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Evolution of Steel Body CoachesEvolution of Steel Body CoachesAspects to be considered for Aspects to be considered for selection of material.selection of material.Why Stainless SteelWhy Stainless SteelUse of Stainless Steel in Rail Use of Stainless Steel in Rail Coaches Coaches –– Present Scenario.Present Scenario.Future ScopeFuture ScopeQuality IssuesQuality IssuesConclusion.Conclusion.
EVOLUTION OF STEEL BODY EVOLUTION OF STEEL BODY COACHESCOACHES
Rail coach building technology undergone a Rail coach building technology undergone a sea change over the yearssea change over the yearsEarlier generation of rail coaches Earlier generation of rail coaches –– wooden wooden body over heavy steel body over heavy steel underframesunderframesLater steel body coaches with riveted Later steel body coaches with riveted construction developedconstruction developedIn 1955, ICF manufactured “all steel” coach In 1955, ICF manufactured “all steel” coach body with all welded construction. These body with all welded construction. These coaches incorporated anticoaches incorporated anti--telescopic end telescopic end construction to withstand high impact loads construction to withstand high impact loads to ensure safety for passengersto ensure safety for passengers
ASPECTS CONSIDERED WHILE ASPECTS CONSIDERED WHILE SELECTING MATERIAL FOR SELECTING MATERIAL FOR
APPLICATIONS IN RAILWAYSAPPLICATIONS IN RAILWAYS
DURABILITYDURABILITY
SAFETYSAFETY
LOW MAINTENANCE COSTLOW MAINTENANCE COST
This means:This means:--
The passenger coaches have to withstand complex The passenger coaches have to withstand complex pattern of vibration stresses and strains, wear and pattern of vibration stresses and strains, wear and tear of components and aggressive environment tear of components and aggressive environment for a long period of time.for a long period of time.
The material selected should have sufficient high The material selected should have sufficient high tensile strength so that thinner sections can be tensile strength so that thinner sections can be used which will lead to lesser weight of the coach.used which will lead to lesser weight of the coach.
The material selected should be corrosion resistantThe material selected should be corrosion resistant
The initial cost and life cycle cost should be as low The initial cost and life cycle cost should be as low as possible.as possible.
STAINLESS STEEL STAINLESS STEEL –– THE IDEAL THE IDEAL MATERIALMATERIAL
The following unique characteristics make The following unique characteristics make stainless steel a designer’s delightstainless steel a designer’s delight
CORROSION RESISTANCECORROSION RESISTANCESTRENGTHSTRENGTHTOUGHNESS AND IMPACT RESISTANCETOUGHNESS AND IMPACT RESISTANCEFORMABILITYFORMABILITYHEAT RESISTANCEHEAT RESISTANCEBETTER AESTHETIC LOOKBETTER AESTHETIC LOOKLOW ON MAINTENANCELOW ON MAINTENANCELONG TERM VALUELONG TERM VALUE
CORROSION RESISTANCECORROSION RESISTANCEStainless steel can resist corrosion in coastal, saline, Stainless steel can resist corrosion in coastal, saline,
and other chloride bearing environment.and other chloride bearing environment.
This characteristic singularly accounts for many This characteristic singularly accounts for many technotechno--economic advantages likeeconomic advantages like--
Savings on constructionSavings on constructionProtection against rustProtection against rustLesser weightLesser weightAllowance for corrosion reducedAllowance for corrosion reducedReduced maintenance requirements and less Reduced maintenance requirements and less ‘Down Time’‘Down Time’
STRENGTHSTRENGTHStainless steel hasStainless steel has
––High tensile strengthHigh tensile strength
––Excellent fatigue properties andExcellent fatigue properties and
––Good Good weldabilityweldability
Higher strength to weight ratio of stainless Higher strength to weight ratio of stainless steel makes weight reduction of structures steel makes weight reduction of structures possible, resulting in energy savings.possible, resulting in energy savings.
TOUGHNESS AND IMPACT TOUGHNESS AND IMPACT RESISTANCERESISTANCE
Stainless steel of certain grades have high toughness Stainless steel of certain grades have high toughness from elevated temperatures to sub zero temperatures. from elevated temperatures to sub zero temperatures. Stainless steel is a good absorber of energy and Stainless steel is a good absorber of energy and therefore exhibits higher impact strength.therefore exhibits higher impact strength.NickelNickel--containing stainless steel is not only stronger containing stainless steel is not only stronger than carbon steel or aluminum but also absorbs 2.5 than carbon steel or aluminum but also absorbs 2.5 times more energy than carbon steel when deformed. times more energy than carbon steel when deformed. This makes it ideal for making safe passenger This makes it ideal for making safe passenger compartments with the coach ends designed to absorb compartments with the coach ends designed to absorb large amounts of energy if deformed by collision.large amounts of energy if deformed by collision.
FORMABILITYFORMABILITY
It is possible to bend and form different It is possible to bend and form different shapesshapes
HEAT RESISTANCEHEAT RESISTANCESpecial high Chromium and Nickel Special high Chromium and Nickel alloyed grades resist high alloyed grades resist high temperature and retain strength in temperature and retain strength in elevated temperatures at 1100° c and elevated temperatures at 1100° c and resists breakdown or collapse of resists breakdown or collapse of structure. structure.
This gives valuable time for This gives valuable time for evacuation of passengers in case of evacuation of passengers in case of fire. fire.
Since Nickel containing stainless steel Since Nickel containing stainless steel does not need painting, the threat of does not need painting, the threat of noxious fumes is minimized.noxious fumes is minimized.
BETTER AESTHETIC LOOKBETTER AESTHETIC LOOK
This is one single characteristic This is one single characteristic which scores over other which scores over other materials. Stainless steel bodied materials. Stainless steel bodied coaches do not normally require coaches do not normally require painting and provides good painting and provides good aesthetic appearance. By careful aesthetic appearance. By careful selection of surface finish in selection of surface finish in different patterns, stainless steel different patterns, stainless steel can form excellent material for can form excellent material for furnishing interior coaches.furnishing interior coaches.
LOW ON MAINTENANCELOW ON MAINTENANCE
Stainless steel normally requires Stainless steel normally requires only a periodic wash with soap and only a periodic wash with soap and water to maintain its original water to maintain its original finish.finish.
LONG TERM VALUELONG TERM VALUE
When the total life cycle When the total life cycle costs are considered, costs are considered, stainless steel is often the stainless steel is often the least expensive material least expensive material option available.option available.
AREAS SUBJECTED TO HIGH RATE OF AREAS SUBJECTED TO HIGH RATE OF CORROSION IN PASSENGER COACHESCORROSION IN PASSENGER COACHES
Trough floor:Trough floor:Areas adjacent to lavatory, door ways, below the Areas adjacent to lavatory, door ways, below the longitudinal partition, luggage compartments and kitchen longitudinal partition, luggage compartments and kitchen area of pantry car.area of pantry car.Side wall bottomSide wall bottomAreas below lavatory and between body side pillars.Areas below lavatory and between body side pillars.Sole BarSole BarSole bar in the lavatory area and door ways. Sole bar in the lavatory area and door ways. Body PillarsBody PillarsBottom portion of the pillar near door ways and lavatory Bottom portion of the pillar near door ways and lavatory area.area.
(continued)(continued)
Cross bearersCross bearersJoint between sole bar and cross bearers.Joint between sole bar and cross bearers.Air reservoirAir reservoirCorrosion due to abrasive action due to dust and sand. Corrosion due to abrasive action due to dust and sand. Battery BoxesBattery BoxesCorrosion due to acid action.Corrosion due to acid action.RoofRoofArea around the ventilator opening.Area around the ventilator opening.
HISTORY OF MATERIALS USED HISTORY OF MATERIALS USED BY ICFBY ICF
For trough floor (Austenitic Stainless steel) to AISI 301
During 89-90Trial)
IRS: M 41 &IS: 2062-67, 42 WC
IRS: M 41 Corten Steel(Low Alloy high tensile)
Since 1976
DIN 1621 St. 37-21 & IS: 2062-67, 42 WC
IRS: M 36 (Mild Steel)Since 1967
Above 4.75 mm thick Hot Rolled to DIN 1621 Grade St.37-21
Deep drawn sheets toDIN 1623 Grade St.VIIb/23
Since inception (1955)
PLATESSHEETS
Switch over from mild steel to Switch over from mild steel to cortencorten steel increased the service steel increased the service life from 5life from 5--6 years to 76 years to 7--10 years.10 years.
However, the coach requires However, the coach requires major corrosion repairs 2 or 3 major corrosion repairs 2 or 3 times in its life cycle of 25 years.times in its life cycle of 25 years.
Use of stainless steel has been introduced in the coach Use of stainless steel has been introduced in the coach body construction for various components. These are:body construction for various components. These are:Trough floorTrough floor--1.7mm thick to 1.7mm thick to SpecnSpecn. AISI 301 with 2B/2D . AISI 301 with 2B/2D finishfinish
Stainless steel Lavatory Inlay Stainless steel Lavatory Inlay --2mm thick to 2mm thick to SpecnSpecn. AISI 304 with 2D finish. AISI 304 with 2D finish
Pantry Car Side wall, roof and partition in the kitchen area Pantry Car Side wall, roof and partition in the kitchen area to to SpecnSpecn. AISI 304 . AISI 304
CounterCounter View of Kitchen areaView of Kitchen area
AC Duct of Jan Shatabdi coaches AC Duct of Jan Shatabdi coaches 1mm thick Hammer Tone finish to 1mm thick Hammer Tone finish to SpecnSpecn. AISI 304. AISI 304
Rail Mart and Mini Pantry of Jan Shatabdi CoachesRail Mart and Mini Pantry of Jan Shatabdi Coaches
Side wall partitionSide wall partition -- stripe finishstripe finishRoof Roof -- HammertoneHammertone finishfinishFloorFloor -- Moon Rock finishMoon Rock finish
Stainless Steel Paneling in I AC ToiletsStainless Steel Paneling in I AC Toilets
End Wall End Wall PanellingPanelling
SS Hand Rail, Cross BarsSS Hand Rail, Cross Bars
Luggage RackLuggage Rack
Hyderabad Metro Hyderabad Metro –– Rainwater GutterRainwater Gutter
Stainless Steel Hand HoldStainless Steel Hand Hold
COMPOSITE STEEL SHELLCOMPOSITE STEEL SHELLICF manufactured 3 Pantry Cars during 1996 with composite ICF manufactured 3 Pantry Cars during 1996 with composite steel shell using stainless steel of different grades.steel shell using stainless steel of different grades.
The stainless steel used in various parts of composite coachThe stainless steel used in various parts of composite coaches es areare ––
SS.3041.6mmToilet Inlay
SS.3011.7mm thickTrough floor
SS.409M2mm thickTurn under and lower side wall sheet upto 450mm
SS.409M2mm thickBody Pillar
SS.409M5mm thickSole Bar
Approximately 3.8 metric tones of stainless steel used for each Approximately 3.8 metric tones of stainless steel used for each shellshell
CANT RAIL (CORTEN STEEL M(CORTEN STEEL M--41)41)
BODY PILLAR S.S (409-M)
Service trials conducted on these Service trials conducted on these composite steel shell indicate composite steel shell indicate satisfactory performance.satisfactory performance.
This design will be implemented for This design will be implemented for all the future pantry cars.all the future pantry cars.
ALL STAINLESS STEEL SHELLALL STAINLESS STEEL SHELL
Two Proto Type shells made of all stainless steel Two Proto Type shells made of all stainless steel were manufactured during 1999were manufactured during 1999--20002000Approximately 11 metric tones of stainless steel Approximately 11 metric tones of stainless steel used in the coach body construction.used in the coach body construction.Stainless steel was used for Stainless steel was used for –––– UnderframeUnderframe–– Trough floorTrough floor–– Side WallSide Wall–– End wallEnd wall–– RoofRoof
IMPROVED EMU SHELLIMPROVED EMU SHELLIn order to minimize the corrosion problem and reduce the In order to minimize the corrosion problem and reduce the
failure of coach components, an improved EMU Shell has failure of coach components, an improved EMU Shell has been designed incorporating use of been designed incorporating use of FerriticFerritic/Austenitic /Austenitic stainless steel for the following components. stainless steel for the following components.
Sole BarSole Bar -- 6mm AISI 409M6mm AISI 409MBody PillarBody Pillar -- 2mm AISI 409M2mm AISI 409MSide wall sheet Side wall sheet uptoupto -- 2mm AISI 409M2mm AISI 409Mwindow levelwindow level
Trough floorTrough floor -- 1.7mm AISI 3011.7mm AISI 301Floor sheet of Floor sheet of -- 2.5mm AISI 4302.5mm AISI 430Vendor compartmentVendor compartment
A prototype shell has been manufactured and successfully A prototype shell has been manufactured and successfully tested by applying squeeze loads at the coach ends.tested by applying squeeze loads at the coach ends.
IMPROVED EMU SHELL IMPROVED EMU SHELL
stainless steel for fire proofing of stainless steel for fire proofing of coaches coaches
In order to improve the fire In order to improve the fire resistance of coaches a number of resistance of coaches a number of measures have been taken on trial measures have been taken on trial basis. These include use of stainless basis. These include use of stainless steel in the coach construction. steel in the coach construction.
Stainless steel Stainless steel claddedcladded compregcompreg has has been used in the following areas of been used in the following areas of prototype coaches.prototype coaches.
0.5mm thick stainless steel (304) 0.5mm thick stainless steel (304) claddedcladdedwith 3mm with 3mm compregcompreg for wall for wall panellingpanellingand partitions and partitions –– FabriqueFabrique finishfinish
0.5mm thick stainless steel (304) 0.5mm thick stainless steel (304) claddedcladdedwith 12mm with 12mm compregcompreg for flooring for flooring ––MacromattMacromatt finishfinish
Stainless Steel SidewallStainless Steel Sidewall
Stainless Steel DoorwayStainless Steel Doorway
Stainless Steel PartitionStainless Steel Partition
A view of Sleeper coach A view of Sleeper coach with Stainless Steel with Stainless Steel PanellingPanelling
2DAISI 409M6x1250x260016
2DAISI 409M5x1250x260015
2DAISI 3015x1200x260014
2DAISI 3013.2x1000x200013
MOONROCKAISI4302.5x1250x300012
2BAISI 409M2x1250x350011
2BAISI 3012x1200x215010
2BAISI 3012x1200x29009
2DAISI 3011.7x1250x19008
2DAISI 3011.7x1250x29007
2DAISI 3011.7x1250x35006
CANVASAISI 3041x1250x25005
HONEYCOMBAISI 3041x1250x25004
STRIPEAISI 3041x1220x24403
HAMMERTONEAISI 3041x1220x24402
4AISI 3041x1250x35001FinishSpecificationSize (mm)Sl.NO
Consumption of Stainless Steel at Consumption of Stainless Steel at ICFICF
46046020042004--20052005
((uptoupto 15.08.04)15.08.04)
1000100020022002--20032003
1460146020032003--2004 2004
20020020012001--20022002
12012020002000--20012001
(in tonnes)(in tonnes)
Use of stainless steel is likely to be extended for the followinUse of stainless steel is likely to be extended for the following g –– Sole BarSole Bar
Body side Pillar Body side Pillar --2mm thick to 2mm thick to SpecnSpecn. AISI 301. AISI 301
Stainless partition below seat/berthStainless partition below seat/berth
Stainless Steel Double Ferrule FittingsStainless Steel Double Ferrule Fittings
S.S FITTINGSS.S FITTINGS
S.S FERRULES.S FERRULE
S.S TUBES.S TUBE
MANUFACTURE OF MANUFACTURE OF STAINLESS STEEL STAINLESS STEEL
COACHES AT ICF COACHES AT ICF –– FUTUREFUTURE
This requires This requires upgradationupgradation of of machinery and plant for stainless machinery and plant for stainless
steel fabrication steel fabrication
The following equipments have been The following equipments have been planned for procurement:planned for procurement:
Laser cutting and welding machine for Laser cutting and welding machine for side wall side wall
Laser cutting machine for componentsLaser cutting machine for components
CNC Spot Welding MachineCNC Spot Welding Machine
Pulse MIG Welding PlantsPulse MIG Welding Plants
Robotic Welding PlantRobotic Welding Plant
EXPORTEXPORT
ICF has bagged an Export order for ICF has bagged an Export order for 11 Meter Gauge Air Conditioned 11 Meter Gauge Air Conditioned Stainless coach shells for MalaysiaStainless coach shells for Malaysia
Stainless Steel AISI 301 is used for Stainless Steel AISI 301 is used for manufacture of the following shell manufacture of the following shell
components.components.Trough FloorTrough FloorBody pillarBody pillarCant railCant railCar linesCar linesSide wall SheetSide wall SheetEnd wall including end End wall including end stancheonstancheonDoor corner pillarsDoor corner pillarsRoof sheetsRoof sheetsBody stiffenersBody stiffenersUnderslungUnderslung water tankswater tanks
COACHES FOR MUMBAI RAIL COACHES FOR MUMBAI RAIL VIKAS CORPORATION VIKAS CORPORATION
(MRVC)(MRVC)
ICF has manufactured three prototype ICF has manufactured three prototype coaches with all stainless steel shells to coaches with all stainless steel shells to grade AISI 301. grade AISI 301.
LIST OF COMPONENTS MADE LIST OF COMPONENTS MADE OUT OF S.S FOR EMU COACHES OUT OF S.S FOR EMU COACHES FOR MRVCFOR MRVC
Sole BarSole BarTrough floorTrough floorBody pillarBody pillarSide wallSide wallRoofRoofEnd wallEnd wall
LIST OF COACH COMPONENTS MADE OUT OF LIST OF COACH COMPONENTS MADE OUT OF STAINLESS STEEL FOR EMUSTAINLESS STEEL FOR EMU
FOR MRVCFOR MRVC
Doorway frame Doorway frame PillarsPillarsDeck sheet in vendors compartmentDeck sheet in vendors compartmentCentral ductCentral ductGrab pole / rail / Hand holdGrab pole / rail / Hand holdSeat frameSeat frameDoorway partitionDoorway partitionBulk head partitionBulk head partition
contd..contd..
STAINLESS STEEL SEAT STAINLESS STEEL SEAT FRAMESFRAMES
Stainless Steel doorway partitionStainless Steel doorway partition
Stainless Stainless Steel Steel Doorway Doorway partition partition (MRVC)(MRVC)
Stainless Stainless steel steel part part partitionpartition
Stainless steel Stainless steel protective protective windowwindowscreen for ACscreen for AC--DC EMU DC EMU
Stainless steel grab rail with SS Stainless steel grab rail with SS hand holdhand hold
Stainless steel Stainless steel Bulk head Bulk head partition for partition for MRVCMRVC
RCF have already commenced manufacture of these coaches RCF have already commenced manufacture of these coaches with stainless steel body. ICF will also manufacture these with stainless steel body. ICF will also manufacture these coaches in a few years time.coaches in a few years time.
QUALITY ISSUESQUALITY ISSUES
Poor quality of stainless steel supplied by Poor quality of stainless steel supplied by industry, reindustry, re--processed and reprocessed and re--cycled material cycled material with subwith sub--standard quality supplied as genuine standard quality supplied as genuine material.material.
InadequateInadequate number of manufacturers of number of manufacturers of stainless steel in Indiastainless steel in India
SquarenessSquareness of the of the sheets suppliedsheets supplied
SquarenessSquareness of the sheets and of the sheets and quality of special finish is very quality of special finish is very important. Sometimes we come important. Sometimes we come across problems on this across problems on this parameters. Proper care should parameters. Proper care should be taken by manufacturers to be taken by manufacturers to maintain themaintain the squarenesssquareness of sheets of sheets supplied.supplied.
While specified Chemical While specified Chemical properties and physical properties and physical properties such as tensile properties such as tensile strength, yield strength etc., strength, yield strength etc., are achieved, requirement are achieved, requirement with regard to elongation is with regard to elongation is not met. not met.
Material for Stainless Steel Material for Stainless Steel Tube and RodTube and Rod
Stainless Steel tubes are normally procured Stainless Steel tubes are normally procured to IS:6913 Gr.`B’ with Nickel percentage 9 to IS:6913 Gr.`B’ with Nickel percentage 9 to 13%. Supplies have been received with to 13%. Supplies have been received with Nickel content ranging form 8 to 10.5%. Nickel content ranging form 8 to 10.5%. The same problem is noticed with Stainless The same problem is noticed with Stainless Steel wire and rod to specification IS 6528 Steel wire and rod to specification IS 6528 Gr. OGr. O44 Cr.18 Ni.10. The specification may Cr.18 Ni.10. The specification may require review.require review.
Presently ICF is procuring Stainless Steel Presently ICF is procuring Stainless Steel from:from:
––Salem Steel Plant (SAIL) / SalemSalem Steel Plant (SAIL) / Salem––JindalJindal Strips / Strips / HissarHissar
Stainless Steel component/equipment Stainless Steel component/equipment suppliers have been directed to obtain the suppliers have been directed to obtain the Stainless Steel only from the above Stainless Steel only from the above sourcessources..
The component suppliers are unable to The component suppliers are unable to procure raw materials in small quantities procure raw materials in small quantities from the above manufacturers. In many from the above manufacturers. In many cases, the firms supply material cases, the firms supply material conforming to 200 series in place of 300 conforming to 200 series in place of 300 series. Mixing up of materials of different series. Mixing up of materials of different grades reported.grades reported.
ICF procures Stainless Steel ICF procures Stainless Steel under the following two headsunder the following two heads
1.1. Stainless Steel Sheets and plates Stainless Steel Sheets and plates procured as raw material directly procured as raw material directly from manufacturers from manufacturers
2.2. The processed stainless steel The processed stainless steel components procured from components procured from vendors.vendors.
SOLUTIONSOLUTION
Major producers such as Major producers such as M/s. SAIL & M/s. M/s. SAIL & M/s. JindalJindalshould clearly indicate who should clearly indicate who are authorised retailers to are authorised retailers to avoid quality problems.avoid quality problems.
PROBLEMS FACEDPROBLEMS FACEDWELDING OF STAINLESS STEELWELDING OF STAINLESS STEEL
Hot cracking during welding of Austenitic Hot cracking during welding of Austenitic stainless steelstainless steel
Diffusion of carbon while welding Mild steel Diffusion of carbon while welding Mild steel with stainless steel with stainless steel -- likely to cause corrosion likely to cause corrosion problem.problem.
Conventional welding processes to be replaced Conventional welding processes to be replaced by modern welding techniques requiring input by modern welding techniques requiring input of Machinery & Plant involving high costs.of Machinery & Plant involving high costs.
contdcontd....
Indigenous availability of Quality Indigenous availability of Quality consumables. Flux cored wire is not consumables. Flux cored wire is not available indigenously. available indigenously.
Consultancy for upgrading the skill, Consultancy for upgrading the skill, process to be adopted for tackling process to be adopted for tackling stainless steel.stainless steel.
Assistance requiredAssistance required
Special training of Artisans and Special training of Artisans and supervisors for welding of stainless supervisors for welding of stainless steel. steel.
ICF is procuring stainless steel ICF is procuring stainless steel sheet to thickness 0.8 mm, 1mm sheet to thickness 0.8 mm, 1mm and 2.5mm to various grades of and 2.5mm to various grades of finish such asfinish such asStripeStripeHonykomHonykomMoon RockMoon RockHammertoneHammertoneMacromattMacromattFabriqueFabrique
Various Various Patterns Patterns
usedused
Stainless Steel of Stainless Steel of special finishspecial finish
There is only one supplier viz., M/s. There is only one supplier viz., M/s. SAIL/Salem for Stainless steel of SAIL/Salem for Stainless steel of special finish. special finish.
InterInter--face between Stainless steel face between Stainless steel manufacturers, ICF and Stainless manufacturers, ICF and Stainless
Steel fabricatorsSteel fabricators
Close coordination is required between Steel Close coordination is required between Steel manufacturer, Component processors and ICF manufacturer, Component processors and ICF i.e. purchaser to identify, locate and develop i.e. purchaser to identify, locate and develop genuine and efficient fabricators and genuine and efficient fabricators and suppliers of Stainless Steel items, so that suppliers of Stainless Steel items, so that quality products can be supplied to ICF.quality products can be supplied to ICF.
CONCLUSIONCONCLUSION
There is tremendous scope for use of stainless steel There is tremendous scope for use of stainless steel in rail coach construction in India. There is an in rail coach construction in India. There is an increasing trend in use of stainless steel for the increasing trend in use of stainless steel for the coach fittings and ICF is switching over from zinc coach fittings and ICF is switching over from zinc coated/powder coated/galvanized components to coated/powder coated/galvanized components to stainless steel.stainless steel.
Success of application of stainless steel in Indian Success of application of stainless steel in Indian Railways depends on the capability of suppliers to Railways depends on the capability of suppliers to supply quality material in sufficient quantities.supply quality material in sufficient quantities.
