Engineering Materials Used in Locomotive Vehicles

MATERIALS AND METALLURGY
U18AUT3004-R21
Team Members
GOKULARAMANAN S K 21BAU204
RAGHUL P 21BAU213
SIVABHARATHI G 21BAU217
ASSIGNMENT – 1
ENGINEERING MATERIALS IN LOCOMOTIVE VEHICLES
ENGINEERING MATERIALS USED IN LOCOMOTIVE
VEHICLES
INTODUCTION
The locomotive is a powerhouse mounted on a frame that
produces the motive power needed for traction on railways. There are three
distinct locomotives used on the railways, each drawing its power from a
different energy source. In a steam locomotive, the motive power is the
steam generated in a pressure vessel called the boiler. Thus the thermal
energy of fuel is converted into the mechanical energy of motion. In a
diesel locomotive, the motive power is an internal combustion engine,
which uses high-speed diesel oil as its source of energy. An electric
locomotive derives its power from an electric conductor running along the
track.
Types of locomotives
 Steam traction by steam locomotives

 Diesel traction by diesel locomotives
 Electric traction by electric locomotives
Steam engine locomotive
The steam engine consists of a cylinder, piston, and other

moving parts. It converts the heat energy of the steam into rotary energy in
the following manner.
 The steam from the boiler is first admitted into a cylinder fitted with a
valve. The valve is operated mechanically.
 Steam enters into the cylinder on one side from behind a steam-tight
piston that is fitted inside the cylinder. The piston can move forward
and backward.
 The steam exerts a force of several tons on the piston. This force is
transmitted to a crank pin fitted out of center on each wheel (away
from the center of the wheel) through rods and other connections.
The linear motion of the piston is converted into rotary motion and the
wheel starts rotating.
Diesel locomotive
The diesel locomotive works on the principle of a diesel

engine. It uses diesel oil as fuel and combustion takes places inside a
cylinder. The air inside the cylinder is compressed, raising the temperature
of the air. The fuel is injected inside the cylinder, causing spontaneous
combustion. The diesel engine mostly comprises of four-stroke cycles
consisting of suction, compression, ignition, and exhaust. The energy thus
generated is utilized for driving the locomotive
Electric locomotive
In electric locomotives, movement is brought about by

means of electric motors. These motors draw power from an overhead
distribution system through pantographs (joined frameworks conveying
current to an electric train from overhead wines) mounted on the
locomotives. There are different systems for feeding power to these
locomotives, namely 1500-V dc, 750-V dc, 25-kV ac single phase, and ac
three-phase. The most economical way of transmitting and distributing
power is to directly transmit ac power at industrial frequency, whereas the
motors most suited for electric traction are dc series motors. Indian
Railways has motives that have the best of both systems, i.e., locomotives
with dc series motors that collect power at 25 kV ac single-phase at an
industrial frequency of 50 cycles. The voltage is stepped down to a lower
voltage by means of a transformer present inside the locomotive, converted
from 1500 V or 750 V ac to dc by means of silicon rectifiers, and this power
is then fed to the dc series motors inside the electric locomotives.
INTRODUCTION TO MATERIALS
There are thousands of materials available for use in

engineering applications. Most materials fall into one of three classes that
are based on the atomic bonding forces of a particular material. These
three classifications are metallic, ceramic and polymeric. Additionally,
different materials can be combined to create a composite material. Within
each of these classifications, materials are often further organized into
groups based on their chemical composition or certain physical
or mechanical properties. Composite materials are often grouped by the
types of materials combined or the way the materials are arranged
together. Below is a list of some of the commonly classified materials.
SPECIFICATION OF WDP-4 LOCOMOTIVE
Power type Diesel-electric

Model GT46PAC
Gauge 5 ft 6 in (1,676 mm)
Wheel diameter 1,092 mm (43.0 in)
Fuel type Diesel
Fuel capacity 5,000–6,100 L
RPM range 200-954 rpm
Engine type 2 stroke v-16 diesel
Aspiration Turbocharged
Cylinders 16 cylinders
Transmission AC electric
Gear ratio 17:77
Loco brake Air, handbrake, blended Dynamic brake
Power output 4000hp (2980 kw)

COMPONENTS & MATERIALS USED IN WDP-4 LOCOMOTIVE
COMPONENTS OF DIESEL-ELECTRIC LOCOMOTIVE

Bogie frame
A chassis or framework that carries a wheelset, attached to a

vehicle—a modular subassembly of wheels and axles.
Material used- Mild steel or Rolled steel
Coupler head
A mechanism typically placed at each end of a railway vehicle

that connects them together to form a train
Material used- Cast steel
Centre pivot
The center pivot transmits the tractive/braking forces and also

bears the vertical load of super structure.
Materials used- Aluminium

Brake cylinder
It feeds brake fluid into the brake circuit to convert the pressure
on the brake pedal to the hydraulic pressure.
Material used – Aluminium

Coil spring
A coil spring is a spiral-shaped spring that is used in

suspensions or poppet valve mechanisms in vehicles.
Material used- Titanium
Axle box
Axle boxes are the linking design element between the

rotating wheel set and the quasi-static frame of the bogie or running gear of
a railway vehicle.
Materials used- High carbon steel (AISI 1030 steel)
Body
A locomotive frame is the structure that forms the backbone of the

railway locomotive, giving it strength and supporting the superstructure
elements such as a cab, boiler or bodywork.
Materials used- Aluminium

Sand box
A sandbox is a container on most locomotives, multiple units and

trams that holds sand, which is dropped on the rail in front of the driving
wheels in wet and slippery conditions and on steep grades to improve
traction.
Materials used – Steel and Glass
Dynamic brake
Dynamic brakes use the kinetic energy of a train's turning wheels to

create electrical energy, which causes the train to decelerate.
Materials used - copper, Iron, aluminum

COMPONENTS MATERIALS
Engine (2 stroke-v16 engine) - Cast Iron
Rail wheels - High carbon steel
Coupler head - cast steel
Centre pivot - Aluminium
Brake cylinder - Aluminium
Coil spring - Titanium
Axle box - High carbon steel

(AISI 1030 steel)
Locomotive body - Aluminium
Bogie Fame - Cast steel
Dynamic brake - copper, iron ,
aluminium
Sandbox - steel and glass

Properties of Materials
Cast iron
 Hardness – material's resistance to abrasion and indentation

 Toughness – material’s ability to absorb energy
 Ductility – material's ability to deform without fracture
 Elasticity – material's ability to return to its original dimensions after
it has been deformed
 Malleability – material's ability to deform under compression
without rupturing
 Tensile strength – the greatest longitudinal stress a material can
bear without tearing apart
 Fatigue strength – the highest stress that a material can withstand
for a given number of cycles without breaking.
Aluminium
It has low density, is non-toxic, has a high thermal conductivity,
has excellent corrosion resistance and can be easily cast, machined and
formed. It is also non-magnetic and non-sparking. It is the second most
malleable metal and the sixth most ductile.
High carbon steel

It has the highest hardness and toughness of the carbon steels and the
lowest ductility.
Titanium
Titanium alloys have good features such as high specific strength, good
high temperature mechanical properties and excellent corrosion resistance,
thus have been applied in aerospace, transportation, power generation and
chemical industries.
REFERENCES
Railway Engineering by SATISH CHANDRA & M.M. AGARWAL
https://www.nde-ed.org/Physics/Materials/index.xhtml
https://indiarailinfo.com/faq/post/1718
http://www.visualdictionaryonline.com/transport-machinery/rail-transport/diesel-electric-
locomotive/diesel-electric-locomotive_2.php
https://rdso.indianrailways.gov.in/works/uploads/File/
FinalDraft_TechSpec_MP.0.40.99.02_Rev02_CPLiner&HCW.pdf

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MATERIALS AND METALLURGY

 Steam traction by steam locomotives

Steam engine locomotive

The steam engine consists of a cylinder, piston, and other

The diesel locomotive works on the principle of a diesel

In electric locomotives, movement is brought about by

There are thousands of materials available for use in

Power type Diesel-electric

Wheel diameter 1,092 mm (43.0 in)

Fuel type Diesel

Fuel capacity 5,000–6,100 L

RPM range 200-954 rpm

Engine type 2 stroke v-16 diesel

Gear ratio 17:77

Loco brake Air, handbrake, blended Dynamic brake

Power output 4000hp (2980 kw)

COMPONENTS OF DIESEL-ELECTRIC LOCOMOTIVE

A chassis or framework that carries a wheelset, attached to a

Material used- Mild steel or Rolled steel

A mechanism typically placed at each end of a railway vehicle

Material used- Cast steel

The center pivot transmits the tractive/braking forces and also

Materials used- Aluminium

Material used – Aluminium

A coil spring is a spiral-shaped spring that is used in

Material used- Titanium

Axle boxes are the linking design element between the

Materials used- High carbon steel (AISI 1030 steel)

A locomotive frame is the structure that forms the backbone of the

Materials used- Aluminium

A sandbox is a container on most locomotives, multiple units and

Materials used – Steel and Glass

Dynamic brakes use the kinetic energy of a train's turning wheels to

Materials used - copper, Iron, aluminum

Engine (2 stroke-v16 engine) - Cast Iron

Rail wheels - High carbon steel

Coupler head - cast steel

Centre pivot - Aluminium

Brake cylinder - Aluminium

Coil spring - Titanium

Axle box - High carbon steel

Locomotive body - Aluminium

Bogie Fame - Cast steel

Dynamic brake - copper, iron ,

Sandbox - steel and glass

 Hardness – material's resistance to abrasion and indentation

High carbon steel

Railway Engineering by SATISH CHANDRA & M.M. AGARWAL

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