(For official use only)

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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

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SPECIFICATION OF NON-ASBESTOS HIGH FRICTION

COMPOSITION BRAKE BLOCKS FOR WDG4 / WDP4 DIESEL
LOCOMOTIVES OF INDIAN RAILWAYS

fof'kf"V la[;k ,e-ih- 0-0100-10 ( fjohtu- 05)

viz®y - 2020

SPECIFICATION NO. MP.0.0100-10 (REV- 05)

April- 2020

vuqla/kku vfHkdYi ,oa ekud laxBu y[kuÅ 226 011

RESEARCH DESIGNS& STANDARDS ORGANISATION
LUCKNOW - 226 011
 CONTENTS

S. No. Description Page No.

1. Scope 1
2.1 Requirement - General 1
2.2 - Friction 1
2.3 Geometrical Characteristics 2
2.4 Mechanical Physical And Chemical 2
Characteristics
2.5 Marking 3
3. Acceptance Procedure 3
4. Inspection 5
5. Testing Facilities 6
6. Revision Of Specification / Drawing 6
7. Packing 6
8. Warranty 6
9. Date of Enforcement 7

ANNEXURE

I Locomotive Data 8
II Friction Band 9
III Brake Dynamometer Test Programme 10
IV Drawing of Composition Brake block 12
V Test Methods 13
 Specification of Non-Asbestos High Friction Composition Brake Blocks For WDG4 & WDP4 Diesel Locomotives

1. SCOPE

This specification covers the requirements of non-asbestos high friction composition brake
blocks for application on WDG4 & WDP4 diesel (General Motors USA Design)
locomotives of Indian Railways.

2. REQUIREMENTS

2.1 GENERAL

2.1.1 This specification defines the necessary characteristics of brake blocks of composition
material.

2.1.2 The high friction composition brake blocks shall be freely interchangeable with
composition brake blocks to RDSO Drg. No. SKDP - 3630 (Alt.2) for WDG4 & WDP4
diesel locomotives having the parameters given in Annexure-I.

2.1.3 The composition of the material and the manufacturing method of series production of
high friction composition brake blocks must always conform with that of the block for
which approval has been given by RDSO.

2.1.4 The use of asbestos is prohibited.

2.1.5 The use of lead and zinc in the metal state or in the form of compounds is not allowed.
The same applies to all other components if in the form of powder, particles or gas
produced during the use of the brake blocks, they may constitute a danger to health or
inconvenience to passengers.

2.1.6 The composition of the material constituting the brake block must be chosen to give the
best balance between:-

- Braking characteristics.
- Wear and service life of blocks.
- Wear on the running surface of the wheels.
- Effect on adhesion between the rail and wheel.
- Proper heat dissipation of heat generated at wheel and brake block interface.

2.1.7 The characteristics laid down in this specification must be maintained for the complete
usable thickness of the braking material.

2.2 FRICTION

2.2.1 As far as possible the co-efficient of friction must be independent of the initial braking
speed, the state of bedding-in of the brake block, the specific pressure as well as the
temperature and atmospheric conditions.

2.2.2 The tolerance bands of the mean co-efficient of friction shall be as per Annexure-II of this
specification. The definition of the coefficients of friction is as per UIC 541-4-OR.

Specification No. MP.0.0100-10 (Rev - 05), April ’2020 Page 1 of 17

 Specification of Non-Asbestos High Friction Composition Brake Blocks For WDG4 & WDP4 Diesel Locomotives

In order to ensure that better performance is achieved by minimising the risk of failure of
wheel disc on account of thermal cracks and ensuring better conductivity, the following
guidelines will be adopted.
i) Minimum 70% of the values of mean coefficients of friction must fall within
specified band.
ii) Maximum 10% of the values of mean coefficients of friction may fall above the
upper limit of the band.
iii) Maximum 30% of the values of mean coefficients of friction may fall below the
lower limit of the band.

2.2.3 Under the influence of dampness i.e. under wet conditions, the average co-efficient of
friction must not vary by more than +15% in relation to the value obtained during braking
when dry, with the other condition remaining the same.

2.2.4 After prolonged braking followed by braking to a stop, a particular high temperature
occurs. Even in such condition the temperature on the opposite friction surfaces, must not
exceed 375 0C. The variation of average co-efficient of friction due to excessive heating
must not exceed +15% in any case, in relation to the value obtained during braking in the
cold and dry state.

2.3 GEOMETRICAL CHARACTERISTICS

2.3.1 The controlling dimensions of the brake block shall conform to the requirements given in
the RDSO Drg. No SKDP – 3630 (Alt.2) placed at Annexure-IV.

2.3.2 The constructional features of the brake block must enable it to wear down to a thickness
of about 10 mm, including the back plate, without the latter coming into contact with the
running surface of the wheel.

2.4 MECHANICAL PHYSICAL AND CHEMICAL CHARACTERISTICS

2.4.1 The various elements making up the brake blocks must be spread uniformly in the body of
the block. There must be no pitting, flakes or other defects. The material must not attack
the opposing friction surface or give rise to the formation of metal inclusions.

2.4.2 The blocks must not cause heat damage to the wheels e.g. hot spots, cracks, flaking.

2.4.3 The values of density, hardness, compression modulus, cross breaking strength, acetone
extract, ash content (loss on ignition), and back plate pull off strength must be given with
the offer. However, the hardness of the brake block material in R scale must be in the
range 85 to 115 and the back plate pull off strength of the brake block must not be less
than 6.5 T. The acetone extract also must not exceed 3%.

2.4.4 The test procedure for these properties (as mentioned in 2.4.3) shall be as given in the
Annexure V.

2.4.5 The manufacturer must mention their product specification, giving sufficient detail of the
mechanical, physical and chemical features in their QAP. They should also indicate the
composition of their material in broader terms indicating percentage of conductive fillers.

Specification No. MP.0.0100-10 (Rev - 05), April ’2020 Page 2 of 17

 Specification of Non-Asbestos High Friction Composition Brake Blocks For WDG4 & WDP4 Diesel Locomotives

2.4.6 No method is laid down for fixing the composite material to the back plate. The back
plate must be designed to withstand the forces likely to occur.

2.4.7 The composition brake block must not unduly affect adhesion between wheel and rail
obtained on vehicles braked with cast iron blocks.

2.5 MARKING

2.5.1 The marking and colour coding on the brake block shall be as per Drawing No. SKDP –
3630 (Alt.2), placed at Annexure –IV.

2.5.2 These marks, preferably be punched, engraved or stamped. These must be applied in such
a way so that the block can be identified, even after fully worn in service. The marking
arrangement shall be got approved by RDSO before undertaking supply.

3. ACCEPTANCE PROCEDURE

3.1 Conditions for Vendor Approval

3.1.1 (a) The firm shall have a technical collaboration with a foreign manufacturer who has
experience in manufacturing rail road brake blocks. The foreign collaborator must
have existing manufacturing and test facilities including Full Scale dynamometer
for manufacturing and testing of brake blocks. The collaborator will have to give
detailed information including type acceptance test data run as per clause 2.2 and
other details in accordance with clause no. 2.4.3. The test on dynamometer will be
carried out by the collaborator as per test scheme given in Annexure – III.

(b) The manufacturer will have to produce adequate evidence from their collaborator
in support of good performance of the collaborator in manufacturer and supply of
composition brake blocks for Rail Road application.

3.1.2 The condition of foreign collaboration is strictly applicable for those companies which are
not in the business of manufacturing friction composition materials for industrial use.
However, the companies, which are in the business of friction composition materials for
industrial use and have established all the requisite manufacturing and testing facilities
including full scale rail dynamometer conforming to ERRI B–126 / RP-18 specification
for indigenous manufacturer of the railway brake blocks and are following a quality
assurance plan to the satisfaction of RDSO may be exempted by the RDSO from the
requirement of foreign collaboration. Such firm should submit dynamometer test results
after testing of samples in their own dynamometer.

3.1.3 The information in para 3.1.1, 3.1.2 and 3.2.2 should be presented together with a request
for type acceptance test by RDSO.

3.1.4 The manufacturer will submit two samples of brake blocks for type acceptance test on
RDSO's brake dynamometer and samples will be tested as per Test scheme given in
Annexure III. Conformance of both the samples to the specification will be treated as
dynamometer test passed. One samples means no. of brake block used per wheel. The
testing charges will be paid by the manufacturer as per the prevailing guidelines for vendor
approval.

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 Specification of Non-Asbestos High Friction Composition Brake Blocks For WDG4 & WDP4 Diesel Locomotives

3.1.5 During the tests, the blocks must not reveal any sign of combustion, formation of flaking,
sweating of the binding material, permanent grating or other defects.

3.1.6 The wear should be uniformly distributed over the entire depth of the block, it should be as
low as possible and be largely independent of the type of brake load application. The
specific wear value of each brake block found by weighing should not exceed 5 cc/kwh.

3.1.7 The brake blocks tested on the dynamometer must meet the requirements given in para 2.2
of this specification.

3.1.8 On successful completion of the dynamometer testing at RDSO, 300 nos. brake blocks
shall undergo field trials for a period of one year.

The manufacturer shall has to submit QAP as per clause 3.2.2 for approval before
undertaking manufacture of these brake blocks.

The brake blocks will be supplied for field trial only after inspection by Motive Power
Directorate of RDSO.

3.1.9 Two samples out of 300 initial brake blocks shall be picked up by the RDSO to under take
full scale dynamometer test. The manufacturer shall arrange this testing of blocks on his
own/with collaborator. Alternatively the manufacturer may send the brake block for
testing at RDSO at his own cost. This test will be carried out as per Test scheme given in
Annexure III

3.2 Conditions For Approved Vendor

3.2.1 The manufacturer shall get his Quality Assurance Plan approved by RDSO before
undertaking manufacture of the brake block. The Quality Assurance Plan must contain the
details of process of manufacture, process controls and quality records maintained as well
as the drawing showing dimensions. The QAP must also contain the acceptable readings
of the following parameters along with the method of testing in detail. The methods of
testing shall however conform to those provided in Annexure V of this specification. In
case of (d), (e) and (f) acceptable limits should be within ± 15% of nominal values.

a) Compression modulus (Max)

b) Cross breaking strength (Min)
c) Acetone extract (Max)
d) Ash content (loss on ignition)
e) Hardness
f) Density
g) Back plate pull of strength
h) Any other test

3.2.2 The approved vendor shall undertake full scale dynamometer test as per Annexure- III and
submit the result to RDSO/MP on the basis of 12,000-15,000 brake blocks supplied to
railways. To audit the quality control RDSO at their discretion may pick up samples for
confirmatory dynamometer testing at RDSO, Lucknow.

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 Specification of Non-Asbestos High Friction Composition Brake Blocks For WDG4 & WDP4 Diesel Locomotives

4 INSPECTION

4.1 The inspection of the brake blocks shall be carried out by Director General / RDSO or his
authorised representative at the premises of the manufacturer. During development stage,
inspection authority will be Motive Power Directorate of RDSO and during series production
stage inspection authority will be QA Directorate of RDSO

4.2 The inspection will be carried out as per the following procedure:-

i) Manufacturer to submit pre-inspection report for the lots offered for inspection as
per the approved QAP of the firm.

ii) Manufacturer to ensure traceability of each block to its parent mix batch number &
heat number.

iii) The inspector shall inspect the quality records maintained by manufacturer for the
entire lot.

iv) Each lot offered for inspection shall consist of 500 brake blocks or part thereof.
The lot No. shall represent the mix batch numbers and heat No. out of which these
brake blocks have been manufactured.

v) 3% of every offered lot of 500 no. brake blocks will be selected at random and
checked for dimensional accuracy, during developmental stage. Once the
manufacturer is approved for regular supply of brake blocks this sample size of 3%
will get reduced to 2%. Dimensions are to be checked as per approved drawing of
manufacturer. However it is to be ensured that blocks from different mix batches
will be taken up for inspection.

(A) One brake block selected at random from the above lot shall be tested for the
following :

a) Compression modulus
b) Cross breaking strength
c) Acetone extract
d) Ash contents (loss on ignition)
e) Hardness
f) Density

The brake block shall be accepted based on acceptable readings given in the RDSO
approved QAP of the manufacturer. The method of testing shall be as given in UIC
-541-4 OR or as per the method of testing indicated in their approved QAP, which
will in general be in conformity with Annexure V.

(B) One brake block selected at random from the same lot to be tested for back
plate pull off strength and accepted based on acceptance values specified in
approved QAP of the firm.

(C) One brake block selected at random will be subjected to any other test to be
included in the QAP of the firm as decided by the manufacturer and RDSO.

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 Specification of Non-Asbestos High Friction Composition Brake Blocks For WDG4 & WDP4 Diesel Locomotives

4.2.1 The brake block shall confirm to the requirements mentioned in the QAP of the firm and
approved by RDSO. If any of the samples selected as per para 4.2 fail to meet the
requirements of any of the requirements, double the quantity of samples stipulated in
clause 4.2 shall be selected for tests. If during re testing any of the brake blocks fail to
meet the requirements of any of the tests the entire lot of brake blocks offered for
inspection shall be rejected and brake blocks shall be rendered unserviceable.

4.2.2 The rejected lot shall be destroyed.

5 TESTING FACILITIES:

i) Manufacturer shall have adequate facilities for checking of brake block according
to dimensional tolerances shown on the drawing.

ii) Manufacturer shall have adequate facilities for determining the characteristics as
laid down in para4.2.(v)

iii) The manufacturer shall have in house full scale dynamometer facilities conforming
to ERRI B–126 / RP-18 specification to test the brake blocks as per test scheme
laid down in Annexure III.

6 REVISION OF SPECIFICATION / DRAWING

i) RDSO reserves right to change / revise any part of the specification.

ii) In case any revision of the specification / drawing takes place within the period of
approval, suitable time period shall be given to the firm depending upon the nature
of the changes to implement the revised specification & the drawing of the product

iii) Subsequent to the revision of the specification, testing of the brake blocks if
required, shall be carried out on Full scale dynamometer at RDSO and the testing
charges in such cases are not to be levied for approved supplier, if the samples are
submitted within the stipulated time. However, if samples fail and re-testing is
carried out, the same shall be charged.

7 PACKING

The brake block shall be securely packed in cardboard boxes so that there is no damage to
brake block during transit & handling. It should be ensured that QAP submitted for
approval by RDSO includes packing details.

8 WARRANTY

The warranty on account of manufacturing defect shall be 18 months from the month of
supply or the duty life cycle i.e. time taken in reaching the wear limit of brake block
whichever is earlier. Manufacturer shall replace defective brake blocks within a month’s
time from the receipt of information from user railway, without any cost.

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 Specification of Non-Asbestos High Friction Composition Brake Blocks For WDG4 & WDP4 Diesel Locomotives

9 Date of Enforcement

The date of enforcement of the specification is with immediate effect i.e. date of issue of
specification.

------------------------------

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Specification of Non-Asbestos High Friction Composition Brake Blocks For WDG4 & WDP4 Diesel Locomotives

Annexure-I

Locomotive Data

S.No. Particulars

1. Max. Axle load (t)

- WDG4 21
- WDP4 19.5

2. No. of Axles/loco 6

3. Wheel dia (mm)

– New 1092
– Condemning 1016

4. No. of brake blocks per wheel 1

5. Locomotive weight (t)

WDG4 126
WDP4 117

6. Total brake force 51.132 t

7. Efficiency 100 %

8. Max. speed (kmph)

- WDG4 100
- WDP4 160

9. Type of brake system Air brake (CCB)

10. Condemning thickness of brake block 10 mm

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Specification of Non-Asbestos High Friction Composition Brake Blocks For WDG4 & WDP4 Diesel Locomotives

Annexure-II

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 Specification of Non-Asbestos High Friction Composition Brake Blocks For WDG4 & WDP4 Diesel Locomotives

Annexure III

PROGRAMME OF TEST FOR HIGH FRICTION COMPOSIOTION BRAKE BLOCKS

ON BRAKE DYNAMOMETER FOR WDG4 & WDP4 DIESEL LOCOMOTIVES

1. Diameter of wheel – 1092 mm

2. No. of brake blocks /wheel – 1
3. Axle load – 21 t
Brake Speed Force per Initial Remarks
application (km/h) wheel (kg) temp. of
No. wheel
tread (oC)
1 2 3 4 5
a-n 60 2000 20-100 Braking to stop until running in
conditions of 85% is obtained.
Weigh the brake block
1-5 40 3400 20-60 Braking to stop under dry conditions
after cooling the wheel if necessary
6-10 60 60-80 -do-
11-15 80 80-90 -do-
16-20 100 -do-
21-25 110 -do-
26-30 120 -do-
31-35 130 -do-
36-40 140 -do-
41-45 150 -do-
46-50 160 -do-( weigh the brake block)
51-55 40 20-60 Braking to stop under wet conditions
after cooling the wheel if necessary
56-60 60 60-80 -do-
61-65 80 80-90 -do-
66-70 100 -do-
71-75 110 -do-
76-80 120 -do-
81-85 130 -do-

86-90 140 -do-

91-95 150 -do-
96-100 160 -do-( weigh the brake block)
101-105 40 4940 20-60 Braking to stop under dry conditions
after cooling the wheel if necessary
106-110 60 60-80 -do-
111-115 80 80-90 -do-
116-120 100 -do-
121-125 110 -do-
126-130 120 -do-
131-135 130 -do-
136-140 140 -do-
141-145 150 -do-
146-150 160 -do-( weigh the brake block)
151-155 40 20-60 Braking to stop under wet conditions
after cooling the wheel if necessary
156-160 60 60-80 -do-
161-165 80 80-90 -do-

Specification No. MP.0.0100-10 (Rev - 05), April ’2020 Page 10 of 17

 Specification of Non-Asbestos High Friction Composition Brake Blocks For WDG4 & WDP4 Diesel Locomotives

166-170 100 -do-

171-175 110 -do-
176-180 120 -do-
181-185 130 -do-
186-190 140 -do-
191-195 150 -do-
196-200 160 -do-(weigh the brake block)
201-202 60 -- 20-40 Drag braking with 45 H.P. for 20
minutes immediately by braking to
stop with brake block force of 3400
kg & 4940 kg per brake block under
warm condition. Measure
temperature of wheel and brake
block after drag braking. Weigh the
brake block at the end of the last
stop.

The following parameters shall be recorded /measured/ calculated during the tests.

1. Wheel tread diameter before and after the tests.

2. Specific wear rate of the brake block.

3. Surface condition of brake blocks after test specifically in respect of grooving

metallic inclusions, burning, non-uniform wear, overheating etc. and surface
condition of wheel tyre in respect of polishing, pitting flaking, cracking and other
defects after every test.

4. Initial and maximum temperature reached on brake block and wheel tread for
each test during brake application.

5. General observations i.e. physical condition deterioration, smoke, smell, sparks

and noise during tests.

6. Mean co-efficient of friction in during drag braking, dry and wet conditions.
The values of mean coefficient of friction are given below:-

Speed (kmph) 40 60 80 100 110 120 130 140 150 160

Upper limit (µ) 0.380 0.368 0.355 0.342 0.334 0.325 0.315 0.305 0.297 0.290
Lower limit (µ) 0.200 0.198 0.193 0.188 0.184 0.180 0.177 0.174 0.172 0.170

Specification No. MP.0.0100-10 (Rev - 05), April ’2020 Page 11 of 17

Specification of Non-Asbestos High Friction Composition Brake Blocks For WDG4 & WDP4 Diesel Locomotives

Annexure IV

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 Specification of Non-Asbestos High Friction Composition Brake Blocks For WDG4 & WDP4 Diesel Locomotives

Annexure V
Test Methods

Test methods to check the mechanical, physical and chemical properties of the brake blocks are
described below-

Preparation of specimens

The specimens are obtained from the brake blocks as described in Fig. 7 (A) in this Annexure.
The diagram shows their location, form and dimension.
The specimens for the hardness test are prepared by first cutting sample of 40 mm x 40 mm x 10
mm from the block location as shown in Fig. 7 (A) of this Annexure, and machining the back until
the whole holding plate has been removed and a smooth surface parallel to the top side (braking
side) is obtained. The specimen intended for the hardness test may be used for density, before the
hardness test is carried out and the specimen should be dried suitably to carry out the hardness
test.
When preparing the specimens for measuring the modulus of elasticity, it must be ensured that the
specimens are not overheated. The centre line of the specimen is arranged to be perpendicular to
the upper side of the block. The end surfaces of the specimens are squared off to be perpendicular
to the centre line of the specimen and parallel to one another. 6 specimens of diameter 13 mm and
height 20 mm are measured to an accuracy of 10µm.
For Acetone Extraction test, two specimens of 3 gm each, representatives of the friction material
is reduced to powder form by filling, milling, turning or boring without excessively heating the
material. The powder is then sieved, using the sieves described under clause 3(c) and clause 3(d),
preserving for extraction only the matter having passed through sieve 3(c) and retained by sieve
3(d). Suitable precaution must also be taken to prevent the powered specimen from absorbing
moisture.
For Ash Content test, a specimen of fine particles of 1 gm of the brake block is prepared by
drilling out with 10mm dia. Drill bit without overheating. The drilling is done perpendicular to the
working surface and the depth of the drilled holes shall not be more than 50% of the total brake
block thickness.
The specimens for the Cross breaking strength test, are prepared by cutting sample of 120 mm x
15 mm x 10 mm from the block. The universal testing machine or special testing machine with
suitable Jig & fixture having supporting span of 100 mm may be used for this test.
1. Measurement of Density:

The specimen is suspended by a thin thread from the hook of a weighing scale and its
weight in air is measured to an accuracy of 1 mg. The Specimen is then freely suspended
in water at temperature
Between 18ºc and 24ºc and then weighed again. Before weighing, any air bubbles
adhering to the specimen must be removed which can be facilitated by adding a trace of
detergent to the water.
The density is then obtained by the following formula:-

Weight in Air
----------------------------------------- (gm/cm3)
Weight in Air - Weight in water

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 Specification of Non-Asbestos High Friction Composition Brake Blocks For WDG4 & WDP4 Diesel Locomotives

Density of water = 1 gm/ cm3

2. Hardness Test

The test is carried out in accordance with method A of standard ASTM D 785-65.
For soft materials (< 100 HRX) a non- standard 19 mm ball is used in order to prevent
vide scatter. The minimum (Initial) load is 10 kgf (98.0665 N), the maximum (total) load
is 60 kgf (588.399 N).

The test scale is called "X".

For hardness value greater than 100 HRX, standard scale "R" is recommended.
Method A (scales "X" and "R").
After putting the specimen into position, the minimum load of 10 kgf is applied and the
small pointer is set to zero within 10 seconds.
The large pointer is set to (B) 30 on the red scale within 10 seconds after the application of
the minimum load and immediately after setting the dial, the minimum load of 10 kgf
(98.0665 N) is increased to the maximum load of 60 kgf (588.399 N). The maximum load
is then reduced to the minimum load after 15 seconds.
The Rockwell hardness HRR /HRX is read off on the red scale 15 seconds after the
reduction of the maximum load.
The hardness value is obtained as follows:
Hardness value = Direct reading is noted.
Number of measurements and calculation of hardness:
Nine measurements are obtained on the two surfaces. Five measurements are to be
obtained from upper surface & four measurements are to be obtained 5mm below the
original upper surface. The minimum distance between two penetrations or between one
penetration and the edge of the specimen shall be 10 mm. The arithmetical mean of these
values is the surface hardness.

3. Acetone Extraction Test:

The following Materials and equipment are required:

a) Pure acetone
b) Apparatus for crushing the specimen into powder
c) A sieve with a nominal mesh of 425 µm in accordance with ISO standard 565 (1)
d) A sieve with a nominal mesh of 250 µm in accordance with ISO standard 565 (1)
e) An analytical scale with an accuracy of 0.001g
f) A Soxhlet extraction apparatus, which has been shown to produce similar results.
g) A drying oven with air circulation adjustable to 50 ±2ºC

Test Procedure:
Two portions of the sieved material must be tested. One specimen of approx. 3 gm is
weighed to an accuracy of 0.01 gm on calibrated filter paper with large pore size or in a

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 Specification of Non-Asbestos High Friction Composition Brake Blocks For WDG4 & WDP4 Diesel Locomotives

thin extraction crucible. The use of whatman filter paper is considered acceptable for this
purpose. After covering the crucible, or the filter paper containing the specimen, so that
none of the powder can escape, the specimen placed into the siphon of the extraction
apparatus. The condenser, siphon and flask, into which 50 ml to 200 ml of pure acetone
has been filled, are then assembled. Heating is regulated so that siphoning occurs 20 to 30
times per hour and extraction is continued for at least six hours. At the end of this period
the flask is withdrawn and the content is transferred to a smaller flask having previously
been weighed to an accuracy of 0.001 gm. The empty flask is rinsed with approximately
20 ml acetone, which is then added to the extract.

The acetone is then evaporated by a suitable method, taking care that the temperature does
not exceed 50 ºC. The receptacle holding the residue is then placed into the oven, where it
remains for 30 minutes at a temperature of 50±2ºC. The receptacle is then removed from
the oven, cooled in a dryer to room temperature and weighed. Heating, cooling and
weighing is repeated until a consistent mass is obtained, i.e. until the difference between
two successive weighing does not exceed 0.003 gm.

The specimen content of matter soluble in acetone is obtained in the form of a mass
percentage by applying the following formula:

m1
----- x 100
m0

Where:
m0 = Mass of the test specimen in gm.
m1 = Mass of dry extract in gm.

The arithmetical mean of the values obtained from the two portions of the test specimens
is considered to be the specimen content of matter soluble in acetone.

4. Modulus of elasticity (Compression):

The specimens are submitted to test on Rockwell hardness tester, on which the ball has
been replaced by a cylindrical mandrel of 13.3 mm diameter.

The minimum (initial) load is 10 kgf (98.0665 N) and the maximum (total) load is 35 kgf
(343.233 N).

Before the test is started, the deflection of the test apparatus between minimum and
maximum load is measured without the test specimen.

The following test sequence is applied to each as shown in the clause 7 (B).

The specimen is placed centrally underneath the mandrel, the minimum load is applied and
the dial is again set to zero (black scale). The maximum load is then applied for 45
seconds, followed by an application of the minimum load for a further 10 seconds. The
dial is again set to zero and the maximum load is applied again. The reading is taken, when
after approximately 10 seconds the movement of the pointer suddenly slows down.

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 Specification of Non-Asbestos High Friction Composition Brake Blocks For WDG4 & WDP4 Diesel Locomotives

The deflection of the apparatus is then subtracted from this reading and the net deflection
expressed in scale graduations is multiplied by two in order to obtain the depression Δh of
the specimen in µm.

The modulus of elasticity E (mean value of the results obtained with the 6 specimens) is
then calculated by the formula:

3.122 x 105 x h
E = -------------------------- N/ mm²
d² x Δh

Where

h = Height of specimen (mm)

d = Diameter of specimen (mm)
Δh = Depression of specimen (µm)

5. Ash content:

Procedure:

Weigh previously ignited and cooled empty crucible (without lid) and record the weight
W1. Load the drilled particles of 1 gm in pre- weighed crucible and weigh to an accuracy
of ± 0.1 gm (W2). The crucible containing the sample is placed in the muffle furnish at
825± 25 ºC and left for 2 hours.

After ignition, the crucible shall be removed, cooled in a desiccators and weigh (W3). The
ash content shall be calculated as follows.

W3 – W1
Ash content in % = -------------- x 100
W2 – W1
Where
W1 = Weight of the crucible in gm
W2 = Weight of the crucible and sample in gm
W3 = Weight of the crucible and sample (after ignition) in gm

6. Cross breaking strength:

The test shall be carried out at room temperature. The specimen shall be placed
symmetrically across two parallel supports on UTM or special testing machine. Distance
between supports shall be of 100 mm.

The load shall be applied squarely across the width of the specimen. The load shall be
increased steadily so that the specimen fractures. Record the load in kg-f.

The cross breaking strength of the specimen is then obtained by the following formula: -
WxL
Cross breaking strength = 1.5 x ----------
B x d²
Where

Specification No. MP.0.0100-10 (Rev - 05), April ’2020 Page 16 of 17

Specification of Non-Asbestos High Friction Composition Brake Blocks For WDG4 & WDP4 Diesel Locomotives

W = Load in kgf
L = Distance between jaws of cross break jig
B = Width of the specimen (cm)
d = Thickness of the specimen (cm)

Figure 7 (A) Location, Form and Dimensions of Test Specimens

Reading

35

Load (kg)

10
Dial to Zero

0 10 55 65 75 85
Time
Figure 7 (B) Test Procedure For Determining The Modulus Of Elasticity (E)

Specification No. MP.0.0100-10 (Rev - 05), April ’2020 Page 17 of 17