ALSTOM CH-8212 Neuhausen a/Rhf Origin Aer Wehimone Technical Specification Date 1.101998 Amendment No. 17.248 Part document 100 Version 07 thor MR Doe: 24022008 : i Pc Helical Suspension Springs . a Nemberofonoee: 10 Nemberoteneae 0 Content 1 GENERAL. 2 MATERIAL... 3 INSTRUCTIONS FOR CONSTRUCTION. 4 ACCEPTANCE. 5 QUALITY CONTROL SYSTEM.. 6 MARKING OF SPRINGS... 7 COUPLING... 8 SURFACE PROTECTION... 9 FINAL ACCEPTANCE OF SPRINGS. 10. TRANSPORT. 11 MODIFICATIONS. Kontrallierte Ausgabe Subject-release N-Moccettl [Visum: Visum: fame gsmroioooy | THE doamon' ates res which arte le rope of ALSTOM Schinefshasups AG, Nausea Ril Neto sit nt patina hie decoment ronal igh cep pb er fe ay er melo er rcs reed fs a rts«—=:«=S:«stézit#SSCsésé,FFEsss«sicsc‘csewc seen ae nea apesTechnical Specification No. 17.248 Part document 100 Version 07 Helical Suspension Springs Page: 2/10 1 13 21 GENERAL Purpose The purpose of this technical specification is: = fo show the customer requirements according to EN 13298 = fo state aspects which are not considered by EN 13298; ~ these components will be named as spring; = in the following the expression customer is equal to ALSTOM ~ to lay down practical knowledge of the customer ~ especially to complete section 5 and 6 of EN 13298 Deviations from this specification are possible only following written agreement between the manufacturer and the customer. Other applicable documentation The order-documents are valid in this order of precedence: 1. Commercial terms of delivery (order of the customer) 2. The drawing listed in the order of the customer 3. This technical specification 4, The technical specification 17.617 “Operative Range of Producls used by ALSTOM” 5. EN 13298 Definitions In accordance to EN 13298 the spring lypes are defined as: as 7:04 Type B Flexicoil Spring Sp defined vertical stiffness Definitions for used parameters F,, Fy, Fy and Fy are in accordance to EN 13298 (section 3.2). MATERIAL The following material is authorised (according to EN 10089): @ of bar ‘Material = 40 mm) 51 CrV4 RE are 52 Cr Mo V 4 25 ... 65 mm 52 SiCrNiS P- & S-Percentage Both for the melt and for the product analysis the value for both phosphor and sulphur must not exceed 0.015 % in weights. ‘ALSTOM Schienenfahrzsuge AG Tai0.1998Technical Specification No. 17.248 Partdocument 100 _-Version 07 Helical Suspension Springs Page: 3/10 2.2. Inclusions According to appendix D of EN 13298 section D2 “examination” 2.3 Shape and dimensions The diameter of the straight rods must be in following limi Diameter [mm] | Tolerances ‘above _fo is 12 6-10 +0.075 10-18 +0.090 18-30 +0.105 30-50 £0,125 50-80 +0.150 3 INSTRUCTIONS FOR CONSTRUCTION 3.1. Formation of the final turn The ends of the spring are applied and ground. The plainness of the ground support surfaces in a slack state must lie within the following lim- Plainness Development of end turn 4 ie actana= Tf] é = norm: 315* Support surfaces (min. 270°) All sharp edges are to be The most extended and continuous transition of beburred cleanly. the end turn possible in the pitch of active turns. ‘ALSTOM Schionenfahrzauge AG TaI0 1996Technical Specification No. 17.248 Part document 100 Version 07 Helical Suspension Springs Page: 4/10 3.2 33 3.4 35 Deviation of the spring’s ends toward the perpendicular The ends of the springs must be perpendicular to the spring axis and shall be parallel. If not declared differently onto the drawing, in consistency with EN 13298 (section A5) for unloaded springs the following maximum deviations (p) toward the spring axis are fo respect: = for springs with a free length of lps 150mm => p< 2%ofly = for springs with a free length of lo > 150mm => ps 1.5%of ly Behaviour of end turns under load Under a vertical load, which is the case in 80 % of spring excursions at F,, both rod ends must rest against the first turn. In the remaining vertical load zone, the contact must follow in a con- finuously rolling manner and there may be no toppling over the support points and no “kinks”. The lengih of the line of contact is lo work out according to EN 13298 appendix A. The begin- ning of the line of contact may not be further than 60° from the end at load Fy. The turn interval is to be held so exactly that no additional contact at any other point on the spring up fo load Fy, occurs. Shape tolerance The concentricity of the wound rods must lie within following limits according to ISO 8015: Rod - <30mm > | O {02 Rod - @ >30mm > | O]04 Vertical stiffness Lovee ~Liara The lengths for the vertical stiffness are to be measured in the relief phase between two horizontal plates. ‘ALSTOM Schiononfahrzeuge AG VETOTechnical Specification No. 17.248 Partdocument 100 _ Version 07 Helical Suspension Springs Page: 5 / 10 3.6 42 5.2 Touching up Repairs of superficial defects are allowed only if they lie within the diameter folerances of the straight rod Only cold repairs may be made (e.g. polishing) ‘ACCEPTANCE Supplier Via subsequent listed, one time tests, the supplier has fo proof process mastering: = Infernal tension profile of the inner side in the area of the final turn and in the spring centre. = Determination of the stress corrosion and crack growth curve Product Certification according to EN 13298, section 8.2, is necessary for: 2) springs from suppliers unknown by the customer. b) springs that are made out of new material from suppliers already known by the customer. The supplier must pass the following testing in additional fo the acceptance testing defined in EN 13298: = Chemical composition is determined by means of a chemical analysis of a cross sec- tion of material. Certification according to EN 13298, section 8.2, is not necessary for: a) new springs from suppliers already known by the customer b) existing springs from suppliers already known by the customer where operating condi- tions has changed The tests are carried out by the supplier on an arbitrary spring and the results must be dis- cussed with the customer. The spring supplier must guarantee by appropriate test planning that the quality characteris- tics, which were used for the “acceptance test spring” remain unchanged for series production, QUALITY CONTROL SYSTEM Quality assurance plan The supplier submits the quality assurance plan to the customer. First article inspection A first article inspection is effected on the first spring manufactured under conditions of series production. All items of quality that are listed on the drawing of the order, in the present specification or in the European Standard prEN 13298 is tested and a record of all fest results are to be kept. ‘ALSTOM Sehienentanvzeuge A TROTTechnical Specification No. 17.248 Part document 100 _—-Version 07 Helical Suspension Springs Page: 6/10 5.3 5.4 55 Series inspection All inspections have to be effected and recorded according to the supplier's fest planning with respect to the drawing of the order, the present specification and the European Standard EN 13298. All inspections have to be accomplished on 100 % of the delivery inspection Proof factor_| Type A | Type B Length under test load 100% x x (according to the drawing) Free transverse deflection r; under proof-load F, 100% x (direction and dimension in mm of the deviation) ie ‘Magnetic detection of surface imperfections 100% Xx X Quality records The recorded individval fest result will be kept by the manufacturer for a period of 10 years following delivery and can be viewed upon demand. Acceptance report With delivery, the manufacturer gives written confirmation of construction and testing accord- ing to the order in an final acceptance test certificate according fo EN 10204 3.1.B. The acceptance report has to be enclosed with the delivery. MARKING OF SPRINGS With reference to prEN 13298: AB x = Year and trademark. x = Running number (starting with 001 at the beginning of each year). _—. = Product identification number of ALSTOM x x ~All markings are to be stamped warm during the coiling operation atthe = Xx beginning of the coil in the area of the first 270 ° (see sketch on Page 7). = The stamping tool must be rounded. xx - The stamping depth must be big enough that the numbers are still legible = xx after the finish coating. = The stamped numbers lie on the underside of the spring. x x ~ Alternatively the product identification number of ALSTOM can be stamped x =x onto a band of bronze, copper or brass, which is positioned according to subsequent sketch. The band is secured with a cyanogen acrylate adhesive (e.g. Loctite Js 496) or with a compression joint. ‘ALSTOM Schienentanrasuge AC TaT0.1998Technical Specification No. 17.248 Part document 100 Version 07 Helical Suspension Springs Page: 7/10 AB alternative band with product Identification number of ALSTOM = Inaddition, each spring generally is to be marked with a band of bronze, XX copper or brass, as shown in the subsequent sketch. The band is secured with a cyanogen acrylate adhesive (e.g. Loctite Js 496) ‘or with a compression joint. The following items are to be stamped on this band: = Spring length under test load F, in (mm). xs = Value "t” of the free transverse deflection in [mm] under test load F, x + band ~ Further, the direction of the free transverse deflection “r," istobe marked. = X= with a band of aluminium adhesive tape (e.g., Tesaflex 171). The band is to be attached to the lacquer-finished spring as in the sketch below. band for marking the free transverse deflection 1, free movement ofthe lower spring end stamped numbers 7 COUPLING If coupling of springs is necessary, itis to be carried out by the supplier. The corresponding instructions are specifically communicated in the order to the supplier. “ALSTOM Schienenfahrzeuge AC TRIOSTechnical Specification No. 17.248 Part document 100 Version 07 Helical Suspension Springs Page: 8/10 8 SURFACE PROTECTION Two painting cycles ~ U and V - are accepted 8.1 Cycle U Painting cycle U is based on synthetic resin. 8.1.1 Phosphatizing Phosphatizing is carried out using zinc phosphate. Thickness of coat approx. (5 ... 10) jim, fine-crystalline 8.1.2 Priming carried out using synthetic resin metal primer. Basis: alkyd resin, air- and oven-dried Pigmentation: zinc phosphate, heavy chip, talcum, tinting pigments Solvent: aromatic substances Dry layer thickness: approx. 80 im 8.1.3. Coating lacquering Coating lacquering is carried out using synthetic resin dipping enamel. Basis: alkyd resin, air- and oven dried Pigmentation: lampblack tinting pigments, extender Solvent: ‘aromatic substances ~ aliphates Dry layer thickness: approx. 40 jim 8.2 Cycle V Painting cycle V is based on an environmental friendly and water-soluble, elastified epoxy sys- fom. Ithas fo pass a 1000h salt spray test, which has to be performed in accordance to DIN53167. Following results must be achieved: Bubble formation MO/GO_—(DIN53209) Rust formation Ri0 (01N53210) ‘Adhesion Gio (D1N53151, both directly after the 1000h sat spray test ‘nd after 24h reconditioning time) Alternatively the same results must be achieved on springs after at minimum: = 300h for springs of type A - 400h for springs of type B. 8.2.1. Priming Basi E.g. water-soluble 2-component epoxy primer ETOKAT AQUA Primer (Mader-Lacke, technical datasheet no. 840.1). Pigmentation: must contain zinc phosphate Solvent: water Dry layer thickness: 80 pm "ALSTOM Sthienenfahrzeuge AG = Sean — Tz 10.1998Technical Specification No. 17.248 Partdocument 100 Version 07 Helical Suspension Springs Page: 9 / 10 8.2.2 Coating lacquering Basis: E.g. water-soluble 1-component final coat AQUAVERN mica paint (Méder-Lacke, technical datasheet no. 502.6a MD). Pigmentation: Solvent: water Dry layer thickness: 60 um 83 Colour The colour of the coating lacquer is stated in the fext of the order. 8.4 Paint repair and maintaining of damages Springs underlie periodic inspections. Thus, for the painting cycle chosen and applied, an agreed repair instruction for maintenance purpose shall be provided for this. Thereby the in- struction shall contain the treatment of damages caused by corrosion and mechanical impacts as well as pre-treatment for paint repair. 9 FINAL ACCEPTANCE OF SPRINGS 9.1. Sample springs The final acceptance of sample springs up fo the production stage is reserved exclusively to the customer. Starfing of the acceptance tests is to be communicated fo the customer at least 2 weeks in advance. 9.2 First article acceptance The supplier informs about exercising the first article testing in time. It is up to the customer to attend to the first article testing. 9.3 Production springs Delivery is subject to contractual acceptance by agencies of the railway administrations. The corresponding instructions are specifically communicated in the order to the supplier. 10 TRANSPORT In the case of coupling of springs by the supplier, there must be no danger of substitution dur- ing shipment. The springs, in particular sets of springs, are to be packed in a way, that dam- ‘ages caused by the packaging process and transport, are closed out. Paint damages as they ‘appear during the packaging of wet painted springs being in contact with packaging material are to close out, 11. MODIFICATIONS [Version [Date ‘Modificat Author A Not existing in Engl., see German version 17.248/000/a |R. Schneider B Not existing in Engl., see German version 17.248/000/b [R. Schneider ie 20.12.1994 | Translation of the original document 17.248/000/c W. Lehmann _ Not existing in Engl., see German version 04 17.248/000/04 W. Lehmann ‘ALSTOM Schienentahrz=uge AG TaO TeTechnical Specificar Helical Suspension Springs No. 17.248 Partdocument 100 Version 07 Page: 10/10 Version [Date Modification Author [05 20.01.1999 | Translation of the original document 17.248/000/05 |W. Lehmann © Replaced Fiat-SIG with ALSTOM - 25.07.2001 |* Added in 1.1 hese components will be L Fontana named as spring * Added section 1.3 Definition + Whole document: prEN 13298 -> EN 13298 ‘* Section 1.1 (Purpose): Definition for customer inserted => whole document “ALSTOM" substituted. * Section 1.2 (Other applicable documentation): now “order-"documents at the first sentence. Under "4." description “part document 000" removed. + Section 1.3 (Definitions): Source for load-definitions given. + Section 2 (Material): ISO 683/14 now EN 10089 Section 2 (Material): 50CrV4 now 51C1V4 ‘+ Section 2 (Material): 51CrMoV4 now 52CrMoV4 ‘© Section 2.1 (P + S-Percentage): Wording refined. Section 3.2 (Deviation of the spring's ends toward the perpendicular) inserted, consequently all subsequent chapters 3.i now are 3.(i+1). * Section 3.5 (was 3.4) (Vertical stiffness): Formula for Ks corrected. Remark “(without spring plate)" re- moved. + Section 4. (Acceptance): Split into 4.1 (Supplier) and 4.2 (Produc). * Section 4.2 (Produci) (was 4. Acceptance}: Second o7 24.02.2004 | Paragraph “The supplior must..." -> Scope reduced. |M. Pinnau Subtracted now in 4.1 (Supplier). ‘© Section 5.3 (Series inspection): Wording in table for “Alignment deviation" -> precision into “Free trans- verse deflection r; under proof-load F,” + Section 6 (Marking of springs): “Product identification number of ALSTOM" inserted. * Section 6 (Marking of springs): Alternative marking for ALSTOM product identification number inserted. * Section 6 (Marking of springs): Wording refined at “In addition, each spring is to be marked ..." to "in addi- tion, each spring generally is to be marked ...". '* Section 6 (Marking of springs): At "Further, the direc- tion..." => “ inserted at "...free transverse deflec- fion...”. Wording for “band” in corresponding sketch precised. + Section 8 (Surface protection) reworked. Section 8.4 (Paint repair and maintaining of dam- cages) introduced. Section 10 (Transpori): Packaging inserted. ‘+ Whole document: some typing errors corrected. ‘ALSTOM Schlenenfahrz=uge AG TET