MATERIALS & WELDING

CONSUMABLES USED FOR COACH

FABRICATION

By
A.GANESH
Sr.Instructor /
HISTORY..

➢ Passenger coach manufacturing started with wooden carriages.

➢ Slowly wood was replaced by mild steel in coach construction.
➢ Transition from Mild steel to corten steel..
➢ Then from corten steel to present day stainless steel.

Various grades of carbon steel and stainless steel materials are used
depending upon area of application.
 MAJOR MATERIALS USED FOR
FABRICATION

➢ Plain Carbon steel

➢ Low alloy steel

➢ Alloy steel (Stainless steel)

CONVENTIONAL COACH EMU COACH

MRVC COACH LHB COACH

 STEEL
- An alloy of carbon in iron (C - 2% max).
- plain carbon steel – contains C, Mn, Si, S & P.
- Low alloy steel - alloying elements in minimum quantities. (<7%)
- Alloy steel – alloying elements in appreciable quantities. (>7%)

CARBON STEEL

Low carbon steel Medium carbon steel High carbon steel

C : 0.01 – 0.3% C : 0.3 – 0.55% C : 0.55 – 1.6%

Very Low carbon steel Mild steel

C : 0.01 – 0.15% C : 0.15 – 0.3%
 IMPORTANT MATERIAL PROPERTIES

➢ STRENGTH – UTS, Yield strength

➢ HARDNESS – Hardenability
➢ DUCTILITY - % Elongation, % Reduction in Area
➢ TOUGHNESS – Notch impact strength
➢ FATIGUE STRENGTH
➢ CREEP RESISTANCE
➢ MALEABILITY
➢ FORMABILITY, MACHINABILITY
➢ WELDABILITY
➢ CORROSION RESISTANCE
 EFFECTS OF ALLOYING ELEMENTS IN
STEEL

➢ CARBON – Hardness, Strength, Hardenability,

➢ MANGANESE – Deoxidiser, desulphuriser, hardenability
➢ SILICON – Deoxidiser, mild hardenability, fluidity
➢ CHROMIUM – Hardness, Strength, corrosion resistance
➢ NICKEL – Ductility, toughness, High temp. strength
➢ MOLYBDENUM – Hardness, Strength, High creep resistance
➢ VANADIUM – Hardness, creep resistance
➢ SULPHUR – often considered as impurity, improves machinability
➢ PHOSPOROUS - often considered as impurity
OVERVIEW OF MATERIALS USED IN ICF

➢ BOGIE FRAME FABRICATION

➢ EMU bogie frames
➢ LHB bogie frames

➢ COACH SHELL FABRICATION

➢ EMU coaches
➢ LHB type Coaches
 IS: 2062/2011
(HOT ROLLED MEDIUM & HIGH TENSILE STRUCTURAL STEEL)

Chemical C Mn Si P S Cu C.E
composition
(%)
E250A 1.5 0.04
0.23 0.40 0.045 - 0.42
5
E250BR 0.04
0.22 1.5 0.40 0.045 - 0.41
E250B0 5
E250C 1.5 0.04
0.20 0.40 0.040 - 0.39
0
UTS YSt % El CHARPY IMPACT (J)
E250CuC**
(MPa) (MPa) 1.5 0.04
0.20 0.40 E250BR 0.040
E250A E250C 0.39
E250B00.17-0.38
0
410 250 23 N.R 27 @ RT 27@0oC 27@-20oC

USES: Bogie frame assembly , LS beam assembly, Bogie & Body bolster
assembly of conventional & EMU coaches.
BOGIE FRAME ASSEMBLY

IS:2062 – Conventional bogie

frames, EMU bogie frames.
 WELDABILITY & CARBON EQUIVALENT
Weldability
“Weldability is capacity of a metal to be welded under fabrication condition imposed
into specific suitably designed structure and to perform satisfactorily in the intended
service.” – AWS

* We can say a steel is weldable if

- there is no crack formation (welding & service)
- strength of weld matches with that of base metal

* Major Factors Affecting Weldability:

Parent metal composition, thickness, weld metal composition, welding process,
welding procedure.
C.E = %C + %Mn + %(Cr + Mo + V) + %(Cu + Ni)
6 5 15
Limits of carbon equivalent (C.E):
C.E < 0.35% - steel can be welded without any specific precautions
C.E : 0.35 to 0.55% - Preheating and / or use of LH electrodes
C.E > 0.55% - Preheating + LH electrodes + PWHT
 EN 10025 – 5
HOT ROLLED STRUCTURAL STEEL WITH IMPROVED
ATMOSPHERIC CORROSION

Chemical C Mn Si Ni Cr Cu P,S Mo Zr
Composition (%)
Grade : 0.16 0.5 0.4 0.25 0.03
S355J2W+N 0.50 0.65 0.3 0.15
max to to to Max
max max max max
1.5 0.8 0.55

Mechanical properties Grade: S355J2W+N

Tensile Strength (Mpa) 470 – 630
Yield strength (Mpa) 355 min
% Elongation 20 min
Impact strength 27J at -20oC
Major components:
FIAT Bogie frame – Upper /Lower web, inner/outer web and stiffeners
FIAT Bogie bolster – Upper/ Lower web, side web, vertical damper support & stiffeners
Train 18 bogie frame components, transom components, body bolster components,
components of Underframe headstock & body bolster of Srilankan metro coaches
 DIN 1630
SEAMLESS CIRCULAR TUBES OF NON ALLOY STEELS WITH
VERY HIGH QUALITY REQUIREMENTS

Chemical Composition (%)

Grade C Mn Si P S

St 52.4 0.22 max 1.6 max 0.35 max 0.04 max 0.035 max

Mechanical properties Grade: St 52.4

Tensile Strength (Mpa) 500 – 650
Yield strength (Mpa) 355 min
% Elongation 21% min (longitudinal), 19% min (transverse)
Impact strength (min) 43J at +20oC (long), 27J at + 20oC (trans)

Major components:
Brake beam tube of FIAT Bogie frames
LHB BOGIE FRAME – EN 10025-5
TRAIN 18 BOGIE FRAME

LHB FIAT BOGIE FRAME

 EN 10293 – STEEL CASTINGS
Chemical Composition (%)
C Mn Si Ni P S
G20Mn5 0.17 – 0.23 1.00 – 1.60 0.60 max 0.80 0.02 max 0.02 max
max
G24Mn6 0.20 – 0.25 1.50 – 1.80 0.60 max -- 0.02 max 0.015 max

Mechanical properties G20Mn5+QT G24Mn6+QT1

Tensile Strength (Mpa) 500 - 650 700 - 800
Yield strength (Mpa) 300 min 550 min
% Elongation 22 min 12 min
Impact test (min) 27J at -40oC (or) 60J at RT 27J at -20oC

Major components:
G20Mn5+QT: Yaw damper console, pin bracket, brake support and other bracket parts
attached to FIAT bogies of LHB.
G24Mn6+QT1: Bogie Components like Spring pot, traction motor fixing bracket, reaction
rod fixing bracket of train 18 bogies.
 LHB BOGIE COMPONENTS
- LAS
COMPONENT MATERIAL THICKNESS
Top & Bottom EN 10025, Gr-S355J2W+N 12 mm
Flange
Vertical Web EN 10025, Gr-S355J2W+N 12 mm
Ribs EN 10025, Gr-S355J2W+N 8 mm
Brake Beam Tubes DIN 1630 (Gr: St 52.4) OD :168mm, ID :140mm
(Seamless) Length: 2506 mm
Bogie Bolster EN 10025, Gr-S355J2W+N Top, Bottom plate – 10mm
Web – 10mm
Inner Ribs – 8 mm
COACH SHELL MATERIALS
IRS M 41: 97 (Corten steel)
CORROSION RESISTANT STRUCTURAL STEEL FOR ROLLING STOCK

Chemical C Mn Si Ni Cr Cu P S
Composition (%)
0.1 0.25 0.28 0.20 0.30 0.35 0.075
0.03
max to to to to to to
Max
0.45 0.72 0.47 0.60 0.60 0.14

Mechanical properties Hot rolled Cold rolled

Tensile Strength (Mpa) 480 min 440 min
Yield strength (Mpa) 340 min 300 min
% Elongation 22 min 26 min

Major components:
1. Sidewall, End wall, roof, stiffeners, cantrails, bodypillar, U/F Headstock, Sole bar,
cross bearers, etc., of conventional coaches and EMUs.
2. Under frame components (Headstock, sole bar, cross bearers, etc.,) of LHB,
Srilankan Metro and Train 18 coaches.
CORTEN STEEL
CORTEN STEEL
CORTEN STEEL
ALLOY STEEL
(STAINLESS STEEL)
 ADVANTAGES OF STAINLESS
STEEL
➢ High strength
➢ High Corrosion resistance
➢ Better Aesthetic look
➢ Low on Maintenance
➢ High temperature applications
➢ Good steel
Stainless toughness at low
can resist temperatures
corrosion in coastal, saline and other
chloride bearing environment.
 COACH MATERIAL LIFE

MILD STEEL 5–6 Requires high

YEARS maintenance

CORTEN 20 YEARS Corrosion repairs

STEEL in every 7-8years

STAINLESS > 40 YEARS Low Maintenance

STEEL
 STAINLESS STEEL – CORROSION
RESISTANCE MECHANISM
The high corrosion resistance of SS is due to the naturally
occurring chromium oxide film on the surface of the steel.
The film is extremely thin & tightly adherent to the metal.

SELF HEALING PROPERTY

chromic oxide
Thin chromic layer removed
oxide layer

Instantaneously Cr2O3
layer forms again

The film is rapidly self repairing on damage by abrasion,

cutting or machining.
 STAINLESS STEEL - CLASSIFICATION
- An alloy steel containing minimum 10.5% Cr.

STAINLESS STEEL

AUSTENITIC FERRITIC MARTENSITIC DUPLEX PH

 FERRITIC STAINLESS STEEL

➢ Ferritic Microstructure. Attracts to Magnet. BCC structure.

➢ Also termed as straight chrome steels.

➢ Contains 10.5% to 30% Chromium, upto 0.2% C, no nickel.

➢ Cannot be hardened on heat treatment.

➢ Relatively inexpensive comparing with other SS types.

➢ AISI 4xx series – AISI 405,409,409M, 430, 442 & 446.

➢ Low toughness on weld due to HAZ grain growth.

In ICF, FSS is used in LHB coaches, Train 18 coaches

SS 409M / IRS M44 (Ferritic Stainless steel)
Spec : RDSO CK 201, Grade: X2 Cr Ni 12

Chemical
C Mn Si P S Ni Cr
Composition
SS 409M 0.3 – 10.5 –
0.03 0.5 – 1.5 1.0 0.04 0.03
(X2 Cr Ni 12 ) 1.0 12.5

UTS (Mpa) YST (Mpa) % El

SS 409M 450 – 650 320 min 20 min
(X2 Cr Ni 12 )

Applications:
Side wall , end wall, body pillars, stiffeners of SS coaches like LHB,
Kolkata Metro & Train 18 coaches.
Structural members of Side wall, endwall and roof of Srilankan Metro.
LHB Side wall made
of SS409M

LHB End wall made

of SS409M
 AUSTENITIC STAINLESS STEEL

➢ Austenitic microstructure at all temperatures. FCC structure, Non

magnetic
➢ Austenitic S.S series contains 16-26% Cr, 8-24%Ni + Mn, upto
0.4%C, and small amounts of Mo, Ti, Nb and Ta.
➢ Good strength, High toughness & ductility over a wide
temperature range.
➢ Good corrosion resistance.
➢ AISI 2XX and 3XX series. Also called Cr-Ni – Mn steels.
➢ Eg: AISI 201, 202, 301, 301L, 304, 316, 321, 347 etc.
➢ Can be easily welded compared to other types of S.S.
➢ Relatively expensive due to the presence of Nickel .
 AUSTENITIC STAINLESS STEELS
Spec : RDSO CK 201

Chemical
C Mn Si P S Ni Cr Mo
Composition
SS 301 0.08 2.0 1.0 0.045 0.03 6–8 16 – 18 --
SS 304 0.07 2.0 1.0 0.045 0.03 8.5 – 10.5 17 – 19 --
SS 316 0.07 2.0 1.0 0.045 0.03 10.5 -13.5 16 – 18 2 –2.5

SS 301 SS 304 SS 316

RDSO grade X2 Cr Ni N 18 7 X5 Cr Ni 18 10 X5 Cr Ni Mo17 12 2

UTS (Mpa) 600-900 550-750 550-700

YST (Mpa) 350 min 235 min 255 min
% El 40 min 40 40 min

Uses: 301 - Trough floor in conventional BG coaches

304 – Corrugated Roof sheet & Trough floor sheet of LHB coaches,
lavatory inlay, pantry car equipment etc..
316 – water tank in LHB, bio toilet system
Stainless steel to ASTM A 666 Gr 301L
(1/8 Hardened)
Austenitic Stainless steel

% Chemical Composition

C Mn Si P S Ni Cr N

0.03 2.0 1.0 0.045 0.03

6–8 16 – 18 0.20 max
max max max max max

Mechanical properties
UTS (Mpa) YST (Mpa) % Elongation
760 min 415 min 35 min

USES:
Sidewall sheet, end wall sheet, corrugated roof sheet, Door corner sheet,
carlines of Srilankan Metro coaches.
Corrugated roof sheet
made of SS 304 (LHB)
Trough floor welded on
underframe

Corrugated Trough floor

made of SS 304 (LHB)
 LHB Under slung water
tanks made of SS316

Biotoilet tanks made of

SS316
 STAINLESS STEEL COACH (LHB) –
CROSS SECTIONAL VEIW

SS:304

3mm

IRS M: 41

C-K 201 X2CrNi12 - SS:409M C-K 201 X5CrNi1810 – SS:304

GROUPING OF MATERIALS
AS PER ISO 15608
 MATERIAL GROUPS

As per international standard ISO: 15608

Group 1 to 11 Steel & its alloys

Group 21 to 26 Aluminium & its alloys

Group 31 to 38 Copper & its alloys

Group 41 to 48 Nickel & its alloys

Group 51 to 54 Titanium & its alloys

Group 61 , 62 Zirconium & its alloys

Group 71 to 76 Grouping system of cast irons

 GROUPING OF STEELS
GROUP 1 TO 11 (ISO:
15608)
GROUPING OF STEELS (CONTD..)
 ALUMINIUM ALOYS

The alloy designation system is briefly descried below.

First digit- Principle alloying element(s).
Second digit – Variation of initial alloy
Third and fourth digits – Individual alloy variations
➢ 1xxx – Pure Al (99.00%)
➢ 2xxx – Al-Cu Alloys
➢ 3xxx – Al-Mn Alloys
➢ 4xxx – Al-Si Alloys
➢ 5xxx – Al-Mg Alloys
➢ 6xxx – Al-Mg- Si Alloys
➢ 7xxx--Al-Zn-Mg Alloys
➢ 8xxx –Al + Other Elements
 APPLICATIONS OF ALUMINIUM ALOYS

* 1xxx series - electrical and chemical industries

* 2xxx - extremely high strength; aircraft industry and

transportation application

* 3xxx- architectural application, stampings, fuel tanks,

chemical equipment etc.,

* 4xxx - used for in welding, for making brazing alloys, welding

electrodes and complex shaped forgings.
 APPLICATIONS OF ALUMINIUM ALOYS

* 5xxx - welded structures, boat hulls, gangplanks, products

exposed to marine environments. Excellent Ductility - impact
and shock loading.

* 6xxx - good corrosion resistance. Widely used for welded

structures, automotive and marine applications.

* 7xxx - airframe structure, pressure vessels, highly stressed

parts and military applications such as armour plate, portable
bridge etc.,
WELDING CONSUMABLES USED FOR
COACH FABRICATION
WELDING OF MILD STEEL WITH MILD STEEL

Parent Process Welding consumables

Material
AWS RDSO
Mild steel to MMAW AWS A 5.1 IRS M 28
IS:2062, Grade: E 6013, Class- A2 /A3 /A4
EN:10025 E 7018
GMAW AWS A 5.18, IRS M 46
Grade: ER70S6 Class- I wire
S.Gas: 100% CO2 S.Gas: 100% CO2 (or)
(or) 80% Argon + 20% CO2
80% Argon + 20% CO2
SAW AWS A 5.17, IRS M 39
W-1 (wire),
F - 1 (Flux)
 WELDING OF CORTEN STEEL WITH
CORTEN STEEL
Parent Process Welding consumables
Material
AWS RDSO
Corten steel MMAW AWS A 5.5 IRS M 28
to IRS M 41 Grade: E 8018W, Class- D
GMAW AWS A 5.28, IRS M 46*
Grade: ER80SG Class- IV wire
S.Gas: 100% CO2 (or) S.Gas: 100% CO2 (or)
80% Argon + 20% CO2 80% Argon + 20% CO2
SAW AWS A 5.17 IRS M 39
W-1 (wire), F - 1 (Flux)
FCAW AWS A 5.29 # IRS M 46
Grade: E81T1-W2 Class- IV wire

* RDSO recommendation for GMAW of corten steel is IRS M 46 class –IV wire (ER80S-G of AWS A
5.28).However in ICF, class –I wire is used.

# In ICF, FCAW for corten steel is not in use.

 WELDING OF STAINLESS STEEL WITH
STAINLESS STEEL

Parent Process Welding consumables

Material
AWS RDSO
Stainless steel MMAW AWS A 5.4 IRS M 28,
to SS 409M, Grade: E308L-XX/ E309L-XX, Class- M2, M4
301, 304
GMAW AWS A 5.9, IRS M 46,
Grade: E308L/E309 Class- VI / VII
S.Gas: Argon wire
FCAW AWS A 5.22 IRS M 46,
Grade: E308LT1-1/ E309LT1-1 Class- VI / VII
S.Gas: 100% CO2 wire
GTAW Electrode: EWTh-2/EWLa-2 of
AWS A 5.12,
Filler wire: ER308L / ER309L
of AWS A 5.9
S.Gas: 100% Argon
 WELDING OF CORTEN STEEL WITH
STAINLESS STEEL

Parent Process Welding consumables

Material
AWS RDSO
Corten steel MMAW AWS A 5.4 IRS M 28,
to IRS M 41 Grade: E 309L-XX, Class- M4
+
GMAW AWS A 5.9, IRS M 46,
Stainless
Grade: ER309L Class- VII wire
steel to SS
S.Gas: Argon + 1-5% O2
409M, 301,
304 FCAW AWS A 5.22 IRS M 46,
Grade: E309LT1-1 Class- VII wire
S.Gas: 100% CO2
GTAW Electrode: EWTh-2 of
AWS A 5.12,
Filler wire: ER309L of
AWS A 5.9
S.Gas: 100% Argon
 SS ELECTRODES FOR MMAW
(AS PER IRS M 28)
Class Description Ref Std. Grade

M1 For welding of 18/8 SS and its IS: 5206 E19.9R26

equivalent (Heavy coated)
M2 For welding of 18/8 SS and its ,, E19.9LR26
equivalent with low carbon (Heavy coated)
M3 For welding of SS 316 ,, E19.12.2R26
(Heavy coated)
M4 For welding of Feritic S.S like IRS ,, E23.12LR26
M-44, AISI 409M etc. (Heavy coated)
M5 For joining manganese steel liners ,, E18.8MnR26
with steel castings & MS (Heavy coated)
M6 For repair welding of stainless ,, E25.20R26
steel castings. (diesel loco gas (Heavy coated)
inlet casings)

M7 For joining cast alloy, dissimilar ,, E29.9R26

metal combinations (c.s to S.S) (Heavy coated)
 EN 10204
METALLIC PRODUCTS – TYPES OF INSPECTION DOCUMENTS

➢ Specifies the different types of inspection documents to be supplied to the

purchaser at the time of delivery of all metallic products like plates, sheets,
bars, forgings, castings etc.,
➢ Also applicable to non-metallic products

Inspection documents based on non specific inspection

➢ “Type 2.1” – Declaration of compliance with the order

➢ “Type 2.2” – Test report based on non specific

inspection
 EN 10204
METALLIC PRODUCTS – TYPES OF INSPECTION DOCUMENTS

Inspection documents based on specific inspection

➢ “Type 3.1” – Inspection certificate issued by manufacturer, validated by

manufacturers authorized rep. independent of manufacturing dept.

➢ “Type 3.2” – Inspection document prepared by both manufacturers

authorized inspection rep. and the purchasers authorized inspection rep./
inspector designated by official regulations

Eg: EN 15085-4 requires “type 3.1” Inspection document for welds with certification
levels CL1 /CL2
 SUMMARY

➢ STEEL – Plain carbon, low alloy, alloy steel - classification

➢ Important properties, effect of alloying elements
➢ Materials for bogies (EMU & LHB)
➢ Materials for coach shell
➢ Grouping of steel as per ISO 15608
➢ Aluminium alloys
➢ Welding electrodes for various steel combinations
➢ EN 10204 – types of inspection documents
QUESTIONS & DISCUSSIONS