NDT Lab

● Testing of CP B weld joints in finished

components (Bogie frames) by radiography
(100%).
● Testing of casted components(eg LHB
Brake shoe support) procured using
radiography.
● DPT of CP C2 weld joints in Bogie frames
of LHB(10%) and Bogie bolster
● UST of Manufactured axles (1%)

Bogie frames of EMU and LHB are received

from Shop 23 and VB bogie frames from LHB
division
Casted components are received from stores
 Non Destructive testing(NDT)

Volume Radiography
Merits Demerits defect test ,
● Without causing damage to ● Sophisticated Ultrasound
test
the component instrumentation
● Non Invasive ● Hard to interpret Surface Visual test,
● Safe to operate (except ● NDT personnel defect Dye penetrant
radiography) needs to be test, Magnetic
particle test
● Quick experienced and
● Reliable certified(ISO 9712) Subsurface Magnetic
defect particle test
 Radiography Testing (ISO 17636 -2)

Principle - Image formation due to the optical density difference produced from the
internal structure of the component during the transmission of penetrating
radiations( X rays, Gamma Rays)

Type
1) X ray radiography
2) Gamma ray Radiography
 X rays

Voltage - Energy of X ray Types of X ray

Current - Intensity of X ray 1) Characteristic
2) Bremsstrahlung or continuous
IGRED - ROLI 3
 X ray radiography Gamma ray radiography

Have relatively larger wavelength, and relatively lower Have shorter wavelength and high penetrating power
penetrating power

Electricity is required Electricity is not required

Energy and intensity can be adjusted by changing Energy and intensity are constant for a given source
voltage and current respectively

Used for components having thickness less than 62mm Can be used for more thicker components

Units are bulky and cannot be used for intricate and Units are accessible to intricate and remote locations
complex components

They are completely safe when turned OFF They continuously emit radiation

High capital investment but source has a longer life Source have shorter life and frequent replacement is
required
 Radiographic imaging

● More the density of specimen

lighter will be the image
● Lower the density, darker the
image will be.
● Depending on the type of film
used
Factors Governing
1) Source size
2) Source to film Distance(SFD)
3) Film to object distance
4) Alignment of radiation
 Radiation monitoring

Pocket dosimeter

Survey meter
Thermoluminescent
dosimeter badges

Zone monitor
 Dye Penetrant Test (DPT)
(ISO 3452-1)
Principle - Based on the capillary action of Dyes and reverse capillary action(Blotting) upon
application of suitable developer.
Procedure
● Surface preparation - Cleaned using wire brush and lint free cloth, free from oil grease.
● Drying
● Penetrant application - Non fluorescent colour contrast penetrant (RED), sprayed uniformly.
Remained for Dwell time = 10-20 mins
● Excess penetrant removal - Cleaner + Lint free white cloth, wiping in only one direction.
● Developer application - Solvent base/ Non aqueous suspension(white colour), Thin uniform
layer, spray distance of 25-30cms. Developing time = 10- 20 mins.
● Inspection - Linear indication (l>3w), Rounded indication (l<=3w).
Ultrasonic waves - Sound waves/mechanical waves with frequency greater than 20kHz.
UST technique -
● A series of ultrasonic waves each lasting for a few micro-seconds are introduced in the material under
test through a coupling medium.
● These pulses propagate in the material in a very narrow beam until they strike an interface such as the
opposite surface of the test object or an internal defect.
● The pulses are entirely or partly reflected back to the transmitter, which now functions as a receiver. The
receiving probe converts the ultrasonic waves to the electrical energy, which is amplified and displayed
on a display unit (CRT/LCD/TFT) in such a manner as to indicate the time difference between the
transmitted pulses and reflected pulses
● The horizontal scale of display unit is calibrated in terms of distance, hence position of flaw peak on
horizontal scale tells the location of the flaw
● The vertical scale of display unit is calibrated with a standard test piece having artificial flaws of known
size, hence the height of the flaw peak tells about the size of the flaw.
 Ultrasonic flaw
detector(UFD)

FRONT PANEL DESIGN

VIEW
 ASSESSMENT OF UFD
(As per IS 12666)
IIW Block type 1

● LINEARITY OF TIME BASE

● LINEARITY OF AMPLIFICATION
● DEAD ZONE
● RESOLUTION
● MAXIMUM PENETRATION
POWER
● PROBE INDEX
● PROBE ANGLE
 Testing of service axles

Techniques
1) Far end
2) Trace delay
3) Near end low angle
(NELA)
4) High angle
 Tentative COP Echoes from Fillets
1) Direct echo = L
S. No. DETAILS DISTANCE SIGNAL
2) Trajectory 1 = L+((D+d)/2)
(mm) (div.) 3) Trajectory 2 =
L+1.82((D+d)/2)
1. Direct Reflection from axle end 2514 8.4
Echoes from Back end
2. Delayed Reflection from Journal fillet 2397 8

3. Delayed Reflection from Wheel seat outer Fillet 2386 8

4. Direct Reflection from Journal Fillet 2236 7.5

5. Direct Reflection from Wheel seat outer Fillet 2190 7.3

6. Delayed Reflection from Wheel seat inner Fillet 880 3

7. Delayed Reflection from Wheel seat inner Fillet 717 2.4

8. Direct Reflection from Wheel seat inner Fillet 517.8 1.7

 Testing of new axles

C&W AXLES- IRS-R-16/95

LOCO AXLES- IRS-R-43/92

For detecting internal discontinuities in new axles the following three tests are done
after Heat Treatment and Machining of End Face

A. Penetration Test
B. Discontinuity Detection Test
C. Longitudinal Discontinuity Detection Test
A-LONGITUDINAL PENETRATION TEST C. Longitudinal Discontinuity Detection Test
● CALIBRATION- 250
● CALIBRATION- mm.
FULL LENGTH ● SENSITIVITY- PEAK
OF THE AXLE. HEIGHT 60% FROM 3.2
● SENSITIVITY- mm FBH IN THE
PEAK HEIGHT STANDARD BLOCK.
12.5 % FROM ● TESTING BY NORMAL
3.2mm FBH IN PROBE FITTED WITH
THE STANDARD PERSPEX OF
BLOCK. MATCHING
CURVATURE.
B-LONGITUDINAL DISCONTINUITY DETECTION
 Mechanical Lab
Mechanical lab deals with the testing of mechanical properties of
metallic materials used for manufacturing of coaches and testing of
quenching/coolant oils and brake shoes.
● The samples may be received from the stores, inspection, other
railways and design
Frequently tested Materials are
● Steel sheets
● Spring bars
● Chain assembly
● Bolts,Nuts
● Quenching oil
● Brake shoes
● Sole bar
 Hardness tests

Brinell Hardness IS 1500 Tungsten carbide 1kgf - 3000 kgf1 Hardened

(HBW) composite ball components like
Springs

Vickers Hardness IS 1501 Square based 10-4kgf - 30 kgf For hardness

(HV) pyramid diamond survey,
indenter(angle = Microhardness
136°)

Rockwell Hardness IS 1586 HRBW - steel ball Pf = 10kgf

dia = 1.5875 mm Total force = 100
kgf

HRC - diamond Pf = 10kgf

cone Total force = 150
kgf
 Tensile test
(IS 1608)

Obtained properties
1) Ultimate tensile strength
2) Yield strength
3) Elongation
Gauge length* = 5.65⎷area
% Elongation = ((Initial
gauge - final gauge
length)/initial gauge
length)*100
 Bend test
(IS 1599)

● Mandrel dia = 4T

● Span distance = D + 3T

● Observations - No cracks should be

present on the face exposed to tension
Micro Examination

ASTM E112
Macro Examination

Inclusion rating
(IS 4163)
 Spring Lab
Process Temperature( deg
Role of spring lab C)
1) EMCD of Bars (5%) and springs
(100%) End tapering 910 - 930
2) Process control in manufacturing Stamping >850
● Monitoring furnace temperature and
heat treatment process Hot coiling 890 - 920

● Intensity of shot peening Before quenching 830-860

● Phosphating - Pointage and DFT
Quenching oil 40 - 70
● Paint - viscosity and DFT
3) Hardness of springs after heat Before Tempering 80 - 120
treatment( Brinell hardness)
Tempering 400 - 500
 Spring Manufacturing
End tampering &
EMCD Bar testing Hot coiling Quenching
stamping

Tempering Scragging Hardness testing End grinding

Shot peening EMCD spring test Load deflection test Phosphating

Painting Colour coding

 Electromagnetic crack detection (EMCD)
(ASTM E 709 - 2021)

Direct magnetization
Parameters Magnitude

Visible light intensity(Lux) 21.5 (max)

UV A light intensity(uW/cm2) 1000

Conc of fluorescent particle bath 0.1 - 0.4 ml in 100 mL

Direct magnetization current (A) 25 * wire dia of spring

indirect magnetization current (A) 15 * spring dia

Indirect magnetization
Ketos ring QQI shim

Hall effect gaussmeter

Pie field indicator

 Welding Lab
Activities of welding lab
● Welder qualification (ISO 9606)
● Testing of pre production samples
a) Resistance spot weld
b) Laser weld
c) Butt seam weld
● Electrodes testing
From stores
For vendor approval
● IDN/ Inspection samples
 Welder qualification

Acceptance criteria
- Level B of ISO 5817
- For excess weld metal, excess
penetration, excess convexity,
excess throat, excess
asymmetry and undercut , Level
C of ISO 5817

Validity
- 1 year in ICF
- 3 years as per ISO 9606

Test specification Butt weld Fillet weld

Visual test ISO 17637 Mandatory Mandatory
Radiographic test ISO 17636 Mandatory Not Mandatory
Bend test ISO 5173 Mandatory NA
Fracture test ISO 9017 Mandatory Mandatory
 Testing of pre production samples
RSW Samples Standard

Visual test 3 EN 15085 table f-2

Indentation measurement 3 EN 15085 table f-2

Tensile shear strength 3 EN 15085 table f-2

LBW Samples Standard

Visual test 3 ISO 1319 -1

Tensile shear strength 3 ISO 15614 - 11

180 degree face bend 3 ISO 15614 - 11

180 degree root bend 3 ISO 15614 - 11

BSW Samples Standard

Visual test 3 EN 15085 - 3 table f - 2

Transverse Tensile strength 3 UTS > UTS of parent metal

 Electrodes used in ICF

MMAW (IRS M - 28)

Class Parent material

A2,A3,A4 Mild steel

D Corten Steel

M series(M4,M5) Stainless Steel

GMAW/FCAW (IRS M - 46)

Class Parent material

Class I (ER 70S6) Mild Steel and Corten Steel

Class VI/VII (E309L) Stainless Steel

ICF/MD/Spec 110 (E309LT-1) Stainless Steel

 Main Lab
Main lab deals with the testing of furnishing components / materials used for
manufacturing of coaches.
● The samples may be received from the stores, inspection, other railways and
design
Frequently tested Materials are
● Flooring materials
● Panelling materials
● Seats cushions and upholstery
● Rubber items
● Electroplated / Galvanised hardwares
● Electrotechnical components
● Adhesives
● sealants
 Flooring materials
1) Compreg
- RDSO C9407,2007,
Rev03

Type I - <10mm

Type II - >10mm
 2) PVC flooring sheet
- RDSO CG12,2006
 Panelling materials

1) FRP panels

a) ICF/MD/Spec
167A
b) ICF/MD/Spec
350
c) ICF/MD/Spec
385
d) MDTS 133
2) LP sheets (RDSO CK 514) 3) ACP sheets (ICF/MD/spec 234)
 Seats and Upholstery

1) Cushions
a) PU foam (RDSO CG04/2007)
b) Recron/DTDP blocks(RDSO
CK 607)
c) Silicon foam(RDSO
CG13/2013)
2) Rexin(Vinyl coated upholstery fabric)
RDSO/CG 07/2008
Rubber Items Electroplated hardware
items
● Polymer IS 1367 part -11 or IS 1573
identification
a) Pyrolysis (IS 3400 ● DFT
part 22) ● Qualitative test for
b) FTIR (ASTM ) coatings
● Ash content(IS 3400 Zinc
part 22) Chromate
● Shore hardness A Tin
Nickel
Silver
 Fire lab (EN 45545 - 2)

1) Cone calorimeter - ISO 5660 -1

2) Smoke density chamber - ISO
5659 - 2
3) Lateral flame spread - ISO 5658 -
2
4) Flooring radiant panel - ISO 9239
-1
5) Oxygen index test apparatus -
ISO 4589 - 2
6) Horizontal and vertical flame test -
ISO 60695 -11
7) Single flame source apparatus -
ISO 11925 -2
8) Toxicity apparatus - NF X70 - 100
1&2