Railways presentation.pptx is on advance material usage to reduce weight and improve corrosion resistance

Stainless steel usage in Railway coaches and wagons- An overview

1. MATERIAL FOR ROLLING STOCKS - AN OVERVIEW

2. ABOUT ME I am known as Ananthanarayanan. A graduate in Mechanical Engineering in year 1969 from Kerala University. After 2 years of plant training, started the work in the Stainless Steel fabrication shop at Atomic Energy, Mumbai. Joined Steel Authority of India in the year 1980 at their Stainless project at Salem. Was attached to the Product Development and Application Department. Took Voluntary retirement in the year 2002. Now enjoying retired life combined with Independent Technical Consulting in the area of Stainless Steel.

3. Iron and Steel are the most commonly used fabrication material

4. Why because…… Abundantly available Lower cost Easy to fabricate, cast and forge Good strength Easy for ameliorating the properties by adding alloying elements and heat treatment Recyclable & eco friendly

5. DEFICIENCIES IN THE PROPERTIES OF STEEL

6. Yes… More prone to general & other forms of corrosion. Corrosion protection processes are costly and time consuming. Higher strength with compromise in workability.

7. DO WE HAVE ANY CHOICE?

8. Yes. Other metals like Aluminum, plastics etc which again have different sets of limitations of fabricability, cost, strength, availability, recyclability, ecology

9. VARIATIONS OF IRON & STEEL LIKE STAINLESS STEEL

10. ADVANTAGES OF SS While normal steel is Ferritic with body centered cubic structure, SS is available in both BCC (Ferritic) & FCC (Austenitic) structures. Austenitics are cold work hardenable (Higher strength without compromising workability) General corrosion resistance. Fabricable, recyclable, indigenously available, eco – friendly Costly per kg, but cheap

11. HOW IS IT POSSIBLE?

12. INTERNATIONAL DATA

13. INTERNATIONAL SCENARIO COACH Basel – Switzerland Grade : Ferritic 1.4589

14. Grade 301L

15. Grade 1.4003 & 304

16. Grade 304

17. Grade 301LN

18. Railcars made of UNS S20100 or UNS S20153 alloys have long-lasting strength and beauty

19. NIROSTA 4003

20. Stainless Steel coach DIN 5512 (IR-CK-201)

21. METRO COACH (301L UNPAINTED)

22. SS IN INDIAN RAILWAYS 1965 – Toilet pan, wash basin in SS 304 1984-85 – Trough floor in SS 301 1990 – Toilet inlays in SS 304 1990 – LHB Coach in SS in DIN 5512 – 1.4003 1995 – Internal furnishings in SS 304 1997 – IRS M 44/97 specs for wagons 1998 – Box N wagon in SS - 44/77 2000 – CK-201 specs of SS for coaches 2000 – 44/97 used for structural in ICF designed coaches.

23. ALL SS COACHES 2003 – Unpainted metro coaches in SS 301L by BEML. 2010 – Unpainted EMU Coach by BEML. 2010 – SLIP FREE SS flooring in EMU Coaches

24. History of Ferritic SS for Wagons/Coach 1980’s – developed in South Africa and UK as 3 CR12 grade utility SS for coal/ore transportation. (low carbon, 11% Cr and Titanium) 1990’s – Modified 3 CR12 for better toughness (low carbon, 11% Cr, 0.3 minimum Ni, Ti removed) DIN 5512 of German Spec for railway SS specify this grade for freight wagons and passenger coach as 1.4003 LHB specifies DIN 5512 (1.4003) for new coach design in India. LHB approves Indian manufacturer. 1997 – IR specifies 44/97 (containing Ti max for trial wagons) 2000 – ASTM spec UNS – 40977 for Utility Ferritic SS (low carbon, 11% Cr, minimum Ni, no Ti) 2001 – IR specifies in CK – 201 utility Ferritic matching 1.4003 2005 – Internationally EN 1.4003 and UNS – 40977 specifications followed for utility grade Ferritic SS (Low carbon, 11% Cr, 0.3 min Ni and NO Ti)

25. Railway Coach Shells are made of following Stainless Steel Grades 409 M 301L 201L (Nickel Free) (Nickel 6-8%) (Nickel 4-5%) & The Surface Treatment Depends on the Stainless Steel Grades Selected for the Shell Components

26. Basic Difference Between The Three Grades of Stainless Steel Cheaper than 301L Costlier Cheapest of the Three Cost Very Good Very Good Very Good Weldability No No Yes For aesthetics Surface Protection Good Good Fair General Corrosion Resistance Very Good Very Good OK Ductility (Workability) Yes (Cold Workable) No Higher Strength Levels No No Yes Ferro Magnetism 201L 301L 409M Property

27. Chemical Composition Utility Ferritic SS Element % X2CrNi12(1.4003) EN 10088 - 2 ASTM S40977 DIN 5512 Part 3 X2Cr11 IR CK – 201 X2CrNi12 (409M) 2002 IRS M 44/97 Carbon Manganese Phosphorous Sulphur Silicon Chromium Nickel Nitrogen Titanium 0.03 max 1.50 max 0.04 max 0.015 max 1.0 max 10.5 – 12.5 0.3 – 1.0 0.03 max Nil 0.03 max 0.5 – 1.5 0.04 max 0.015 max 1.0 max 10.5 – 12.5 0.3 – 1.0 0.03 max Nil 0.03 max 0.5 – 1.5 0.04 max 0.03 max 1.0 max 10.5 – 12.5 0.3 – 1.0 0.03 max Nil 0.03 max 0.8 - 1.5 0.03 max 0.03 max 1.0 max 10.8 – 12.5 1.5 max Nil 0.75 max

28. Mechanical Properties Utility Ferritic SS Property X2CrNi12(1.4003) EN 10088 - 2 ASTM S40977 DIN 5512 Part 3 X2Cr11 IR CK – 201 X2CrNi12 (409M) 2002 IRS M44/97 Yield Strength (MPa) Tensile Strength (MPa) Percentage Elongation 280/320 450 - 650 20 320 450 - 600 18 - 20 320 450 – 650 20 350 - 450 500 25

29. Chemical Composition Austenitic SS Element % 304 (1.4301) 301L (1.4318) 201L (1.4371) Carbon Manganese Phosphorous Sulphur Silicon Chromium Nickel Nitrogen Titanium 0.07 max 2.0 max 0.045 max 0.03 (0.015) max 0.75 (1) max 17.5 – 19.5 8 – 10.5 0.10 (0.11 Max) Nil 0.03 max 2.0 max 0.045 max 0.03 (0.015) max 1 max 16 – 18 (16.5 – 18.5) 6 – 8 0.20 (0.1 – 0.2) max Nil 0.03 max 5.5 – 7.5(6 - 8) 0.045 max 0.03 max (0.015) 0.75 max (1) 16 – 18 (16 - 17) 3.5 – 5.5 0.25 max (0.15 – 0.2) Nil

30. Mechanical Properties (annealed condition) Austenitic SS Grade Tensile Yield Elongation Strength Strength % MPa MPa -------------------------------------------------------------------------------------------- 201L 655 260 40.0 301L 550 220 45.0 304 515 205 40.0

31. Mechanical Properties Strain Hardened Austenitic SS 301L & 201L Temper UTS min. MPa YS min. MPa Elongation min. % Low Tensile LT (2B Finish) 700 340 45 Special Tensile ST 760 415 35 Medium Tensile MT 830 550 25 High Tensile HT 1,000 750 20

32. NUANCES OF STAINLESS STEEL

33. SELECTION OF RIGHT GRADE AND PROCESS OF FABRICATION PLAY AN IMPORTANT ROLE IN GETTING VALUE FROM STAINLESS STEELS

34. STEEL IS MADE STAINLESS BY ADDITION OF CHROMIUM (11%) NICKEL, MOLY ETC.

35. WHEN IN CONTACT WITH ATMOSPHERE CHROMIUM FORMS IRON-FORMS PASSIVE CHROMIUM RUST-IRON OXIDE OXIDE STAINLESS STEEL CARBON STEEL RESISTS CORROSION RUSTS & CORRODES BY FORMING CHROMIUM BY FORMING IRON OXIDE LAYER OXIDE LAYER ON SURFACE ON SURFACE

36. BEHAVIOUR OF MILD STEEL AND STAINLESS STEEL IN NORMAL ATMOSPHERE

37. - + GALVANIC CORROSION ANODE CATHODE NEED * DIFFERENT METALS * ELECTROLYTIC CONTACT THE METAL WHICH IS - LESS NOBLE - LESS PASSIVE - MORE ACTIVE - LESS NOBLE - LESS PASSIVE - MORE ACTIVE0 GALVANIC SERIES GOLD MONEL STAINLESS TYPE 316 STAINLESS TYPE 304 STAINLESS 430 SILVER ALUMINIUM BRONZE COPPER BRASS CAST IRON CARBON STEEL ZINC MAGNESIUM BECOMES THE ANODE THE CATHODE - CORRODES AT INCREASED RATE - IS PROTECTED - CORRODES LEAST OR NIL

38. EFFECT OF COLD WORK ON MECHANICAL PROPERTIES OF 301/304 STAINLESS STEEL YIELD AND TENSILE STRENGTH MPa COLD WORK, PERCENT ELONGATION PERCENT 20 40 60 40 80 5 200 400 600 800 1000 1200 1400 TENSILE STRENGTH YIELD STRENGTH ELONGATION

39. :::::::: :::::::: SCHEMATIC ILLUSTRATION OF SENSITIZATION WITHIN THE HAZ, WITH ASSOCIATED CHROME CARBIDE PRECIPITATION AND CHROMIUM DEPLETION AT THE GRAIN BOUNDARIES. WELD DEPOSIT HAZ PARENT METAL SENSITIZED REGION CORROSION ALONG AND AROUND THE GRAIN BOUNDARIES GRAINS ACTUALLY DISSOLVED OUT SCHEMATIC ILLUSTRATION OF SENSITIZATION WITHIN THE HAZ, WITH ASSOCIATED CHROME CARBIDE PRECIPITATION AND CHROMIUM DEPLETION AT THE GRAIN BOUNDARIES. WELD DEPOSIT HAZ PARENT METAL SENSITIZED REGION CORROSION ALONG AND AROUND THE GRAIN BOUNDARIES GRAINS ACTUALLY DISSOLVED OUT

40. 1 X 3 2 5 5 10 20 30 10 30 M+F F+M M M +A A = AUSTENITE CHORIMIUM EQUIVALENT (%Cr+%Mo+1.5 x %Si+0.5 x %Nb) NICKEL EQUIVALENT(%Ni+30 x %C+30 x %N+0.5 x %Mn) SCHAEFFLER-DE LONG DIAGRAM SHOWING THE FERRITE CONTENT OF THE WELD METAL 20 15 25 5 15 25 F = FERRITE M = MARTENSITE CARBON STEEL M+A+F 100% F 40% F A+F 4 12 FN 6 FN 2 FN OFN - WELD METAL X - SHEET & PLATE X

41. Easy Identification of SS grades Identifying SS from Chrome Plated Steel

42. Identifying 304 & 316 grade SS

43. Identifying 304 & 316

44. Identifying different SS 430 grade SS 4 % Nickel SS 304 Grade SS 1 % Nickel SS 2 % Nickel SS

45. CLEANING OF SS WELDS

46. Why Low Carbon in SS

47. AT LOWER CARBON CONTENTS IT TAKES LONGER FOR THE MATERIAL TO BE SUSCEPTIBLE TO INTERGRANULAR CORROSION 0.2 0.5 1.0 5 10 50 100 1000 500 600 700 800 900 TIME, MIN TEMPERATURE ºC 1h 10h C=0.08 C=0.06 C=0.05 C=0.03 C=0.02

48. SCHEMATIC ILLUSTRATION OF THE THREE ZONES OF WELDING AND THE RELATED CONFINED AREA OF HIGH TEMPERATURE WELD METAL HEAT AFFECTED ZONE PARENT METAL(UNAFFECTED) WELD ZONE TEMPERATURE(ºC) ROOM TEMPERATURE MELTING POINT

49. EFFECT OF CHROMIUM CONTENT ON CORROSION RATE % CHROMIUM 2 4 6 8 10 12 14 16 0.025 0.050 0.075 0.100 0125 0.150 0.175 0.200 CORROSION RATE mmpy

50. SS USED ABROAD FOR RAILWAY APPLICATIONS

51. The effect of nickel price on the price difference between AL 201HP™ alloy and Type 304 based on the Ni raw-material surcharge [2]

52. Samples of UNS S20100 alloy and Type 304 following 100 hours of exposure in a salt spray test [15] UNS S20100 Type 304

53. From NIROSTA 4003 Type 4003 provides good corrosion resistance, excellent abrasion resistance, hence does not need coating or painting systems to be applied for performance reasons. For aesthetic reasons it may be desirable in some applications to apply paint, especially as type 4003 will tend to discolor in corrosive conditions. Type 4003 has exceptional under-paint corrosion resistance and will continue to resist corrosion even where the paint coat has been damaged. Normal preparation is required such as ensuring a clean surface free of grease and other contamination. A primer coat is recommended for cold roll material due to its smoother surface, but hot rolled 1D finish material may be suitably painted in a single coat .

54. Dull Satin Finish for Painting

55. AT HIGH TEMPERATURE – STRENGTH UGINE – F12

56. Comparison of Moon Rock V/s Slip Free Finishes for Floor Applications

57. Parameter Moon Rock Finish Slip Free Finish Grade SS 430 SS 304/ SS 430 Type  2 dimensional 3 dimensional Rigidity Low 250 Mpa (passed through one etched and one plain roll)    High 375 Mpa (passed thru  male/female deep engraved rolls)            Relief Low – 270 N/mm² (depth is  around 0.15 mm) High – 400 N/mm²(depth is around 1.5 mm minimum) Over the relief thickness will be around 2.5mm Slippage High possibility (top surface is plain with ditches  at low level )    Least slippage (contoured Surface with ups and downs) Test procedure attached Hardness Lower – Vickers 185 (lesser reduction in pass) Wear Resistance low Higher – Vickers 275 (more reduction due to male /female system ) Wear Resistance High Process of making      Rolled with oil (oil surface possible)  Dry process rolling Suggested thickness  2.5 mm                1.25MM /1.6 mm Weight. per unit area 16 Kg / Sq.Mtr 10 Kg / Sq. Mtr Cleanability  Difficult (dirt accumulates in ditches) Easy and self cleaning (easy flow pattern for water) International Practice Not for flooring                      Best used in flooring Cost Rs.103 / Kg and Rs1648 / Sq. Mtr Rs. 100 / Kg andRs. 1000 / Sq. Mtr

58. Corrosion Comparison

59. 3CR12 South Africa HYFAB 3/12 United Kingdom 1.4003 Germany F 12 N France YUS 410W Japan S41003 USA GRADES SIMILAR TO 409M (IRS)

60. Under the Paint Corrosion Carbon Steel 409M

61. Summary I suggest Change 301 to 301L for all trough floors of coaches (Improves weldability and corrosion resistance Modify IRS – M44 in line with CK 201 to meet International standards For LHB coach use 301L for trough floor and roof Can avoid painting for wagons (if required one primer coat) Avoid heating 4003 panels as it reduces the strength Use dull satin finish 2F for external panel for better paintability and avoid sand blasting Design inner structural members with 201L for metro coaches and use 201L for exterior panel of metro coach with/without painting Design tank wagons with 201L to reduce weight. Use double side embossed slip free finish for flooring and reduce weight Use Stretch forming process for making structural members to avoid wrinkles Use more of spot welding for fixing structural to panel

62. WHAT NEXT Unpainted normal SS coaches (301L panel, 1.4003 structural) Painted normal SS coaches with weight reduction (1.4003 panels, 201L structurals) Painted Cost effective Metro coaches (1.4003 panels, 201L structurals) Tank wagons (Thickness reduction and unpainted) – 201L

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64. Thank You For Your Kind Attention