AAR Manual of Standards and Recommended Practices

08/2009 Wheels and Axles

M-101

AXLES, CARBON STEEL, HEAT-TREATED

Specification
M-101

Adopted: 1914; Revised: 1996, 2004, 2005, 2009

1.0 SCOPE
These specifications cover heat-treated axles of all sizes for passenger cars and freight cars to
designs shown in Section G. These specifications also cover heat-treated locomotive axles. The
grades of carbon steel axles are as follows:

Grade F—Double normalized and tempered. (All freight axles over 6 1/2 in. nominal di-
ameter at center shall be Grade F.)
Grade G—Quenched and tempered.
Grade H—Normalized, quenched, and tempered.
Grades F, G, and H—Axles are used in heavy duty service on locomotives, cars, and other equip-
ment.
2.0 QUALIFICATION AS MANUFACTURER
Qualification as a manufacturer of axles for use in AAR interchange service must be in accordance
with Appendix C of this specification. Qualification is effective until revoked for cause by the Com-
mittee. Failure to maintain reasonable quality standards in manufacturing is an example of cause.
Axle manufacturers must meet the requirements of the AAR Manual of Standards and Recom-
mended Practices, Section J, Specification M-1003, “Specification for Quality Assurance.”
3.0 MANUFACTURE
3.1 Process
The steel shall be made by any of the following processes: open hearth, electric furnace, or basic
oxygen.
3.2 Discard
A sufficient discard shall be made from each ingot to ensure freedom from piping and undue segre-
gation.
3.3 Reduction Practice
The axles may be made directly from the ingot or from blooms. The total reduction from ingot or
strand-cast bloom to forging or extrusion shall be not less than 3 to 1, unless otherwise specified.
Note: The process for manufacturing strand-cast blooms shall be designed to ensure freedom from
center porosity and undue segregation.
4.0 COOLING AND HEATING
4.1 After axle blooms are produced, they shall be slow-cooled in closed containers, hoods, or fur-
naces.
4.2 Blooms shall be reheated for working in a manner that will prevent internal bursts and over-
heating.
4.3 After reduction, axles shall be slow-cooled in closed containers, covered conveyors, or in
hoods. If axles (Grades F, G, and H) are heat-treated directly from reduction, they shall be
slow-cooled following the final heat treatment.

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4.4 Axles (Grades F, G, and H) that are heat-treated directly from reduction 1) shall be cooled
below the transformation temperature or to approximately 1,000 °F before any reheating opera-
tion; and 2) must not be permitted to cool below 500 °F without slow-cooling as defined in
paragraph 4.3.
Note: As the temperature of the axles approaches the minimum of 500 °F, a supplemental heat
source may be necessary to ensure an effective slow-cooling cycle.
4.5 When properly vacuum-degassed steel is used, the slow-cooling requirements of paragraphs
4.1, 4.3, and item 2 of paragraph 4.4 may be omitted, but axle blooms must then be pile cooled.
4.6 The slow-cooling requirements of paragraphs 4.1, 4.3, and item 2 of paragraph 4.4 may be
accomplished by piling and covering the piled blooms or axles with insulating materials in lieu of
using closed containers, hoods, furnaces, and covered conveyors. Covered piles must be capable of
providing effective cooling rates in accordance with the manufacturer’s procedure or specification.
5.0 HEAT TREATMENT
5.1 Axles for heat treatment shall be reheated gradually and uniformly to a suitable temperature
to refine the grain structure.
5.2 Normalizing
After being heated to a suitable temperature, the axles shall be withdrawn from the furnace and
allowed to cool uniformly in air. A furnace charge thus treated is termed a normalizing charge.
Cooling may be accelerated by increased air circulation, which must be controlled to provide rea-
sonably uniform cooling.
5.3 Double Normalizing
The procedure shall consist of two separate normalizing treatments. The second treatment shall
be performed at a lower temperature than the first treatment. A furnace charge thus treated is
termed a double normalizing charge. Cooling may be accelerated by increased air circulation,
which must be controlled to provide reasonably uniform cooling.
Note: A single normalizing treatment shall be permitted when all other requirements for Grade F
can be met.
5.4 Quenching
After being heated to a suitable temperature, the axles shall be quenched in a suitable medium
under reasonably uniform conditions. A furnace charge thus treated is termed a quenching charge.
5.5 Tempering
Axles shall be reheated gradually to, and held at, a suitable temperature below the critical range
and shall then be allowed to cool under suitable conditions. A furnace charge thus treated is
termed a tempering charge.
5.6 Heat treatment may be performed in either batch-type furnaces or continuous furnaces.
6.0 STRAIGHTENING
Straightening shall be done before machining and preferably at a temperature not lower than
950 °F. Straightening performed at temperatures lower than 950 °F shall be followed by stress
relieving or an applicable heat treatment.

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7.0 CHEMICAL COMPOSITION

The steel shall conform to the requirements for chemical composition shown in Table 7.1.
Table 7.1 Chemical composition
Grade F Grades G and H
Heat-Treated
Min. Max. Min. Max
Carbon, percentage 0.45 0.59 — —
Manganese, percentage 0.60 0.90 0.60 0.90
Phosphorus, percentage — 0.045 — 0.045
Sulphur, percentage — 0.050 — 0.050
Silicon, percentage 0.15 — 0.15 —

8.0 LADLE ANALYSIS

8.1 An analysis of each heat of steel shall be made by the manufacturer to determine the percent-
age of carbon, manganese, phosphorus, sulfur, and silicon. The chemical composition thus deter-
mined shall be reported to the purchaser or purchaser’s representative and shall conform to the
requirements of paragraph 7.0.
8.2 Identification of Heats in Consecutive Strand Castings
If more than one heat is consecutively strand cast at one time, ladle analyses shall be obtained of
each heat. If the ladle analysis of one heat does not meet the requirements of the specification, the
bloom or blooms that comprise a mix of the two consecutive heats shall be deemed to be outside the
requirements of the specification unless additional chemical analyses prove compliance. If both
ladle analyses are in compliance with the specification, the heat number assigned to the cast prod-
uct shall remain unchanged until all of the steel in the bloom is from the following heat. Alterna-
tively, when all of the mixed portion of two consecutive heats is in one bloom, that bloom may be
given the heat number that comprises the larger portion of the bloom on either side of the mixed
portion.
9.0 CHECK ANALYSIS
Analysis may be made by the purchaser from one axle representing each heat. The chemical com-
position thus determined shall conform to the requirements of paragraph 7.0, subject to tolerances
included in Table 9.1. The sample for these analyses shall be taken from one end of the test axle or
full-size prolongation at a point midway between the center and surface. If drillings are taken,
they shall be obtained using a 5/8-in.-diameter drill, or turnings may be taken from a tensile test
specimen.
Table 9.1 Permissible variations for check analysis
Permissible Variations, Over the Maximum Limit
or Under the Minimum Limit
Elements Percentage
Manganese 0.030
Phosphorus 0.008
Sulphur 0.008
Silicon 0.020

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10.0 TENSION TESTS

10.1 Grades F, G, and H axles shall conform to the requirements in Table 10.1.
Table 10.1 Tensile requirements for carbon steel heat-treated axles
Size Tensile Yield Elongation Reduction
(Solid Diameter or Thickness) Strength Strength in 2 in. of Area
(in.) (psi) (psi) (percentage) (percentage)
Grade Over Not Over Min. Min. Min. Min.
F — 8 88,000 50,000 22 37
(Double Normalized
and Tempered)
G — 4 90,000 55,000 20 39
(Quenched 4 7 85,000 50,000 20 39
and Tempered) 7 10 85,000 50,000 19 37
H
(Normalized, — 7 115,000 75,000 16 35
Quenched, 7 10 105,000 65,000 18 35
and Tempered)

10.2 The size classification shall be determined by the finished diameter of the journal.
10.3 The diameter of the test prolongation shall be at least equal to the as-formed diameter of the
journal.
10.4 The tensile properties for all grades listed in Table 10.1 shall be determined by the
procedure described in ASTM A 370, “Standard Methods and Definitions for Mechanical Testing of
Steel Products.” The yield strength shall be determined using the 0.2% offset technique. A
Class B2 or more accurate extensometer shall be used.
10.5 The use of automated devices that determine the offset yield strength without the need for
plotting a stress-strain curve are acceptable.
10.6 Tests shall be made only after final heat treatment of Grades F, G, and H axles.
11.0 TENSION TEST SPECIMENS
11.1 Tension test specimens shall be taken from the test prolongation or an axle in accordance
with the provisions of paragraph 12.0.
11.2 Unless otherwise specified, the axis of the specimen shall be located at any point midway
between the center and surface of the axle or full-sized prolongation and shall be parallel to the
axis of the axle.
11.3 Tension test specimens shall conform to dimensions shown in Fig. C.1.
11.4 Tension tests from the prolongations shall have minimum tensile strength and yield point
values 5% greater than shown in Table 10.1. For example, Grade F tension tests from axle prolon-
gations shall have 92,500 psi minimum tensile strength and 52, 500 psi minimum yield point.
11.5 Tension test specimens from axles shall be taken from the journal of the axle at the
mid-radius, halfway between the surface and center, with the gauge dimension parallel to the axis
of the axle. For tensile specimens removed from the prolongation, samples shall be taken from the
mid-radius, halfway between the surface and center, with the gauge dimension parallel to the axis
of the axle.

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12.0 PROLONGATION FOR TEST

12.1 For test purposes, prolongations shall be attached to at least 5% of the axles in each size
classification of each heat in each heat-treating lot.
12.2 If axles with prolongations have been expended, then axles may be used for test procure-
ment.
12.3 Test reports shall state prolongation sizing prior to test or the use of axles for test.
13.0 MICROSCOPIC TEST FOR HEAT-TREATED AXLES (GRADES F, G, AND H)
13.1 A specimen, representing each size classification of each heat in each heat-treatment lot,
shall be taken for microscopic test from the tension test specimen. This section for microscopic test
shall be cut from the large undistorted portion of the tension test specimen in such a way as will
give a face transverse to the axis of the axle.
13.2 The face shall be polished practically free from scratches and shall be etched to define the
microstructure. The specimen shall be examined under a magnification of 100 diameters.
13.3 The entire specimen shall show a uniform, fine-grained structure, and shall have a grain
size of 5 or finer as measured in accordance with ASTM Standard Method E112, latest version.
14.0 NUMBER OF TESTS
14.1 Unless otherwise specified by the purchaser, mechanical tests for grades and sizes shown in
Table 10.1 shall be made from heat-treated axles as covered in paragraph 14.2
14.2 One test per grade, per heat, per size classification is required, but each test shall represent
no more than 70 axles, including the test axle. The axles represented by this test shall be called a
heat-treatment lot. Each heat-treatment lot of axles shall be heat-treated together, whether in
batch-type or continuous furnaces. In the event that the mechanical properties of a test do not con-
form to the requirements specified, all of the axles from the heat-treatment lot are to be retreated in
accordance with paragraph 15.2 of this specification.
14.3 If any test specimen fails because of mechanical condition of the testing apparatus, it may be
discarded and another specimen taken.
15.0 RETEST
15.1 If the results of the mechanical tests of any lot do not conform to the requirements specified
because a flaw developed in the test specimen during testing, a retest shall be allowed if the defect
is not caused by ruptures, cracks, or flakes in the steel.
15.2 If the result of the mechanical test of any lot of Grade F, G, or H axles does not conform to
the requirements specified, the axles may be retreated, but not more than three additional times,
and retests shall be made in accordance with paragraph 10.0.

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16.0 ULTRASONIC TESTING (NEW AXLES ONLY—RADIAL AND AXIAL)

16.1 Scope
16.1.1 This paragraph becomes effective July 1, 2009.
16.1.2 This paragraph applies to all new axles.
16.2 Time of Inspection
16.2.1 Axial—anytime during production following axle end facing and center drilling, but before
drilling cap screw holes.
16.2.2 Radial—anytime during production following initial rough turn (forged surfaces cannot be
effectively radial UT-tested).
16.3 Test Equipment
Type Pulse-echo-type broadband pass amplifier
Quantity One or more. Multiple transducer arrays must be capable of monitoring individual transducers.
A couplant must be used between the face of the transducer and the test surface. Same couplant
Couplant
to be used for test and calibration.
At least annually and each time the system receives maintenance that affects system
Machine Calibration
performance.

16.3.1 Axial Transducers

Frequency 1.0– 2.25 MHz
Size/shape 0.75–1.00 in. diameter or 1.00 in.2

16.3.2 Radial Transducers

Frequency Range 1.0–5.0 MHz
Size/shape 0.50–1.00 in. diameter or 1.00 in.2

16.4 Personnel
16.4.1 All personnel performing ultrasonic inspection operations must be prequalified to
non-destructive testing (NDT) Level 1, at a minimum, in accordance with American Society for
Nondestructive Testing (ASNT), Recommended Practice SNT TC-1A, latest edition.
16.4.2 All personnel setting up ultrasonic inspection systems must be prequalified to NDT Level 2,
at a minimum, in accordance with ASNT, Recommended Practice SNT TC-1A, latest edition.
16.4.3 Each manufacturer must employ the services of an individual who is prequalified to NDT
Level 3, at a minimum, in accordance with ASNT, Recommended Practice SNT TC-1A, latest edition.
16.5 Records
Each facility must maintain the following records for the duration indicated. Records must be
accessible within 4 hours upon request by any AAR representative.
• A procedural specification for each validated UT process (current revision)
• A posted controlled copy of each UT specification in each UT testing equipment area(s)
(current revision)
• All individual axle test results in printable form, including individual heat, axle serial
number, and date of inspection (10 years from date of manufacture)

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16.5.1 Personnel certifications for UT testing must be, at a minimum, in accordance with ASNT,
Recommended Practice SNT TC-1A, latest edition. Each certification must be endorsed by a
responsible official of that facility and the verifying level III (10 years).
16.5.2 Reference block semiannual validation record, including the inspector’s name/ID, revalida-
tion date, and measured surface finish of the reference block. (10 years)
16.6 Validation
Validation (system testing) must be performed using the same couplant used during axle testing.
All contact surfaces must be smooth with a surface roughness better than 125 microinch for axial
test and 500 microinch for the radial test. It also should be free from dirt and grit.
16.6.1 Axial
16.6.1.1 Calibration and System Tests
The ultrasonic inspection system must be validated initially upon installation and at least once
every year after initial installation.
16.6.1.1.1 Calibration—1/8-in. flat-bottom hole at 15-in. depth, set up at 20% full-screen height
using 16-in.-long reference block manufactured from a Grade F axle forging.
16.6.1.1.2 Detection Capabilities
1/8-in. flat-bottom hole From 2 in. to 15 in. depth, detectable in reference axle
1/4-in. flat-bottom hole From 15 in. to 30 in. depth, detectable in reference axle
3/8-in. flat-bottom hole From 30 in. to 46 in. depth, detectable in reference axle

16.6.1.2 Alternate reference standards may be used to calibrate or test system sensitivity, pro-
vided the output from the alternate standard is cross-referenced with the reference block and axle
of paragraph 16.6.1.1.1.
Example: the following alternates provide equivalent sensitivity:
• 1-in. indication from a #1 series “A” Alcoa block
• 1 1/2-in. indication from an ASTM E-127 block #1-0300
16.6.1.3 Reference standards must be inspected and certified semiannually for surface finish on
the inspection face(s) of 80 microinch to 125 microinch.
16.6.1.4 Periodic
16.6.1.4.1 Periodic tests shall be made during production testing against the 16-in.-long refer-
ence block described above, and adjustments shall be made to instrument controls to ensure com-
pliance with the specifications.
16.6.1.4.2 Periodic tests must be made at least once every 4 hours of use.
16.6.1.5 Continuous
16.6.1.5.1 Unscheduled system tests shall be made during production testing against the
16-in.-long reference block described above, and adjustments shall be made to instrument controls
to ensure compliance with the specifications.
16.6.1.5.1.1 Tests must be made every time there is a change of system operators.
16.6.1.5.1.2 Tests must be made every time there is a change of transducers, cables, or any other
system hardware or accessories.
16.6.1.5.1.3 Tests must be made every time there is an equipment malfunction or upon powering
on.

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16.6.2 Radial
16.6.2.1 Calibration and System Tests
16.6.2.1.1 The ultrasonic inspection system must be validated initially upon installation and at
least once every year after initial installation.
16.6.2.1.2 Calibration—The system must be calibrated to exhibit an 80% full-screen-height indi-
cation from the backface reflection in the thickest part of the production axle section (wheel seat).
16.6.2.1.3 Tests must be made every time there is an equipment malfunction or upon powering
on.
16.6.2.1.4 When a change to the equipment power source, transducer, operator, or coaxial cable
occurs, the system set-up must be reverified.
16.7 Inspection
16.7.1 General
16.7.1.1 Inspection surfaces must be free of all dirt and grit prior to the start of testing.
16.7.1.2 The same couplant must be used for calibration and examination.
16.7.1.3 During the axial discontinuity inspection test and the radial loss of back face reflection
test, an additional 6 dB shall be added to the reference or sensitivity level for scanning purposes.
Discontinuity evaluation shall be performed at the original recorded sensitivity level prior to final
disposition.
16.7.2 Axial
16.7.2.1 The amplitude of the ultrasonic indication must be considered in relation to its distance
from the testing surface to evaluate its significance. This can be accomplished by an electronic
device or by distance amplitude curves that are described in Appendix B, paragraph 2.0.
16.7.2.2 The variation in cross-section of the axle may produce spurious indications. These
expected indications must be recognized and are not cause for rejection.
16.7.2.3 Both end faces of the axle must be scanned to the full extent of the surfaces (100% area
coverage). The axle end faces must be prepared with a surface finish of 125 microinch or better.
16.7.2.3.1 If the amplitude of any indication exceeds the DAC curves as defined in Appendix B,
the axle is rejected.
16.7.2.3.2 If any backface reflection does not exceed 40% of screen height, the axle is rejected.
16.7.3 Radial
16.7.3.1 The variation in cross-section of the axle may produce spurious indications. These
expected indications must be recognized and are not cause for rejection.
16.7.3.2 Scan the entire length of the axle radially through the diameter along one line only. At a
minimum, the axle surface must be rough-turned with a surface finish of 500 microinch or better.
16.7.3.3 The axle will be rejected for a location if a loss of back reflection of 80% or greater is
experienced, unless the loss is attributed to geometry.
16.8 Marking
All axles that are to be tested radially must have the character “R” immediately following the axle
grade marking. All axles failing the radial test must be immediately identified and segregated for
scrapping.

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17.0 DIMENSIONS AND TOLERANCES

17.1 For other than the standard freight and passenger car axles referenced in this specification,
standard tolerances and allowances will apply, if not specified in axle drawings provided by the
purchaser.
17.2 Axle centers shall conform to Fig. C.5.
17.3 For all axles ordered for finished end facing by the purchaser, the overall length shall range
from 1/8 in. to 1/4 in. over the specified minimum length.
17.4 Rough machined journals and wheel seats shall be 1/8 in. to 1/4 in. over the finished diame-
ters and longitudinally 1/8 in. to 1/4 in. of metal shall be allowed at each change of cross section for
finish machining.
17.5 The smooth machined body shall be to the specified size, with no more than 1/8 in. over on
the diameters and shall have no more than 1/8 in. allowance longitudinally at each change of cross
section, unless specified otherwise in Fig. C.3.
18.0 WEIGHT
The approximate weights of the passenger and freight car axles covered by this specification are
shown in Specification M-101.
19.0 WORKMANSHIP AND FINISH
19.1 Axles shall be machined to a smooth machined finish between the wheel seats. The wheel
seats and journals shall be rough machined; the rough machining shall be free from objectionable
ridges and chatter marks. Journals, dust guard seats, and wheel seats of axles supplied in finished
form will comply with applicable provisions of the AAR Manual of Standards and Recommended
Practices, Section G, Part II, “Wheel and Axle Manual.”
19.2 Finish
The axles shall be free from injurious defects. The machining shall be done in a workmanlike man-
ner.
19.3 The interpretation of injurious defects in axles shall comply with Appendix A, “Interpreta-
tion of Defects Considered Injurious in Axles.”
20.0 MARKING
Axles shall be legibly cold stamped with characters not less than 1/4 in. high in accordance with
the AAR standard marking requirements shown in Fig. C.2.
21.0 INSPECTION
21.1 The inspector representing the purchaser shall have free entry, at all times while the work
on the contract of the purchaser is being performed, to all parts of the manufacturer’s works that
concern the manufacture of the material ordered. The manufacturer shall afford the inspector, free
of charge, all reasonable facilities and necessary assistance to satisfy the inspector that the mate-
rial is being furnished in accordance with these specifications. Tests and inspection for acceptance
shall be made at the place of manufacture.
21.2 The purchaser may make tests to cover the acceptance or rejection of the material in pur-
chaser’s own laboratory or elsewhere. Such tests shall be made at the expense of the purchaser.
21.3 The inspector shall examine each axle in each heat for workmanship, defects, and confor-
mity to the dimensions given on the order or drawing. If in this inspection defects are found that
the manufacturer can remedy, manufacturer may correct such defects.

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22.0 REJECTION
22.1 Any axle that fails to meet the requirements of these specifications will be rejected.
22.2 Axles that show injurious defects subsequent to their original inspection and acceptance at
the manufacturer’s works or elsewhere will be rejected and the manufacturer shall be notified.
23.0 REHEARING
Samples of axles tested in accordance with these specifications that represent rejected material
shall be held for 14 days from date of the test report. In case of dissatisfaction with the results of
the tests, the manufacturer may request a hearing within that time.
24.0 CERTIFICATION
Upon request of the purchaser in the contract or order, a manufacturer’s certification that the
material was manufactured and tested in accordance with this specification, together with a
report of the test results, shall be furnished at the time of shipment.
25.0 The following supplementary requirements shall apply only when specified by the
purchaser. Details shall be agreed upon by the manufacturer and the purchaser.
25.1 Macroscopic Tests
The prolongation from the largest axle in each heat shall be sawed normal to the axis of the axle
and shall then be split longitudinally. The transverse and the longitudinal face shall be etched for
microscopic examination. Reference shall be made to Specification ASTM E381, “Standard Method
of Macroetch Testing Steel Bars, Billets, Blooms, and Forgings.”
25.2 The purchaser may specify axle wheel seat diameters 1/8 in. larger than those shown under
dimension “I” in Fig. C.3.
26.0 This specification includes Appendices A, B, C, Figs. C.1 through C.5, and Specification M-101.

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M-101 APPENDIX A

APPENDIX A
INTERPRETATION OF DEFECTS CONSIDERED INJURIOUS IN AXLES
1.0 The conditions that have been most difficult for inspectors to evaluate are light lines visible to
the normal unaided eye, variously described as actual seams, hairlines, stringers, shadow seams,
ghost lines, etc., that appear after the axles have been finish-machined and burnished or ground. It
is therefore advisable to describe these conditions in more detail.
2.0 The interpretation of injurious defects as enumerated below is not to be considered as
precluding other unforeseen or objectionable conditions not specifically listed. The right of the
purchaser is reserved to reject temporarily such axles and make final settlement on the basis of
further negotiations between representatives of the manufacturer and the purchaser who are
especially qualified to decide such questions.
3.0 Any transverse or circumferential seams, cracks, or laps of indeterminate depth on the axle
surfaces other than the discolorations listed in paragraph 4.0, regardless of their location, are
considered to be injurious and are cause for rejection without further machining.
4.0 Ghost lines, shadow marks, or other similar discolorations, visible to the normal unaided eye
that are not actual separations in the metal are not considered injurious, regardless of location.
5.0 Any longitudinal discontinuity, variously termed hairline, stringer, or fine seam, in machined
fillets is considered to be injurious and is cause for rejection without further conditioning.
6.0 JOURNALS AND DUST GUARDS
6.1 Roller Bearing Axles
Fine longitudinal discontinuities on the finished (burnished or ground) surfaces variously termed
hairlines, stringers, or fine seams are not considered injurious if they meet the following condi-
tions:
6.1.1 Must not extend into fillets.
6.1.2 Must not be over 3/4 in. long individually in the journal or 1/2 in. long individually in the
dust guard seat.
6.1.3 Total length of such imperfections over 1/4 in. long must not exceed 2 in. in any one end of
axle.
7.0 WHEEL AND GEAR SEATS
7.1 Freight Car Axles (Roller Bearing)
Longitudinal seams in wheel seats of freight car axles are not considered injurious if they meet the
following conditions:
7.1.1 Must not extend into the dust guard or body fillets.
7.1.2 Must not be over 2 in. long individually.
7.1.3 Total length of such imperfections, 1/4 in. to 2 in. long, must not exceed 4 in. in any one end
of axle.

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7.2 All Other Axles

Longitudinal discontinuities on the finished machined surface of wheel and gear seats, variously
termed hairlines, stringers, fine seams, tight seams, surface imperfections, etc., are not considered
injurious if they meet the following conditions:
7.2.1 Must not extend within 1 1/2 in. of either end of wheel or gear seat.
7.2.2 Must not be over 1/2 in. long individually.
7.2.3 Total length of such imperfections, 1/4 in. to 1/2 in. long, must not exceed 3 in. in any one
end of axle.
8.0 AREAS BETWEEN WHEEL (AND GEAR) SEATS (BODY)
8.1 Machined Bodies
Longitudinal discontinuities on the finished surfaces, variously termed hairlines, stringers, or fine
seams, are not considered injurious if they meet the following conditions:
8.1.1 Must not extend into fillets adjacent to wheel or gear seat.
8.1.2 Must not be over 1/2 in. long individually.
8.1.3 Total length of such imperfections, 1/4 in. to 1/2 in. long, must not exceed 1 1/2 in. in any
12 in. of body length.
8.1.4 Axles containing longitudinal discontinuities in the body in excess of those described in
paragraphs 8.1.2 and 8.1.3 above may be reconditioned by grinding or machining, provided the
diameter is not reduced below the specified limit.

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M-101 APPENDIX B

APPENDIX B
DISTANCE AMPLITUDE CORRECTION
1.0 ALTERNATE REFERENCE STANDARDS
Alternate references may be used to establish the test sensitivity if they are cross-referenced with
the reference test block described in paragraph 16.6.1.1.1. For example, the following are alternate
references for heat-treated axles that give equivalent sensitivity: 1) a 1-in. indication from a #1
series “A” Alcoa block; and 2) a 1 1/2-in. indication from an ASTM E-127 block #1-0300.
2.0 DISTANCE-AMPLITUDE CORRECTION
The amplitude of an ultrasonic indication from a given discontinuity size varies with its distance
from the test surface. To compensate for this effect, a distance-amplitude relationship is employed.
The relationship can be established by an electronic device or by curves. Because the dis-
tance-amplitude relationship is influenced primarily by the ultrasonic transducer and instrument,
it is necessary to relate this factor to the specific equipment used. Appropriate distance-amplitude
curves shall be developed. A typical example is shown in Fig. B.2 as related to the axle in Fig. B.1.
3.0 SPURIOUS ULTRASONIC INDICATIONS FROM CONTOUR VARIATIONS
Because an axle varies in cross-section, it is possible to produce spurious indications, particularly
at changes of cross-section. These must be recognized and are not reason for rejection. It is not
practical to define these indications in the specification, but the competent operator or technician
will recognize these spurious indications as responses from axle contours.
4.0 NEAR-FIELD RESOLUTION
It should be recognized that detection of discontinuities near the test surface is limited by the
ultrasonic test frequency. In the case of heat-treated axles, this is approximately 1 in. from the test
surface.

Fig. B.1 Showing location of reference holes in axles

Fig. B.2 Typical distance-amplitude curve for heat-treated axle (as determined with a Sperry reflectoscope, Type UM
using a 1 1/8-in.-diameter, 2.25 MHz quartz transducer)

08/2009 G [M-101] 13
 AAR Manual of Standards and Recommended Practices
08/2009 Wheels and Axles
APPENDIX C M-101

APPENDIX C
QUALIFICATION OF MANUFACTURER’S PLANT AS A PRODUCER OF
AXLES FOR AAR INTERCHANGE SERVICE
1.0 Applications for approval are to be submitted to the AAR. Applications shall be provided in
electronic file format and must provide a general description of the facility and the equipment to
be used in the production of axles. In the event it is desired to deliver mounted wheel sets,
information indicating that equipment is available to comply with the wheel mounting
requirements of the AAR Manual of Standards and Recommended Practices, Section G, Part II,
“Wheel and Axle Manual,” should be included.
2.0 After satisfactory review of the data submitted with the application, the Committee will
authorize the applicant to contact the AAR for information concerning product testing. This will
consist of the applicant furnishing three axles, at applicant’s expense, for testing by the AAR. All
costs are to be paid by the applicant upon notification of the testing charges.
3.0 Subsequent to the satisfactory completion of the tests and approval by the Committee of test
results, the AAR will inspect for proper equipment the plant where the axles are to be produced
per S-649. If mounted wheels are to be provided, an AAR inspection will be arranged for the wheel
shop. These inspections will require that all costs be paid by the applicant. Upon the granting of
AAR approval, company marks to be stamped on the axle end face will be assigned.
4.0 All plants desiring to maintain their status as an AAR-approved manufacturer of axles for
use in AAR interchange service must be inspected as described in S-649. The costs of inspection
are to be borne by the axle producer. In the event that a facility fails to satisfy inspection or testing
expense obligation, the AAR, in conjunction with the Committee, reserves the right to withhold or
withdraw approval.
5.0 In the event that a facility ceases production for less than a year and has not received its
scheduled annual inspection, an inspection of the facility is required prior to the delivery of any
items for use in interchange service. In the event a plant ceases production of axles for AAR
interchange service for more than 60 days and less than 1 year, the AAR must be notified no later
than 2 weeks prior to reopening.
6.0 In the event a plant does not receive its annual inspection or ceases production of axles for
AAR interchange service for more than 1 year, requalification will be required prior to delivery of
any items for use in AAR interchange service.
7.0 In addition to the foregoing, axle manufacturers must meet the requirements of the AAR
Manual of Standards and Recommended Practices, Section J, Specification M-1003, “Specification
for Quality Assurance.”
8.0 All plants desiring to maintain their status as an AAR-approved manufacturer of axles for
use in AAR interchange service must also have their steel suppliers and heat-treating
subcontractors inspected if they do not use their own facility. These inspections will be made in
conjunction with the facility inspection, and the cost will be borne by the applicant.
9.0 Axle manufacturers using a native language other than English are responsible for the
accurate communication of all applicable AAR and customer requirements within the plant.
9.1 Plant practices and the final product must conform to the English language versions of any
applicable standards or specifications.
9.2 Critical records are defined as the standards, internal procedures, and forms necessary to
demonstrate compliance with this Specification M-101 and with MSRP Section J, Specification
M-1003. Critical records must be kept up to date with production and be maintained in English.

G [M-101] 14 08/2009
 AAR Manual of Standards and Recommended Practices
08/2009 Wheels and Axles
M-101 APPENDIX C

NOTE:
THE GAUGE LENGTH, PARALLEL SECTION, AND FILLETS SHALL BE AS SHOWN, BUT THE
ENDS MAY BE OF ANY SHAPE TO FIT THE HOLDERS OF THE TESTING MACHINE IN SUCH A
WAY THAT THE LOAD SHALL BE AXIAL.

Fig. C.1 Standard round tension test specimen with 2-in. gauge length
Paragraph 11.3

08/2009 G [M-101] 15
 AAR Manual of Standards and Recommended Practices
08/2009 Wheels and Axles
APPENDIX C M-101

STAMP HERE NOTE 4 NOTE 6 NOTE 5

11-66 66 A001 F R NOTE 7

ROLLER BRG. L 00000 USS-H

PASSENGER CARS NOTE 1 NOTE 2 NOTE 3
ONLY
CIRCUMFERENTIAL DEVELOPMENT
OF AXLE END

NOTE 6
NOTE 1

ROLLER BRG.
FREIGHT CARS NOTE 2
ONLY NOTE 4
NOTE 7
NOTE 5 NOTE 3
AAR STANDARD AXLE MARKINGS

NOTES: GENERAL NOTES:

1. LABORATORY ACCEPTANCE STAMP—FOR USE BY PURCHASER TO SIGNIFY • REFER TO THE LATEST MECHANICAL DIVISION CIRCULAR LETTER LISTING
ACCEPTANCE OF AXLES SO MARKED PRIOR TO SHIPMENT BY PRODUCER OF AAR-APPROVED AXLE MANUFACTURERS FOR CURRENT APPROVAL
2. SERIAL NUMBER. STATUS.
3. MANUFACTURER’S NAME OR BRAND (SEE TABLE BELOW) • ALL MARKS WILL BE DEEPLY AND LEGIBLY STAMPED WITH CHARACTERS
4. MONTH AND YEAR MADE NOT LESS THAN 1/4 IN. HIGH.
5. GRADE OF AXLE • ALL MARKS FOR FREIGHT CAR ROLLER BEARING AXLES MUST BE
LOCATED ADJACENT TO THE PERIPHERY OF THE CENTERING HOLE.
F =Double Normalized and Tempered • MANUFACTURERS MUST FINISH ONE END OF THE AXLE FOR STAMPING.
G =Quenched and Tempered • THE ABOVE ARE THE MINIMUM MARKING REQUIREMENTS, BUT THE LOCA-
H =Normalized, Quenched and Tempered TIONS ON INDIVIDUAL ITEMS MAY VARY FROM THAT ILLUSTRATED.
6. HEAT IDENTIFICATION NUMBER
7. IF AXLE IS RADIALLY UT’D, THEN STAMP IMMEDIATELY FOLLOWING AXLE
GRADE = R.

Manufacturer’s Name or Brand

AXIS AXIS LLC Paragould AR RW S. C. SMR S.A. Bals, Romania
BF Bumar-Fablock S.A. Chrzanow. Poland SCOTa/ Scot Forge Clinton, Wisconsin
BSa/ Bethlehem Steel Corporation Johnstown, PA SFC or Sa/ Standard Forgings
CAF Construcciones y Auxiliar de Ferrocarriles (CAF) Beasain, Spain SMI Sumitomo Metal Industries LTD. Osaka, Japan
CBa/ Cobrasma Brazil SPTa/ British Steel Templebourough
Works, England
CCC CNR Changchun Railway Vehicle Facilities Jilin Province,
Co.,Ltd. China SSD Standard Steel LLC. Burnham,
Pennsylvania
CF Valdunes (formerly Creusot-Loire) Dunkerque, France
SW SWASAP Works Germiston, South
CHB Baotou Baotou Inner
Africa
Mongolia PRC
Ta/ British Steel Trafford Park
CHT Jinxi Axle Company LTD. (Formerly Norinco Jinxi) Taiyuan, Shanxi
Works, England
Province, P.R.C
THM or TZ Taiyuan Heavy Industries Company LTD. Taiyuan, Shanxi
DDAP DDAP/RAX Dneprderzhinsk,
Province, P.R.C
Ukraine
TW plus a/ Hawker Siddeley Trenton Canada
DSS JSC Dneprospetsstal, Zaporozhye (DSS) Zaporozhye,
Ukraine UF Ural Forge Chebarkul, Russia
HM Huta Gliwice-Osie Sp. zo.o Gliwice, Poland USS-Fa/ United States Steel Corp. Fairfield Works
JAW Standard Forged Products Johnstown, PA USS-Ga/ United States Steel Corp. Gary Works
KWa/ Klockner West Germany USS-Ha/ United States Steel Corp. Homestead Works
L Lucchini Sidermeccanica SpA (Formerly Temi) Lovere, Italy V Valdunes (formerly Creusot-Loire) Valenciennes,
France
LCKZ LugCentroKuZ Lugansk, Ukraine
WAP Rail Wheel Factory Indian Railways (Formerly Yelahanka,
LP Huta L. W. (Formerly Lucchini Poland) Warsaw, Poland
Wheel and Axle Plant) Bagalore, India
MKa/ Makrotek Mexico
ZB Bonatrans a.s. (Formerly ZAD) Bohumin, Czech
MRF Standard Forged Products McKees Rocks, Republic
Pennsylvania
MW MWL Rodas & Eixos LTDA (Formerly Mafersa) Cacapavz, Sao a/ No Longer in Production
Paulo, Brazil

Fig. C.2 AAR standard marking requirements

Paragraph 20.0
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 AAR Manual of Standards and Recommended Practices
08/2009 Wheels and Axles
M-101 APPENDIX C

NOTE: “V” DIMENSION DESIGNATES MINIMUM LENGTH OF FULL THREAD. DEPTH OF DRILLED
HOLE MUST EQUAL “V” DIMENSION PLUS —7" MAXIMUM.
CHECK LOCATION WITH GAUGE 8
SHOWN ON MSRP SECTION G-II MAXIMUM PERMISSIBLE VARIATION IN JOURNAL DIAMETER AT ANY PLACE MUST
RP-634, Fig. 5.8 NOT EXCEED .001 INCH AND THERE SHALL BE NO ABRUPT CHANGES OR STEPS
OVER THE LENGTH OF THE JOURNAL.
“T” U.N.C.–2B TAP
3-HOLES COUNTERSINK 1/8" ± 1"— OVERALL LENGTH
O 16
LARGER THAN BOLT DIA. CL TO CL OF JOURNAL
BOLT DIA. “T” – REMOVE N
SHARP CORNERS. BREAK 1"R + 01" 3"R
SHARP +0 1—
2 –— E E
1"R
CORNER V 1—
2 –—1" 16
16
120
°
120

J
R

K
G

I
AXLES SHALL BE MACHINED TO 250 µin.
120° X B C D 2" MAX. BETWEEN WHEEL SEATS
1" + 0
STAMP ( * L)3'–11 —
4 –— 1"
IDENTIFICATION MARKS ±161"— 4
ON THIS SURFACE. W M
MACHINE CHAMFER TO
U ±161"—
250 µin. MAX. MATERIAL AAR SPECIFICATION
1"
— 1"
— M–101
16 R. MIN. TO 8 R. MAX.
ENLARGED SECTION SHOWING OPTIONAL * THE “L” DIMENSION NEED NOT BE CORRECTED FOR
RADIUS WHEN USING CONTOUR GRINDER LENGTH EACH TIME THE WHEEL SEATS ARE TURNED

NOTES:
1. “I” DIMENSION TOLERANCE IS +0.015 –0.015.
ON NEW AXLES MACHINE 3 in.
RADIUS AT SPECIFIED
2. MAXIMUM ALLOWABLE RUNOUT BETWEEN “G” AND “H” IS .006" TOTAL DIAL INDICATOR. DIMENSION “L” FOR ANY
3. MAXIMUM ALLOWABLE RUNOUT BETWEEN “G” AND “I” IS .008" TOTAL DIAL INDICATOR. WHEEL SEAT DIA.
4. FOR 7" × 12" JOURNALS, END CHAMFER IS 4° 15' 5/8" ±1/8".
L*

3"
5. REQUIRED FOR PRESS FIT OF ROLLER BEARING BACKING RING WHERE THE “H”
DIAMETER IS TOLERANCED. FINISH TO 125 µIN. MAXIMUM WHEN TOLERANCED. 2"
6. THE "W" DIMENSION CANNOT EXCEED THE TOLERANCE LIMITS OF THE GAUGE SHOWN IN
MSRP SECTION G-II, RP-634, FIG. 5.26.
OVER SIZE DIA.
7. RUNOUT ON JOURNAL SURFACE “G”, WHEN ROTATED ON CENTERS, MUST NOT EXCEED
.015" TOTAL DIAL INDICATOR.
WORN DIA.
NEW DIA.
8. DIMENSIONS “B” AND “N” ARE CONSIDERED ENGINEERING DATA FOR TRUCK DESIGN AND

1"
+—
8
–0
DO NOT NECESSARILY AGREE WITH AXLE MANUFACTURING TOLERANCES.

J
9. JOURNAL FINISH MUST NOT EXCEED 63 µIN., IF GROUND OR TURNED ONLY. IF TURNED
AND ROLLED, THE TURNED FINISH MUST NOT EXCEED 125 µIN., AND THE ROLLED FINISH ENLARGED VIEW SHOWING
MUST NOT EXCEED 16 µIN. CONDITION AT FILLET JOINING
BODY PORTION OF AXLE TO
INSIDE EDGE OF WHEEL SEAT.

Fig. C.3 Axle for freight car roller bearing—raised wheel seat (page 1 of 2)
Standard 1963; Revised 1984, 1998; Effective March 1, 1985
Paragraph 17.5 and Paragraph 25.2

08/2009 G [M-101] 17
 APPENDIX C
08/2009

CLASSIFI- DIMENSIONS
CATION SIZE OF
OF AXLE JOURNAL B C D E G H I J K M N O R T U V W X Y
D 5 1/2 × 10 5 1/2" 1 3/4" 7 5/8" 3" max 5.1915 6 3/8" 7 9/16" 6 3/4" 5 7/8" 62 1/2" 77" 86 1/8" 1 3/4" 7/8" – 9 66" 1 7/8" 10 1/6" 1 1/4" 2°8"
min. 5.1905 + 0/- 1/4
E 6 × 11 5 15/16" 1 13/16" 7 5/8" 3" max 5.6915 7.032 8 1/4" 7 5/16" 6 7/16" 62 1/2" 78" 88" 1 15/16" 1" – 8 66 1/8" 2" 10 15/16" 1 1/4" 2°8"
min. 5.6905 7.030 + 0/- 1/4
F 6 1/2 × 12 6 7/16" 1 13/16" 7 5/8" 3" max 6.1915 7.532 8 3/4" 7 7/8" 7 3/8" 62 1/2" 79" 89 5/8" 2 1/8" 1 1/8" – 7 66 1/8" 2 1/8" 11 3/4" 1 1/4" 2°8"
min. 6.1905 7.530 + 0/- 1/4
G 7 × 12 5 15/16" 2 5/16" 7 5/8" 3" max 7.004 8.002 9 1/2" 8 9/16" 8" 62 1/2" 79" 89 1/4" 2 5/16" 1 1/4" –7 67 1/8" 2 1/4" 11 1/16" 5/8" 4°15"
min. 7.003 8.000 ± 1/8

G [M-101] 18
K 6 1/2 × 9 4.853" 3.397" 7 5/8" 3" max 6.1915 7.532 8 3/4" 7 7/8" 7 3/8" 62 1/2" 79" 87.156" 2 1/8" 1 1/8"–7 69.294" 2 1/8" 8.931" .250" 10°
min. 6.1905 7.530 ± 0.20
Wheels and Axles

L 6×8 4.457 3.293 7 5/8" 3" max 5.6915 7.032 8 1/4" 7 5/16" 6 7/16" 62 1/2" 78" 85.5" 1 15/16" 1" – 8 69.086" 2" 8.207" — —
min. 5.6905 7.030
M 7×9 4.750 3.500 7 5/8" 3" max 6.5040 7.532 9 1/2" 8 9/16" 8" 62 1/2" 79" 87.500" 2 1/8" 1 1/8" – 7 69.500" 2 1/8" 9.000" — —
min. 6.5030 7.530
Fig. C.3 Axle for freight car roller bearing—raised wheel seat (page 2 of 2)
AAR Manual of Standards and Recommended Practices
M-101

08/2009
 AAR Manual of Standards and Recommended Practices
08/2009 Wheels and Axles
M-101 APPENDIX C

Freight Car Axles

Class Size (in.) A (in.) B (in.) C D (in.) E
D 5 1/2 × 10 3.5000 6 3/16 5.195 2 3/8 .740
E 6 × 11 3.8750 6 11/16 5.695 2 5/8 .850
F 6 1/2 × 12 4.2500 7 3/16 6.195 2 7/8 .955
G 7 × 12 4.6250 8 7.008 3 1/2 1.080
K 6 1/2 × 9 4.2500 7 3/16 6.195 2 7/8 .955
L 6×8 3.8750 6 11/16 5.695 2 5/8 .850
M 7×9 4.625 7 3/16 6.508 2 7/8 0.955
Amtrak Passenger Car Axles
D 5 1/2 × 10 3.0000 6 1/2 5.507 1 7/8 .636
E 6 × 11 3.5000 7 6.007 2 3/8 .749
F 6 1/2 × 12 3.8750 7 1/2 6.507 2 5/8 .749

MATERIAL: ASTM A-576, GRADE 1045 OR EQUIVALENT. PARTS TO BE HARDENED AND SURFACES MARKED “G” ARE TO BE GROUND. BREAK SHARP CORNERS. TOLER-
ANCE ON ALL DIMENSIONS TO BE 1/64 IN. UNLESS OTHERWISE SPECIFIED.

Fig. C.4 Pin-type gauge for cap screw holes in ends of roller bearing axles
Standard 1979; Revised 1982, 1998

08/2009 G [M-101] 19
 AAR Manual of Standards and Recommended Practices
Wheels and Axles
APPENDIX C M-101

FINISHED DIMENSIONS

AXLE SIZES
E – 6" × 11"
F – 6 2" × 12"
1

AXLE SIZES G – 7" × 12"

A – 3 4" × 7"
3
K – 6 2" × 9"
1 FOR AXLE WITH
FREIGHT ROLLER SPLINE BUSHING
B – 4 4" × 8"
1
L – 6" × 8"
C – 5" × 9" BEARING AND ALL M – 7" × 9"
PLAIN BEARINGS
D – 5 2" × 10"
1

16"
1
THICK STEEL
HARDENED

LATHE CENTER

NOTE:
DEPTH OF COUNTERBORE IN ROUGH AXLE SHALL BE INCREASED FROM THAT SHOWN TO COMPENSATE FOR STOCK ALLOWED TO FACE AXLE. WHEN SECONDHAND
AXLES ARE RECENTERED, DIAMETER AND DEPTH MAY BE INCREASED SUFFICIENTLY TO PRODUCE AN ACCURATE 60º CENTER.

Fig. C.5 Axle centering and gauge for axle center and lathe center
Adopted 1944; Revised 1966, 1979
Paragraph 17.2

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