WHEELS AND TYRES FOR RAILWAYS

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 COMMITTED TO WHEELS

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Railway wheels and tyres
KLW is the wheels brand of
global steel company Interpipe.
Interpipe has more than
seventy years of experience in
manufacturing railway wheels
at the company’s renowned
Interpipe NTRP mill in
Dnepropetrovsk, Ukraine. These
wheels are supplied to the
customers worldwide through
sales company KLW Wheelco
SA (Switzerland). With annual
production of over 600,000
pieces, Interpipe NTRP has
a huge portfolio of over 200
products. All the products have
distinctive KLW stamp insignia.
KLW global network is strong
with clients in 60 countries
on five continents. Years of
manufacturing and supply
experience enable KLW
to compete successfully
everywhere where there is a
major railway operation. As
our company has evolved we
have gained over forty years
of experience in partnership
with railway operators in
countries as far afield as India
and Australia as well as in
traditionally large markets like
Germany and Russia.
KLW is committed to providing all of the key mechanical and
the highest quality railway operational properties as well
wheels according to the as life cycle costs.
specifications and requirements
of the customer, corresponding Our product portfolio has
to strict international standards. developed rapidly over the
Our products are guaranteed years as our business has
by the quality control expanded globally. Now we
and management system provide an extremely wide
certified by TUV (Germany) range of railway wheels
corresponding to the norms of and products to the highest
DIN EN ISO 9002. international requirements,
including tyres.
Quality control is enforced
at all stages of product
manufacturing – from steel
melting to the acceptance test
of wheels and tyres. Our focus
on reliability includes a wide
range of measures including
reducing residual stress and 3
increasing durability as well
as using mechanical, chemical
and metallographic control
measures in the Interpipe NTRP
Central Laboratory.
High levels of investment
and R&D continue to bring
significant benefits across
the design, development and
production of our wheels. This
allows us to achieve the best
results for our customers across
 Range of railway wheels and tyres
Wheels

Outside diam- Inside diameter Width Diameter Height Diameter of Thickness of Mass, kg
eter Ø d1, Ø d2 mm of rim H, mm of hub Ø d, mm of hub L, mm hole in hub Ø disk
Ø D, mm d0, mm t1, t2, mm
650-1269 600-1100 95-160 185-500 90-405 60-200 15-80 165-1050

Tyres

Outside diameter Inside diameter Width of rim Width of flange Mass, kg

Ø D, mm Ø d, mm Ø d, mm Ø h, mm
690-1300 550-1100 80-150 15-50 100-600
List of standards

The railway wheels and tyres are exported according to the

specifications and requirements of the Customer, the norms of
international standards, including:

AAR M 107/208 MOR-M-2001-2 TJZL 02-99

ASTM A504 NF EN 10228-3 TTS 094
ASTM A551 NF F 01-111 TTS 248
ASTM A551-81 NF F 01-115 UIC 810-1
BN 918277 NF F 01-131 UIC 812-1
BS 5892 part 4 NF F 01-33 UIC 812-3
BS 5892, part 3: 92 PN-84 UNI 6102
BS24 PN-84 H84027/06
IRS R 15-95 PN91/K91032
IRS R 3403 PN-92
IRS R 19-93, parts 1-5 PN-92/K91018 pr
ISO 1005 EN 13262
JIS E 5402 RSP #SM-55/2543
KRS 2242-2107 SNCB A-12
M4T 2000 TJZL 01-98
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Quality Management System

ISO 9001-2000 AAR M-1003

Our approvals
AAR – Freight & Locomotive Wheels
DB – Locomotive Wheels
Railtrack – Freight Car Wheels
ÖBB - Freight Car Wheels
DB – Freight Car Wheels
PKP – Freight Car Wheels
SZ - Freight & Locomotive Wheels
BZ - Freight & Locomotive Wheels
 Production facility
Interpipe NTRP

Railway wheels shop includes:
z Forging-rolling line for
production of wheels from
650 to 1269 mm
z Forging-rolling for production
of tyres
z Mechanical finishing floor
z Heat treatment lines
z Shot blasting line
z Non-destructive testing
(ultrasonic, magnetic
and hardness testing)
z Finishing line
In 2002 -2007 Interpipe
invested in increase of
production capacities by
building new finishing and
testing lines, mechanical
hardening (ultrasonic, magnetic
hardness testing, geometry
control, mechanical operation).
As a part of its strategic
investment program, Interpipe
has purchased equipment for
the installation of a new full
profile line for railway wheels
machining. The automated line
will include four RQQ machines,
the complex of inter-machine
equipment (systems for loading
and unloading of wheels).
The expected capacity of the
automated line, which has self-
operated control for full profile
railway wheel machining,
is 100,000 finally machined
wheels per year.

Key facts:
1935 - the first railway wheel rolled off the
production line in starting one of the
most absorbing stories of modern
industrial times
1970 - Interpipe NTRP wheel shop produced
its 10 millionth railway wheel just 35
years after the first one had rolled off
the production line
1979 - the company started to supply wheels
across Eastern Europe
1987 - new purpose-built railway wheels and
tyres shop, which started to produce
railway tyres
1991 - the KLW brand entered the Indian
market
1996 - the first wheels were supplied in China
Steel Making Process
Steel for the production of
railway wheels and tyres is
melted in the open-hearth
furnaces with the charge of 250
tons and tapping in two ladles.
High quality characteristics
of steel are provided by the
subsequent processing at the
out-of-furnace complex of steel
treatment. The ladles with
metal are delivered in turn to
the unit furnace-ladle, where
the metal finishing and refining
takes place. Steel blowing in
the ladle by argon along with
the refining process provide
for the sulphur content in the
finished metal equal to 0.010%
phosphorus – 0.015% and less,
and uniform distribution of
another elements. Degassing
process is effected by means
of removing the hydrogen,
nitrogen, oxygen dissolved in
metal at the vacuum degassing
set simultaneously with argon
blowing. Hydrogen content in
steel is within the limits up to 2
ppm.
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 The Technology of the Production of Railway Wheels
1 2 3 4

Open-hearth furnace Ladle Ladle-furnace Vacuum

degassing set
5 6 7 8

Bottom pouring Notching and breaking of Billets inspection Billets heating in the
ingot into initial billets and repairing rotary furnace
9 10 11 12

Hydroscaling of cinder Open forging on the Closed forging on the Punching on the press
press 20MN press 50MN 100MN
13 14 15 16

Wheel rolling on the Wheel calibration on the Intermediate cooling Cooling of the wheel
rolling mill press 35/8 MN and and anti-floking in open air
piercing of central hole isometric holding
17 18 19 20

Machining Wheels heating Rim quenching Tempering in pit in the

8 furnaces
21 22 23 24

Adjustable cooling CNC machining, Automated non-destruc- Wheels inspection and

imbalance checking tive control (ultrasonic measuring, hardness
test, magnetic particle determination
inspection etc)
25 26

Testing of mechanical Storage

and other properties
on the samples
The Technology of the Production of Railway Tyres
1 2 3 4

Open-hearth furnace Ladle Ladle-furnace Vacuum

degassing set
5 6 7 8

Bottom pouring Notching and breaking of Billets inspection Billets heating in the
ingot into initial billets and repairing rotary furnace
9 10 11 12

Hydroscaling of cinder Open forging on the Weighing Punching and

press 20MN closed piercing
13 14 15 16

Piercing Rolling on one Marking Hot dressing

or two mills
17 18 19 20

Thermal treatment Non-destructive control Selection of the samples Inspection and measur-
(anti-flocking, hardening (hardness, ultrasonic and holding of all testing ing
with tempering test) on the samples 9
or normalizing)
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Storage
 Products Quality Control
High quality characteristics of
the products corresponding
to the requirements of
international standards, are
guaranteed by the system
of quality control and
management certified by
the firm TÜV (Germany) for
correspondence to the norms
of DIN EN ISO 9002.
Quality control is effected
at all the stages of product
manufacturing – from steel
melting to the acceptance test
of the wheels and tyres:
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z Control of the chemical
composition of raw-
materials, steel during
melting process, ready
rolled-stock is effected on
the spectrometers “Polyvac
2000” type
z Control of hydrogen content
in liquid steel is effected
before and after vacuum
degassing using sound
determination by “HYDRIS”
device of company “Heraeus
Elecro-Nite”
z Control of nitrogen, oxygen,
hydrogen content is
performed at the devices
PH-402 and TS-236 of the
firm “Leco”
z 100% automated Ultrasonic
test as well as magnetic
particle of ready products,
is effected to determine the
presence of internal defects
inspection
z Control of the hardness
on the rim surface of the
wheels and tyres is realized
during the production using
durometer of “EMCO”
company
z Metal testing for
elongation is realized at the
machine UTS-600-1 with
microcomputer control and
automatic registration of
parameters and printing-out
of the results
z Pendulum testing impact
machine Psd 50/15 of “Wpm
Werkstoffprufmaschinen
GmbH” company is used
to determine the impact
strength of steel
z The determination of steel
toughness K1C according
to the ASTM-E 300 is
effected on the universal
computerized testing
machine “Hydropuls Sinus
250” by company “Carl
Schenk”
z By the request of the
customers the testing of
wheels and tyres by the
falling weight or static
compression, as well as
the control of micro – and
macro structure and nature
of stresses are made by the
up-to-date methods
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Countries supplied to:

Argentina Croatia Kenya Romania Turkey
Armenia Egypt Kirghizstan Russia Turkmenistan
Australia Finland Korea, North South Africa Ukraine
Austria France Korea, South Slovakia United Kingdom
Azerbaijan Georgia Latvia Slovenia Uruguay
Bangladesh Germany Lithuania Spain USA
Belgium Greece Macedonia Sri-Lanka Uzbekistan
Brazil Hungary Malaysia Sweden Vietnam
Bulgaria India Mauritania Switzerland Yugoslavia
Byelorussia Indonesia Moldova Tajikistan Zambia
Canada Iran Poland Tanzania
Chile Italy Netherlands Thailand
China Kazakhstan Norway Tunisia
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SETTING THE WORLD IN MOTION

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C H - 69 02 P a r a d i s o - L u g a n o, Sw i t ze r l a n d
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