge
at the probe index marking and the velocity of the ultrasonic wave in
the perspex.

3. If the thickness of the perspex wedge at the probe index marking is more
than the one used for the preparation of this code, the onset of the
signal is likely to shift towards right side of the standard position of the
signal.

4. It may be ensured that, calibration and sensitivity setting shall be carried

out before ultrasonic testing of the axles.

5. Various characteristics of the equipment and probes may be checked as

per IS-12666 at least once a month.

5. CRITERIA FOR ACCEPTANCE:

(a) Axle found to produce flaw signal other than those standard signals as
shown in the relevant trace patterns during scanning by Far End and
Near End Low Angle Scanning techniques shall be withdrawn from
service. Further confirmation of the defect may be carried out by Trace
Delay & high angle scanning.

(b) Axle found to produce signals as per the standard signals as given in
the Annexure should be declared satisfactory.

(c) During service, few standard signals may disappear due to change in the
geometrical configuration of axle. This aspect may be kept in view.

6. MAGNETIC PARTICLE TESTING:

Axles found defective during ultrasonic examination described above
should be subjected to magnetic particle examination after removal of
the wheels, bearings etc. as the case may be. Record of magnetic
particle examination and observations made shall be maintained in the
register.

7. RECORDING OF TEST DETAILS:

Ultrasonic personnel conducting the test shall maintain a register

indicating the complete details of axle identification, technique
employed, observation made , code of procedure followed and his
remarks. He should also record his observations on visual examination
of the axles.

Page 34 of 75
 Annexure-I

Theoretical calculations and relative positions of signals of axle of Tie

Tamping Machine UD62.3301 SP 1668/1676 (Driving) for 09-32 CSM & 08-32
Duomatic of M/s Plasser India Pvt. Ltd. (Tentative).

(A)FAR END SCANNING : 1 Main Scale Div. = 250 mm (compression wave)

Probe: 20/25mm, 2.5 MHz

From ‘X’ End Side:

SL . Details Distance Signal Echo

No. (mm) (Div.)

1. Direct reflection from axle end. 2162 8.6

2. Direct reflection from journal fillet 2021 8.0

3. Delayed reflection from fillet at a distance of 1690 6.8

1417 mm from probing end

4. Delayed reflection from fillet at a distance of 1567 6.3

1417 mm from probing end

5. Direct reflection from fillet at a distance of 1417 5.7

1417 mm from probing end

6. Delayed reflection from fillet at a distance of 1481 5.9

1185 mm from probing end

7. Delayed reflection from fillet at a distance of 1347.5 5.4

1185 mm from probing end

8. Direct reflection from fillet at a distance of 1185 4.7

1185 mm from probing end

9. Delayed reflection from wheel seat inner fillet 594 2.4

10. Delayed reflection from wheel seat inner fillet 471 1.9

11. Direct reflection from wheel seat inner fillet 321 1.3

Page 35 of 75
From ‘Y’ End Side:

SL. Details Distance Signal Echo

No. (mm) (Div.)

1. Direct reflection from axle end 2162 8.6

2. Direct reflection from journal fillet 2021 8.0

3. Delayed reflection from fillet at a distance of 1479 5.9

1206 mm from probing end

4. Delayed reflection from fillet at a distance of 1356 5.4

1206 mm from probing end

5. Direct reflection from fillet at a distance of 1206 4.8

1206 mm from probing end

6. Delayed reflection from wheel seat inner fillet 594 2.4

7. Delayed reflection from wheel seat inner fillet 471 1.9

8. Direct reflection from wheel seat inner fillet 321 1.3

(B) TRACE DELAY SCANNING:

From ‘X’ End: ( 1 main scale div. = 50 mm)

0-500 mm:

S. NO. Details Distance Signal

(mm) (divn.)

1. Direct reflection from wheel seat inner fillet 321 6.4

2. Delayed reflection from wheel seat inner fillet 471 9.4

500 mm- 1000 mm

S. NO. Details Distance Signal

(mm) (divn.)

1. Delayed reflection from wheel seat inner fillet 94 1.9

Page 36 of 75
1000mm - 1500 mm:

S. NO. Details Distance Signal

(mm) (divn.)

1. Direct reflection from fillet at a distance of 206 4.1

1206 mm from probing end

2. Delayed reflection from fillet at a distance of 356 7.1

1206 mm from probing end

3. Delayed reflection from fillet at a distance of 479 9.6

1206 mm from probing end

1500mm - 2000 mm: NIL

2000mm - 2500 mm:

S. NO. Details Distance Signal

(mm) (divn.)

1. Direct reflection from journal fillet 21 0.4

2. Direct reflection from axle end 162 3.2

Page 37 of 75
From ‘Y’ End: ( 1 main scale div. = 50 mm)

0-500 mm:

S. NO. Details Distance Signal

(mm (divn.)

1. Direct reflection from wheel seat inner fillet 321 6.4

2. Delayed reflection from wheel seat inner fillet 471 9.4

500 mm - 1000 mm:

S. NO. Details Distance Signal

(mm) (divn.)

1. Delayed reflection from wheel seat inner fillet 94 1.9

1000mm - 1500 mm:

S. Details Distance Signal

NO.
(mm) (divn.)

1. Direct reflection from fillet at a distance of 185 3.7

1185 mm from probing end

2. Delayed reflection from fillet at a distance of 347.5 7.0

1185 mm from probing end

3. Direct reflection from fillet at a distance of 417 8.3

1417 mm from probing end

4. Delayed reflection from fillet at a distance of 481 9.6

1185 mm from probing end

1500mm - 2000 mm :

S. Details Distance Signal

NO.
(mm) (divn.)

1. Delayed reflection from fillet at a distance of 367 7.3

1417 mm from probing end

2. Delayed reflection from fillet at a distance of 490 9.8

1417 mm from probing end

Page 38 of 75
2000mm - 2500 mm:

S.NO. Details Distance Signal

(mm) (divn.)

1. Direct reflection from journal fillet 21 0.4

2. Direct reflection from axle end 162 3.2

(C) NEAR END LOW ANGLE SCANNING 1 Main Scale Div. = 50mm

(Compressive Wave)

Probe : 15/20mm, 2.5 MHz

FROM ’X’ & ‘Y’ END SIDE :

S.NO. Details Distance Signal Echo

(mm) (div.)

1. Direct reflection from wheel seat inner fillet. 340 6.8

(Wedge : 17.5, Central beam at 38 mm from

edge of the axle)

HIGH ANGLE SCANNING: 1 Main Scale Div. = 50 mm (Shear wave)

Probe: 20/25mm. , 2.5 MHz., Wedge 37

From ‘X’ & ‘Y’ END :

S.NO. Details Distance Signal Echo

(mm) (div.)

1. Direct reflection from wheel seat inner fillet. 100 3.0

(Wedge : 37 with dia. of curvature 144mm,

Stand off distance 144 mm from wheel seat
inner fillet.)

Page 39 of 75
 METHOD OF ULTRASONIC TESTING & ACCEPTANCE STANDARD
FOR LOCOMOTIVE WHEELS

(RDSO Report No.IRS R–34-2003

(TO BE USED FOR WHEELS OF LARGE TRACK MACHINES ALSO)

For detecting internal discontinuities in the rim and the hub of the wheel,
ultrasonic inspection shall be carried out by following the procedure shown
below and by using equipment which complies with the following
requirements. Reference standard used for sensitivity setting shall be from
wheels conforming to this standard. The surface finish of probing face shall
be in accordance with the relevant wheel drawing. Ultrasonic inspection
shall be performed after final thermal and machining operations.

A-1 ULTRASONIC TESTING ON WHEEL RIM

The rims of the wheels will be checked through ultrasonic inspection

to detect the defects at two orientations.

i) Defect parallel to the rim face (axial testing)

ii) Defect parallel to the running tread (radial testing)

A-1-1 AXIAL TESTING

All wheels will be subjected to ultrasonic testing of rim through

probing axially along the rim face to defect any flaw having orientation
parallel to the rim face.

A-1-1-1 Equipment:

A-1-1-1-1 Automatic ultrasonic testing equipment shall be used. The

instrument shall have a pulse echo transmitter and receiver and
shall have an operating frequency range of 2 to 5 MHz. The
manufacturer shall have on-line test facility to inspect 100%
wheels. For determination of final rejection, manual ultrasonic
equipments approved by the purchaser may be employed.

A-1-1-1-2 The transducers shall be of normal (o degree) type comprising

of high sensitivity Piezo electric ceramic crystal operating at 2 to
2.5 MHz frequency and of 18-20 mm diameter.

A-1-1-1-3 An automatic flaw system shall be used in conjunction with the

ultrasonic instrumentation to facilitate flaw indication beyond
acceptable level.

Page 40 of 75
A-1-1-1-4 An immersion or contact type testing technique shall be used in
automatic on-line testing. For manual testing of suspect wheels
a suitable couplant shall be used between the test surface and
the transducer. In case of dispute in respect of couplant the
decision of the inspecting officer shall be final and binding.

A-1-1-1-5 Calibration block 50mm x 50mm x 50mm block of steel to grade

45C8 of IS:1875.

A-1-1-1-6 Standard reference piece shall be from a portion of the wheel

having a 3 mm diameter flat bottom hole drilled perpendicular to
the rim face and to a depth of 25 + 2mm at the mid thickness of
the rim (see fig. 4.1).

A-1-1-1-7 Alternate reference piece: Alternate reference piece shall be

from a portion of the wheel having a small diameter hole of dia 3
mm drilled at a distance from the testing surface equal to the
depth of the hole indicated in A-1.1.1.6 (see fig. 4.2). The
instrument shall be adjusted to give an equal test value to that of
a 3 mm diameter flat bottom hole.

A - 1.1.2 Calibration

A-1.1.2.1 Time base: Set the time base of ultrasonic flaw detector using 0
degree longitudinal wave with the help of calibration block as
mentioned in para A-1.1.1.5. Three multiple echoes will be
observed.

A-1.1.2.2 Sensitivity setting: Sensitivity setting shall be done with the help
of standard wheel piece (see fig. 4.1). Gain level should be
adjusted to produce 60% height from the reference standard as
mentioned in para A-1.1.1.6.

A-1.1.2.3 Alternatively sensitivity setting shall be done with the help of an

alternate reference piece as mentioned in para A-1.1.1.7 (see
fig. 4.2) and shall be used only with the specific approval of the
purchaser.

A-1.1.2.4 Reference standard for the inspection of heat-treated wheels

shall be fabricated from heat-treated wheels.

A - 1.1.3 Scanning:

A-1.1.3.1 Wheels shall be inspected axially from either the out side or
inside rim face by automatic scanning see figs. 4.1 and 4.2. For
determining acceptance or otherwise, probing from both sides
may be carried out.
Page 41 of 75
A-1.1.3.2 The speed of scanning shall permit efficient detection of the
reference standard discontinuities.

A - 1.1.4 Rejection criteria:

A-1.1.4.1 Any wheel with a flaw indication equal to or larger than 60% of
the full scale height shall be rejected. If more than 1 defect of
amplitude 20% or above are observed, the wheel shall be
rejected. If two defects of amplitude 20% or above are observed,
and if these defects are closer than 50 mm the wheel shall be
rejected.

A-1.1.4.2 Ultrasonic indications that result from wheel geometry or

spurious signal shall not be valid cause for rejection. The
judgement of the inspecting officer shall be final and binding in
this respect.

A-1.1.4.3 The final disposal of rejection of wheels may be determined by

manual resting of disputed areas. The surface finish of rim of
reference standard will be almost same as that of wheels tested
manually by contract probing.

A - 1.2 RADIAL TESTING:

All wheels will be subjected to ultrasonic testing of rim through

probing circumferentially along the treat surface to detect any
flaw having orientation parallel to the tread surface.
A -1.2.1 Equipment:

A-1.2.1.1 Equipment shall be same as described in clause A-1.1.1.

A-1.2.1.2 Calibration Block: 50x50x50mm block of steel to grade 45C8 of

IS:1875.

A-1.2.1.3 Standard reference piece:

Reference piece will be from a portion of new wheel having 3

mm diameter flat bottom hole drilled from opposite to tread
surface (see fig.5) to depth of 20mm.
A - 1.2.2 Calibration:
A-1.2.2.1 Time Base: Set the time base of ultrasonic flaw detector using
O degree longitudinal wave with the help of calibration block as
mentioned in para A.1.2.1.2. Three multiple echoes will be
observed.

Page 42 of 75
A-1.2.2.2 Sensitivity setting: Sensitivity setting shall be done with the help
of standard wheel piece as mentioned in para A-1.2.1.3 (see
fig.5). Probing shall be done from the tread opposite to flat
bottom hole and the gain level shall be adjusted to produce an
echo of 60% height of vertical scale of CRT. This gain level
shall be reference gain for acceptance or otherwise for the
wheel.

A - 1.2.3 Scanning :

Increase the gain level by 6dB over and above the gain level
described at para A-1.2.2.2. Apply couplant on the tread
surface, place the probe on this face and scan entire
circumference on the wheel in case of contact type automatic
scanning equipment. For immersion type of equipment, the
wave propagation shall be through the liquid used for immersing
the wheel. No back echo will appear. Care shall be taken
during probing to cover full width of the tread. In case a flaw
signal is observed reduce the gain by 6 db.

A-1.2.4 Rejection criteria:

Any wheel with a flaw indication equal to or larger than 60% of

the full scale height shall be rejected. If more than 3 defects of
amplitude 20% or above are observed, the wheel shall be
rejected. If two defects of amplitude 20% or above are
observed, and if these defects are closer than 50 mm, the wheel
shall be rejected.

A-1.2.5 The final disposal of rejection of wheels may be determined by

manual testing of disputed areas. The surface finish of tread of
reference standard will be almost same as that of wheels tested
manually by contact probing.

A. 2 ULTRASONIC TESTING ON WHEEL HUB

Only such wheels, which pass ultrasonic test for the rim, shall be
subjected to ultrasonic testing of hub.

A - 2.1 Equipment:

Equipment shall be the same as used for ultrasonic testing of

the rim portion of the wheels, suitably calibrated for hub
thickness. However, manual testing of hub will be permitted.

Page 43 of 75
 For hub testing, the back wall echo shall be adjusted to full
screen height using a wheel hub free from internal
discontinuities.

Surface finish of reference piece shall be similar to wheels

tested if manual testing is resorted to.

A-2.2 Rejection criteria:

A-2.2.1 Any wheel with a flaw indication equal to or larger than 60% of
the full scale height shall be rejected. If more than 3 defects of
amplitudes less than 60% are observed, the wheel shall be
rejected. If two defects of amplitudes less than 60% are
observed, and if these defects are closer than 50mm, the wheel
shall be rejected.

A-2.2.2 Where there is a partial suppression of the back echo and flaw
echo is also absent the back echo shall not be less than 30% of
the full screen height without change of testing parameters.

MARKING: Wheel conforming to the above ultrasonic stipulations shall be

stencilled ‘UT’ on the back plate with red colour paint using
characters at least 25 mm in height or at such locations as may
be shown on the drawing or specified by the purchaser.

Page 44 of 75
Page 45 of 75
Page 46 of 75
CODE OF PROCEDURE OF ULTRASONIC TESTING FOR AXLE
(POWERED) TO M/s PHOOLTAS TAMPER Pvt. Ltd., PATNA’s DRG. No.
UTV1-01 02/00 REV. 0 IN SERVICE (TENTATIVE).

1. SCOPE : To ensure safety and reliability of rolling stocks, axles are

required to be examined periodically for presence of cracks. This code stipulates
the testing procedure, calibration method and sensitivity setting for detection of in
service cracks of Axle (Powered) to M/s Phooltas Tamper Pvt. Ltd., Patna’s Drg.
No. UTV1-01 02/00 REV.0.

2. NORMATED REFERENCES: The following RDSO / IS standards contain

provisions, which through reference in this text constitute provisions of
this code of procedure. At the time of publication, the editions
indicated were valid.

Specification No. Title

RDSO specification No. Technical specification for battery cum-
mains operated ultrasonic flaw detector
M&C/NDT/104/2000 having memory calibration and 100 mm X
(Rev.1) April 2005 80 mm screen.
or

RDSO specification Portable digital ultrasonic flaw detector with

No.M&C/NDT/125/2004 A-scan storage.

RDSO specification No. Soft grease

WD-17-MISC-92

IS:1628-1986 Axle oil

Reaffirmed in Feb.1996

IS: 1875-1992 Carbon steel billets, blooms, slabs and bars

for forging.

IS:12666-1988 Methods for performance assessment of

ultrasonic flaw detection equipment.
Reaffirmed in 1993

Page 47 of 75
3. PROCEDURE OF EXAMINATION:

3.1 Equipment and accessories to be employed:

3.1.1 Equipment: Ultrasonic flaw detector approved by RDSO, Lucknow to

RDSO specification No.M&C/NDT/104/2000 (Rev.1) April 2005 or
No. M&C/NDT/125/2004, July’2004 or any other ultrasonic flaw
detector meeting RDSO specification No. M&C/NDT/104/2000
(Rev.1) April 2005 or No. M&C/NDT/125/2004, July’2004.

3.1.2 Accessories : Far end scanning : Normal probe of 2.5 MHz, 20/25mm dia.,
Lead zirconate titanate or crystal of similar characteristics.

Near end low angle scanning : Normal probe of 2.5 MHz, 15/20 mm
dia., Lead zirconate titanate or crystal of similar characteristics with
perspex wedge capable of producing ultrasonic wave at 15o angle or
angle probe of 150 .

High angle scanning : Normal probe of 2.5 MHz, 20/25 mm dia.,

Lead zirconate titanate or crystal of similar characteristics with perspex
wedge capable of producing ultrasonic wave at 37.5 o angle or angle
probe of 37.50 angle having dia. of curvature 176 + 200 mm .

3.1.3 Couplant: Soft grease or axle oil (medium) to RDSO specification No. WD-
17- MISC-92 or IS :1628 (86) Reaffirmed in Feb. 96 .

3.1.4 Standard bar : 50mm dia. x 500 mm long and 50mm dia. X 182 mm long
steel bar to designation 45C8 of IS:1875 –1992 rolled/forged and
normalized having grain size No.5 or finer to ASTM/E-10-39T.

3.2 Personnel engaged in testing: Testing of Axles shall be done only by trained
and certified personnel having valid RDSO certificate. Under no
circumstances testing shall be carried out by any other personnel not
meeting this requirement.

3.3 Scanning techniques :

3.3.1 Far end scanning : This technique shall be used for testing the full length
of the axle from both the ends.

The time scale shall be calibrated to 250mm per main scale division of
compression wave. The normal probe of 2.5 MHz having 20/25 mm
dia shall be placed on the clean axle end faces with suitable couplant.
The probe shall be given slight rotary movement for proper acoustic
coupling.
Page 48 of 75
3.3.2 Examination by Trace Delay Technique: This technique shall be
employed to examine the axle in part of 500 mm each. This
technique may be utilized for confirmation of the findings during
Far End scanning.

3.3.3 Near End - Low Angle Scanning: This technique is used for
examination of fatigue cracks if any, in the raised wheel seat inner
fillet area, which remains unscanned during far end scanning.

The time scale shall be calibrated to 100 mm per main scale

division of compression wave. The normal probe of 2.5 MHz having
15/20 mm dia fitted with a Perspex wedge capable of producing
ultrasonic wave at 150 or angle probe of 150 shall be placed on the axle
end face directing the central beam towards the wheel seat inner fillet.
The same procedure shall be followed for both the ends scanning.

3.3.4 High Angle Scanning : This technique may be employed for

confirmation of the findings during Near End Low Angle
Scanning.

The time scale shall be calibrated to 50 mm per main scale division

for shear wave with the help of 50 mm dia. X 182 mm long steel
bar (since 5 X 182 = 910 mm longitudinal wave is equivalent to 5 X
100 mm = 500 mm of shear wave).

High angle scanning is carried out from the body of the axle. The time
scale shall be calibrated to 50mm per main scale division of shear
wave with the help of 50mm dia. x 182 mm long steel bar ( since 5x
182mm = 910 mm longitudinal wave is equivalent to 5 x 100 mm =
500 mm of shear wave. A normal probe 20/25 mm dia fitted with
Perspex wedge of 37.50 or angle probe of 37.50 having dia of
curvature 176 + 200 mm shall be placed on the axle end facedirecting
the central beam towards the wheel seat inner fillet. The same
procedure shall be followed for both the ends scanningshall be placed
on the body of the axle at a distance of 132 mm from wheel seat inner
fillet with suitable couplant directing the central beam towards wheel
seat inner fillet. The probe shall be given slight rotary movement for
proper acoustic coupling. The expected signals have been shown in
Annexure.

3.3.5 Scale expansion: The analysis of oscillogram pattern having closely placed
echoes may be simplified by expanding the relevant part of the
pattern. This can be done with the scale expansion control
provided in the machine.

Page 49 of 75
4. IMPORTANT NOTE :

1. Prior to ultrasonic testing it may be ensured that the axle end faces are
smooth for achieving proper acoustic coupling. If required, the end
faces of the Axle should be properly smoothened by filing /emery
finishing for achieving proper acoustic coupling.

2. In low angle and high angle scanning the onset of the signal in relation
to the initial pulse is a function of the thickness of the perspex wedge
at the probe index marking and the velocity of the ultrasonic wave in
the perspex.

3. Various characteristics of the equipment and probes may be checked as

per IS-12666 at least once a month.

5. CRITERIA FOR ACCEPTANCE:

(a) Axle found to produce flaw signal other than those standard signals as
shown in Annexure ‘A’ during scanning by Far End and Near End
Low Angle Scanning techniques shall be withdrawn from service.
Further confirmation of the defect may be carried out by Trace Delay
Annexure ‘B’ or high angle scanning technique Annexure ‘A’ as the
case may be.

(b) Axle found to produce signals as per the standard signals as given in
the Annexure ‘A’ by Far End and Near End Low Angle Scanning
technique should be declared satisfactory.

(c) During service, few standard signals may disappear due to change in the
geometrical configuration of axle. This aspect may be kept in view.

6. MAGNETIC PARTICLE TESTING:

Axles found defective during ultrasonic examination described above

should be subjected to magnetic particle examination after removal of
the wheels, bearings etc. as the case may be. Record of magnetic
particle examination and observations made shall be maintained in the
register.

7. RECORDING OF TEST DETAILS:

Ultrasonic personnel conducting the test shall maintain a register

indicating the complete details of axle identification, technique
employed, observation made , code of procedure followed and his
remarks. He should also record his observations on visual examination
of the axles.
Page 50 of 75
 Annexure- A

Theoretical calculations and relative positions of signals for axle (powered) of

M/s Phooltas Tamper Pvt. Ltd. Patna’s to Drg. No. UTVI-01 02/00 Rev.0 in
service (Tentative).

(B) FAR END SCANNING : 1 Main Scale Div. = 250 mm (compression wave)

Probe: 20/25mm, 2.5 MHz

Probing from Gear End Side:

SL . Details Distance Signal

No. (mm) (Div.)

1. Direct reflection from axle end. 2390 9.6

2. Delayed reflection from journal fillet 2376.5 9.5

3. Delayed reflection from Wheel seat outer fillet 2294 9.2

4. Direct reflection from journal fillet 2229 8.9

5. Direct reflection from Wheel seat outer fillet 2125 8.5

6. Delayed reflection from a fillet at a distance of 1911 7.6

1587 mm from probing end

7. Delayed reflection from a fillet at a distance of 1767 7.0

1417 mm from probing end

8. Delayed reflection from a fillet at a distance of 1765 7.0

1587mm from probing end

9. Delayed reflection from a fillet at a distance of 1609.5 6.4

1417 mm from probing end

10. Direct reflection from a fillet at a distance of 1587 6.3

1587 mm from probing end

11. Direct reflection from a fillet at a distance of 1417 5.7

1417mm from probing end

12. Delayed reflection from Gear seat fillet 1393 5.6

Page 51 of 75
13. Delayed reflection from Gear seat fillet 1246 5.0

14. Direct reflection from Gear seat fillet 1067 4.3

15. Delayed reflection from wheel seat inner fillet 778 3.1

16. Delayed reflection from wheel seat inner fillet 633 2.5

17. Direct reflection from wheel seat inner fillet 456 1.8

18. Delayed reflection from near end Groove 375.3 1.5

19. Delayed reflection from near end Groove 162.5 1.0

20. Direct reflection from near end Groove 125 0.5

PROBING FROM FREE END SIDE:

SL . Details Distance Signal

No. (mm) (Div.)

1. Direct reflection from axle end. 2390 9.6

2. Delayed reflection from journal fillet 2376.5 9.5

3. Delayed reflection from Wheel seat outer fillet 2294 9.2

4. Direct reflection from journal fillet 2229 8.9

5. Direct reflection from Wheel seat outer fillet 2125 8.5

6. Delayed reflection from a fillet at a distance of 1917 7.7

1593 mm from probing end

7. Delayed reflection from a fillet at a distance of 1771 7.1

1593 mm from probing end

8. Delayed reflection from Gear seat fillet 1679 6.7

9. Direct reflection from a fillet at a distance of 1593 6.4

1593 mm from probing end

10. Delayed reflection from Gear seat fillet 1532 6.1

11. Delayed reflection from a fillet at a distance of 1348 5.4

998 mm from probing end

12. Direct reflection from Gear seat fillet 1353 5.4

Page 52 of 75
13. Delayed reflection from a fillet at a distance of 1190.5 4.8
998 mm from probing end

14. Direct reflection from a fillet at a distance of 998 4.0

998 mm from probing end

15. Delayed reflection from wheel seat inner fillet 778 3.1

16. Delayed reflection from wheel seat inner fillet 633 2.5

17. Direct reflection from wheel seat inner fillet 456 1.8

18. Delayed reflection from near end Groove 375.3 1.5

19. Delayed reflection from near end Groove 162.5 1.0

20. Direct reflection from near end Groove 125 0.5

Page 53 of 75
(B) NEAR END LOW ANGLE SCANNING 1 Main Scale Div. = 100 mm

(Compressive Wave)

Probe : 15/20mm, 2.5 MHz

PROBING FROM BOTH ENDS:

S. NO. Details Distance Signal

(mm) (div.)

1. Direct reflection from wheel seat inner fillet. 472 4.7

(Wedge : 15, Central beam at 30 mm from edge)

(C) HIGH ANGLE SCANNING: 1 Main Scale Div. = 50 mm (Shear wave)

Probe: 20/25mm. , 2.5 MHz

PROBING FROM BOTH ENDS:

S. Details Distance Signal

NO.
(mm) (div.)

1. Direct reflection from wheel seat inner fillet.(Wedge : 224 4.5

37.5 having dia of curvature 176mm or more, Stand
off distance 134 mm from wheel seat inner fillet.)

Page 54 of 75
 Annexure ‘B’

(D) Trace Delay Scanning: 1 main scale div. = 50 mm (compressive wave)

Probe: 15/20 mm, 2.5 MHz

PROBING FROM GEAR END SIDE:

(0-500) mm

S. NO. Details Distance Signal

(mm) (divn.)

1. Direct reflection from wheel seat inner fillet 456 9.1

2. Delayed reflection from near end groove 375.3 7.5

3. Delayed reflection from near end groove 162.5 3.2

4. Direct reflection from near end groove 125 2.5

(500 mm- 1000) mm

S. NO. Details Distance Signal

(mm) (divn.)

1. Delayed reflection from wheel seat inner fillet 278 5.5

2. Delayed reflection from wheel seat inner fillet 133 2.7

(1000mm – 1500) mm

S. NO. Details Distance Signal

(mm) (divn.)

1. Direct reflection from a fillet at a distance of 417 8.3

1417 mm from probing end

2. Delayed reflection from Gear seat fillet 393 7.9

3. Delayed reflection from Gear seat fillet 246 5.9

4. Direct reflection from Gear seat fillet 67 1.3

Page 55 of 75
(1500 – 2000) mm

S. Details Distance Signal

NO.
(mm) (divn.)

1. Delayed reflection from a fillet at a distance of 411 8.2

1587 mm from probing end

2. Delayed reflection from a fillet at a distance of 267 5.3

1417mm from probing end

3. Delayed reflection from a fillet at a distance of 265 5.3

1587 mm from probing end

4. Delayed reflection from a fillet at a distance of 109.5 2.2

1417mm from probing end

5. Direct reflection from a fillet at a distance of 87 1.7

1587mm from probing end

(2000 – 2500) mm:

S. NO. Details Distance Signal

(mm) (divn.)

1. Direct reflection from axle end 390 7.8

2. Delayed reflection from journal fillet 376.5 7.5

3. Delayed reflection from wheal seat outer fillet 294 5.9

4. Direct reflection from journal fillet 229 4.6

5. Direct reflection from wheal seat outer fillet 125 2.5

Page 56 of 75
PROBING FROM FREE END SIDE:

(0 - 500) mm:

S. NO. Details Distance Signal

(mm (divn.)

1. Direct reflection from wheel seat inner fillet 456 9.1

2. Delayed reflection from near end groove 375.3 7.5

3. Delayed reflection from near end groove 162.5 3.2

4. Direct reflection from near end groove 125 2.5

(500 - 1000) mm:

S. NO. Details Distance Signal

(mm) (divn.)

1. Direct reflection from a fillet at a distance of 498 9.9

998 mm from probing end

2. Delayed reflection from wheel seat inner fillet 278 5.6

3. Delayed reflection from wheel seat inner fillet 133 2.7

(1000 – 1500) mm:

S. Details Distance Signal

NO.
(mm) (divn.)

1. Direct reflection from gear seat fillet 353 7.0

2. Delayed reflection from fillet at a distance of 348 7.0

998 mm from probing end

3. Delayed reflection from fillet at a distance of 190.5 3.8

998 mm from probing end
Page 57 of 75
(1500 – 2000) mm :

S. Details Distance Signal

NO.
(mm) (divn.)

1. Delayed reflection from fillet at a distance of 417 8.3

1593 mm from probing end

2. Delayed reflection from fillet at a distance of 271 5.4

1593 mm from probing end

3. Delayed reflection from Gear seat fillet 179 3.6

4. Delayed reflection from fillet at a distance of 93 1.9

1593 mm from probing end

5. Delayed reflection from Gear seat fillet 32 0.6

(2000 – 2500) mm:

S.NO. Details Distance Signal

(mm) (divn.)

1. Direct reflection from axle end 390 7.8

2. Delayed reflection from journal fillet 376.5 7.5

3. Delayed reflection from Wheel seat outer fillet 294 5.9

4. Direct reflection from journal fillet 229 4.6

5. Direct reflection from Wheel seat outer fillet 125 2.5

Page 58 of 75
Page 59 of 75
Page 60 of 75
Page 61 of 75
Testing Procedure and Equipment used for Ultrasonic testing of the
following Tie Tamping Machine axles in service:

1. CSM SATELLITE Or Driving Bogie axle to CPOH Drg. No. C-1411

CSM

2. Driving axle DUOMATIC to IRTMTC Drg. No. D-1402 DUO-R1

3. Driving axle front of Unimat to CPOH Drg. No. UNI-1402

4. Driving axle Rear of Unimat to CPOH Drg. No. UNI-1401

5. Running axle CSM to IRTMTC Drg. No. C-1406 CSM

Equipment and accessories recommended:

Equipment :
Any Ultrasonic Flaw Detector approved by RDSO, Lucknow (specn.
No.M&C/NDT/104/2000).
Accessories:
Probes and Wedges:

Far – end Scanning : Normal probe of 2.5 MHz, 20/25 mm dia Of lead
zirconate titanate or similar crystal.
Low Angle Scanning : Normal probe of 2.5 MHz, 15/20 mm dia Of lead
zirconate titanate crystal with Perspex wedge 17.5°.
High Angle Scanning : Normal probe of 2.5 MHz, 20/25 mm dia Of lead
zirconate titanate crystal with Perspex wedge 37°, 140 mm Diameter of
curvature for scanning wheel seat inner filler both for Free End and Gear
End side.

Couplant : A suitable couplant like soft grease or Axle Oil (medium) shall
be used.

Calibration Bar : Round bars 50 mmx500 mm long and 50mm x 182mm

long are applicable. The round bars shall confirm to designation 45C8 of
IS 1875 1992, rolled/forged and normalised. The grain size shall be
ASTM 5 or finer when determined according to ASTM E – 19-39 T.
Testing Procedure :
Far End Scanning : This technique shall be used for testing the full length
of the axle. The time scale shall be calibrated to 250 mm per main scale
division of compression wave. The probe shall be placed on the cleaned
axle end face with suitable couplant. The probe shall be given slight rotary
movement for proper acoustic coupling. Some stray signals may appear
near the initial echo due to press fit components.
Page 62 of 75
Near End Low Angle Scanning: This technique is used for testing the
vulnerable portion of the axle near the probing end. This technique is
meant for the examination of cracks, if any, in the raised wheel seat,
which is not scanned during Far-End scanning or for conforming the flaw
obtained to 100mm per main scale division for compression wave. A
normal probe 15/20mm dia, fitted with a Perspex wedge of 17.5° angle
shall be placed on the axle end face directing the central beam towards
the wheel seat inner fillet, both for Gear End side and Free End side
respectively.

High Angle Scanning : Depending upon the accessibility, this technique

may be applied for conformation of the finding during Near End Low Angle
scanning. The time scale shall be calibrated to 50mm per main scale
division for shear wave. A normal probe of 20/25mm dia, fitted with Perspex
wedge 37° having dia of curvature 140mm or higher shall be placed on the
body of the axle with probe index marking at distance 104mm from
wheel seat outer fillet both for Gear End & Free End side, for getting
reflection from wheel seat inner fillet. The probe shall be moved
forward and backward longitudinally from the mean position up to
20mm circumferentially.
Examination by Scale Expansion : The analysis of oscillogram pattern
having closely placed echoes may be simplified by expanding the
relevant part of the pattern. This can be done with the scale expansion
control provided in the Ultrasonic Flaw detector.

CRITERIA FOR ACCEPTANCE AND OTHERWISE :

Axle found to produce flaw signal other than those standard signals during
scanning by far end and near end low angle technique (Conformed by
high angle scanning ) shall be withdrawn from service. During service extra
signals may appear due to change in geometrical configuration of axles.
This aspect may be kept in view while declaring the serviceability of the
axle.

BEFORE TESTING THE AXLES, CALIBRATE THE EQUIPMENT AND

CHECK THE FUNCTION AND SENSITIVITY OF THE EQUIPMENT
AND PROBES, USE ONLY THE EQUIPMENT AND ACCESSORIES
MENTIONED IN THIS CODE.

Page 63 of 75
Theoretical calculations and relative positions of signals of CSM SATELLITE
OR Driving Bogie Axle to CPOH Drg.No.C-1411 CSM in service (Tentative)

(C) FAR END SCANNING : 1 Main Scale Div. = 250 mm (compression wave)

Probe: 20/25mm, 2.5 MHz

FROM FREE END SIDE:

SL . Details Distance Signal

No. (mm) (Div.)

1. Direct back reflection from axle end. 2166 8.7

2. Direct reflection from journal fillet 2025 8.1

3. Delayed reflection from journal fillet 2160 8.6

4. Direct reflection from Wheel seat outer fillet 1998 8.0

5. Delayed reflection from Wheel seat outer fillet 2152.5 8.6

6. Direct reflection from Bearing seat fillet 1425 5.7

7. Delayed reflection from Bearing seat fillet 1575 6.3

8. Delayed reflection from Bearing seat fillet 1698 6.8

9. Direct reflection from Gear seat fillet 1208 4.8

10. Delayed reflection from Gear seat fillet 1370.5 5.5

11. Delayed reflection from Gear seat fillet 1504 6.0

12. Direct reflection from wheel seat inner fillet 338 1.4

13. Delayed reflection from wheel seat inner fillet 487.5 2.0

14. Delayed reflection from wheel seat inner fillet 610 2.4

Page 64 of 75
FROM GEAR END SIDE:

SL . Details Distance Signal

No. (mm) (Div.)

1. Direct back reflection from axle end. 2166 8.7

2. Direct reflection from journal fillet 2025 8.1

3. Delayed reflection from journal fillet 2160 8.6

4. Direct reflection from Wheel seat outer fillet 1998 8.0

5. Delayed reflection from Wheel seat outer fillet 2152.5 8.6

6. Direct reflection from Bearing seat fillet 1425 5.7

7. Delayed reflection from Bearing seat fillet 1575 6.3

8. Delayed reflection from Bearing seat fillet 1698 6.8

9. Direct reflection from Gear seat fillet 1208 4.8

10. Delayed reflection from Gear seat fillet 1370.5 5.5

11. Delayed reflection from Gear seat fillet 1504 6.0

12. Direct reflection from wheel seat inner fillet 338 1.4

13. Delayed reflection from wheel seat inner fillet 487.5 2.0

14. Delayed reflection from wheel seat inner fillet 610 2.4
(B) NEAR END LOW ANGLE SCANNING : 1 MSD = 100mm (Compression wave)

Probe 15/20 mm dia., 2.5 MHz

FROM FREE END SIDE & GEAR END SIDE :

S.No. Details Distance (mm) Signal (Div.)

1. Direct reflection from wheel sear 355 3.6

inner fillet,

(Wedge = 17.5°, central beam at

22 mm from edge of axle)

Page 65 of 75
 (C) HIGH ANGLE SCANNING : 1 MSD = 50mm (Shear wave)

Probe 20/25 mm dia., 2.5 MHz

FROM FREE END SIDE & GEAR END SIDE :

S.No. Details Distance (mm) Signal (Div.)

1. Direct reflection from wheel seat 190 3.8

inner fillet,

(Wedge = 3.7°, central beam at

104 mm from Wheel seat inner

fillet, Dia. of curvature = 140mm)

NOTE: POSITION OF SIGNAL MAY VARY WITH THE THICKNESS OF WEDGE.

Page 66 of 75
Theoretical calculations and relative positions of signals of Driving Axle
DUOMATIC to IRTMTC Drg.No.D-1402 DUO R1 in service (Tentative)

(A) FAR END SCANNING : 1 Main Scale Div. = 250 mm (compression wave)

Probe: 20/25mm, 2.5 MHz

FROM FREE END SIDE:

SL . Details Distance Signal

No. (mm) (Div.)

1. Direct back reflection from axle end. 2148 8.6

2. Direct reflection from Wheel seat outer fillet 2004 8.0

3. Delayed reflection from Wheel seat outer fillet 2133.5 8.5

4. Direct reflection from Bearing seat fillet 1410 5.6

5. Delayed reflection from Bearing seat fillet 1560 6.2

6. Delayed reflection from Bearing seat fillet 1683 6.7

7. Direct reflection from Gear seat fillet 1190 4.7

8. Delayed reflection from Gear seat fillet 1352.5 5.4

9. Delayed reflection from Gear seat fillet 1485.7 5.9

10. Direct reflection from wheel seat inner fillet 324 1.3

11. Delayed reflection from wheel seat inner fillet 473.5 1.9

12. Delayed reflection from wheel seat inner fillet 596 2.4

FROM GEAR END SIDE:

SL . Details Distance Signal

No. (mm) (Div.)

1. Direct back reflection from axle end. 2148 8.6

2. Direct reflection from Wheel seat outer fillet 2004 8.0

3. Delayed reflection from Wheel seat outer fillet 2133.5 8.5

Page 67 of 75
 4. Direct reflection from Bearing seat fillet 1198 4.8

5. Delayed reflection from Bearing seat fillet 1348 5.4

6. Delayed reflection from Bearing seat fillet 1471 5.9

7. Direct reflection from Gear seat fillet 1073 4.8

8. Delayed reflection from Gear seat fillet 1235.5 4.9

9. Delayed reflection from Gear seat fillet 1368.7 5.5

10. Direct reflection from wheel seat inner fillet 324 1.3

11. Delayed reflection from wheel seat inner fillet 473.5 1.9

12. Delayed reflection from wheel seat inner fillet 596 2.4
(B) NEAR END LOW ANGLE SCANNING : 1 MSD = 100mm (Compression wave)

Probe 15/20 mm dia., 2.5 MHz

FROM FREE END SIDE & GEAR END SIDE :

S.No. Details Distance (mm) Signal (Div.)

1. Direct reflection from wheel seat 340 3.4

inner fillet,

(Wedge = 17.5°, central beam at

30 mm from edge of axle)

(C) HIGH ANGLE SCANNING : 1 MSD = 50mm (Shear wave)

Probe 20/25 mm dia., 2.5 MHz

FROM FREE END SIDE & GEAR END SIDE :

S.No. Details Distance (mm) Signal (Div.)

1. Direct reflection from wheel seat 190 3.8

inner fillet,

(Wedge = 3.7°, central beam at

104 mm from Wheel seat inner

fillet, Dia. of curvature = 140mm)

NOTE: POSITION OF SIGNAL MAY VARY WITH THE THICKNESS OF WEDGE.

Page 68 of 75
Theoretical calculations and relative positions of signals of Driving Axle Front
of Unimat to CPOH Drg.No.UNI 1402 in service (Tentative)

(D) FAR END SCANNING : 1 Main Scale Div. = 250 mm (compression wave)

Probe: 20/25mm, 2.5 MHz

FROM FREE END SIDE:

SL . Details Distance Signal

No. (mm) (Div.)

1. Direct back reflection from axle end. 2166 8.7

2. Direct reflection from journal fillet 2025 8.1

3. Direct reflection from Wheel seat outer fillet 1998 8.0

4. Delayed reflection from Wheel seat outer fillet 2152.5 8.6

5. Direct reflection from Bearing seat fillet 1357 5.4

6. Delayed reflection from Bearing seat fillet 1507 6.0

7. Delayed reflection from Bearing seat fillet 1630 6.5

8. Direct reflection from Gear seat fillet 1229 4.9

9. Delayed reflection from Gear seat fillet 1391.5 5.5

10. Delayed reflection from Gear seat fillet 1524.75 6.1

11. Direct reflection from wheel seat inner fillet 338 1.4

12. Delayed reflection from wheel seat inner fillet 487.5 2.0

13. Delayed reflection from wheel seat inner fillet 610 2.4

Page 69 of 75
FROM GEAR END SIDE:

SL . Details Distance Signal

No. (mm) (Div.)

1. Direct back reflection from axle end. 2166 8.7

2. Direct reflection from journal fillet 2025 8.1

3. Direct reflection from Wheel seat outer fillet 1998 8.0

4. Delayed reflection from Wheel seat outer fillet 2152.5 8.6

5. Direct reflection from Bearing seat fillet 1279 5.1

6. Delayed reflection from Bearing seat fillet 1429 5.7

7. Delayed reflection from Bearing seat fillet 1552 6.2

8. Direct reflection from Gear seat fillet 1062 4.2

9. Delayed reflection from Gear seat fillet 1224.5 4.9

10. Delayed reflection from Gear seat fillet 1357.7 5.4

11. Direct reflection from wheel seat inner fillet 338 1.4

12. Delayed reflection from wheel seat inner fillet 487.5 2.0

13. Delayed reflection from wheel seat inner fillet 610 2.4
NEAR END LOW ANGLE SCANNING : 1 MSD = 100mm (Compression wave)

Probe 15/20 mm dia., 2.5 MHz

Page 70 of 75
 FROM FREE END SIDE & GEAR END SIDE :

S.No. Details Distance (mm) Signal (Div.)

1. Direct reflection from wheel sear 355 3.6

inner fillet,

(Wedge = 17.5°, central beam at

22 mm from edge of axle)

© HIGH ANGLE SCANNING : 1 MSD = 50mm (Shear wave)

Probe 20/25 mm dia., 2.5 MHz

FROM FREE END SIDE & GEAR END SIDE :

S.No. Details Distance (mm) Signal (Div.)

1. Direct reflection from wheel seat 190 3.8

inner fillet,

(Wedge = 3.7°, central beam at

104 mm from Wheel seat inner

fillet, Dia. of curvature = 140mm)

NOTE: POSITION OF SIGNAL MAY VARY WITH THE THICKNESS OF WEDGE.

Page 71 of 75
Theoretical calculations and relative positions of signals of Driving Axle Rear
of Unimat to CPOH Drg.No.UNI 1401 in service (Tentative)

(A) FAR END SCANNING : 1 Main Scale Div. = 250 mm (compression wave)

Probe: 20/25mm, 2.5 MHz

FROM FREE END SIDE:

SL . Details Distance Signal

No. (mm) (Div.)

1. Direct back reflection from axle end. 2166 8.7

2. Direct reflection from journal fillet 2025 8.1

3. Direct reflection from Wheel seat outer fillet 1998 8.0

4. Delayed reflection from Wheel seat outer fillet 2133 8.5

5. Direct reflection from Bearing seat fillet 963 3.9

6. Delayed reflection from Bearing seat fillet 1113 4.5

7. Delayed reflection from Bearing seat fillet 1236 4.9

8. Direct reflection from Gear seat fillet 835 3.3

9. Delayed reflection from Gear seat fillet 997.5 4.0

10. Delayed reflection from Gear seat fillet 1130.7 4.5

11. Direct reflection from wheel seat inner fillet 338 1.4

12. Delayed reflection from wheel seat inner fillet 487.5 2.0

13. Delayed reflection from wheel seat inner fillet 610 2.4

Page 72 of 75
FROM GEAR END SIDE:

SL . Details Distance Signal

No. (mm) (Div.)

1. Direct back reflection from axle end. 2166 8.7

2. Direct reflection from journal fillet 2025 8.1

3. Direct reflection from Wheel seat outer fillet 1998 8.0

4. Delayed reflection from Wheel seat outer fillet 2133 8.5

5. Direct reflection from Bearing seat fillet 1873 6.7

6. Delayed reflection from Bearing seat fillet 1823 7.3

7. Delayed reflection from Bearing seat fillet 1540 6.8

8. Direct reflection from Gear seat fillet 1456 5.8

9. Delayed reflection from Gear seat fillet 1618.5 6.5

10. Delayed reflection from Gear seat fillet 1754.7 7.0

11. Direct reflection from wheel seat inner fillet 338 1.4

12. Delayed reflection from wheel seat inner fillet 487.5 2.0

13. Delayed reflection from wheel seat inner fillet 610 2.4
(B) NEAR END LOW ANGLE SCANNING : 1 MSD = 100mm (Compression
wave)

Probe 15/20 mm dia., 2.5 MHz

Page 73 of 75
 FROM FREE END SIDE & GEAR END SIDE :

S.No. Details Distance (mm) Signal (Div.)

1. Direct reflection from wheel seat 355 3.6

inner fillet,

(Wedge = 17.5°, central beam at

22 mm from edge of axle)

© HIGH ANGLE SCANNING : 1 MSD = 50mm (Shear wave)

Probe 20/25 mm dia., 2.5 MHz

FROM FREE END SIDE & GEAR END SIDE :

S.No. Details Distance (mm) Signal (Div.)

1. Direct reflection from wheel seat 190 3.8

inner fillet,

(Wedge = 3.7°, central beam at

104 mm from Wheel seat inner

fillet, Dia. of curvature = 140mm)

NOTE: POSITION OF SIGNAL MAY VARY WITH THE THICKNESS OF WEDGE.

Page 74 of 75
Theoretical calculations and relative positions of signals of Running Axle
CSM to IRTMTC Drg.No.C-1406 CSM in service (Tentative)

(A) FAR END SCANNING : 1 Main Scale Div. = 250 mm (compression

wave)
Probe: 20/25mm, 2.5 MHz

FROM GEAR END SIDE:

SL . Details Distance Signal

No. (mm) (Div.)
1. Direct back reflection from axle end. 2166 8.7
2. Direct reflection from journal fillet 2025 8.1
3. Delayed reflection from journal fillet 2160 8.6
4. Direct reflection from Wheel seat outer fillet 1998 8.0
5. Delayed reflection from Wheel seat outer fillet 2152.5 8.6
6. Direct reflection from wheel seat inner fillet 338 1.4
7. Delayed reflection from wheel seat inner fillet 487.5 2.0
8. Delayed reflection from wheel seat inner fillet 610 2.4

(B) NEAR END LOW ANGLE SCANNING : 1 MSD = 100mm (Compression wave)
Probe 15/20 mm dia., 2.5 MHz
FROM FREE END SIDE & GEAR END SIDE :

S.No. Details Distance (mm) Signal (Div.)

1. Direct reflection from wheel sear 355 3.6
inner fillet,
(Wedge = 17.5°, central beam at
22 mm from edge of axle)
(C) HIGH ANGLE SCANNING : 1 MSD = 50mm (Shear wave)
Probe 20/25 mm dia., 2.5 MHz
FROM FREE END SIDE & GEAR END SIDE :

S.No. Details Distance (mm) Signal (Div.)

1. Direct reflection from wheel seat 190 3.8
inner fillet,
(Wedge = 3.7°, central beam at
104 mm from Wheel seat inner
fillet, Dia. of curvature = 140mm)

NOTE: POSITION OF SIGNAL MAY VARY WITH THE THICKNESS OF WEDGE.

Page 75 of 75