Thermal Cracks 2010 Field Manual

Thermal Cracks 2010 Field Manual

Thermal Cracks 2010 Field Manual

Only one in book without magnetic particles

Thermal Cracks
Why Problematic?
Formed due to tensile stresses
Wheel Rim is manufactured with a compressive hoop stress
Heating produces expansion and more compression
But excessive heating or cyclic heating can cause surface of
wheel to yield and plastically deform
This results in in substantial tensile hoop stress when the
wheel cools
If the tensile hoop stress is high enough, the wheel will
crack perpendicular to the circumferential direction

Crack will grow through fatigue from rolling stresses

Crack may propagate through rim with further
heating

Recent Thermal Crack Activity

Nearly all L1,R2,L3,R4 wheels on a coal train set were
found with thermal cracks (2007)
Several more in 2008 and 2009
ALSO- large increase in non-unit trains

Thermal Crack (WM74)Billable Investigation

Large Increase in WM74
during 2007-2009
Shoe type and overriding/
abnormal position strongly
correlated
UP Shoe Replacement
Strategy throughout 08-09

UPRR Actions have remained constant WM74 Numbers Grew

WM74 Correlations
Although UP has had various shoes on various car series
since 1998, few problems with WM74 were apparent
until the 2007 timeframe.

Believed to be due to:

Recent Changes
Shoe Position on Wheel
Shoe Chemistry
Shoe Design

Events Leading to Rule 41 change

10/3/07 - 2/11/08
WM74 investigation of UCEX wheels by RSI (verified wm74)
8/21/08-9/25/08
WM74 investigation of CEFX wheels by RSI (verified wm74)
1/12/09 -TILX train set
No WM74 on half of train with SHOE A All WM74 on other half with SHOE B

2/3/09 WABL asked to better define WM74

2/20/09 - AAR MID special investigation - report in conflict with UP
2/24/09 Greenbrier(Meridian) KC investigation (AAR/FRA/UP/Others)
Verified wm74 by cutting on lathe
3/5/09 Progress Rail Sidney investigation (AAR/FRA/UP/Others)
WM74s verified by lathe truing
7/1/09
WABL revamps Rule 41 to align / provide clarity in matter

Recent Events
12/25/09 Derailment of the CSMLH-22
MP589551 Thermal Crack w/suspect shoes
1/15/2010 MID inspection at North Platte
52 of 54 WM74 wheels said to be removed improperly (not thermal cracks)

Prompted another investigation (Destructive Testing at RSI)

3/9/2010 - MID inspection at Council Bluffs

10 WM74 wheelsets
MID Non cracked Opinion / UP all 10 cracked

UPRR/MID walked entire train with close inspection

MID No thermal cracks / UP 4 thermal cracks

Destructive Test Overview

UPRR shipped a truckload of WM74 wheels from
North Platte MID special investigation
9 were machined for testing
7-inch span
1 thickness at center
Loaded until failure

3 WM11 wheels also tested

L
O
A
D

Test Results

No
t
Cr a
cke
d

UP removed WM74 wheels - all contained

surface thermal cracks (highly oxidized and
black indicating formation while hot)
UP removed WM74 wheels all failed at
reduced loads compared to the non cracked
wheels
WM74 wheels all Brittle fracture (sharp edge)
Non WM74 wheels Ductile/tough (45 shear lips)
Sample # Car Init Car # Wheel Mfg Wheel Date Serial # Breaking Load Average Load
1
TTZX 858081
SW
11/03
14908
70,000
2
TTZX 858081
SW
11/03
2718
75,000
3

TTZX 866386

SW

10/06

4427

48,000

MP

583257

GK

10/06

1530

NoTest Data

MP

583257

GT

09/06

71487

66,000

MP

583257

GK

10/06

1440

71,000

CRDX

9221

GK

06/00

99462

48,000

TTZX 866386

SW

12/04

1945

22,000

TTZX 865958

SW

12/04

103578

64,000

NON #1

SHPX

43244

GK

08/98

33053

90,437

NON #2

SHPX

43244

GK

08/98

33053

93,093

NON #3

SHPX

43244

GK

08/98

33053

103,720

Notes

66,000

Center Cracked

44,667

Edge Cracked

95,750

Not Cracked

#1 SW 11/03 14908 70k

Brittle Fracture
No Shear Lips

#2 SW 11/03 2718 75k

#3 SW 10/06 4427 48k

#4 GK 10/06 1530 - ??k

#5 GY 09/06
71487 66k

#6 GY 10/06 1440 70k

#7 GK ??/90 9221 48k

#8 SW 12/04 1945 22k

Brittle Fracture
No Shear Lips

#9 SW 12/04 3578 64k

3 Samples: Not Thermal Cracked

Shear Lips
Ductile Fracture
Tough/Strong

#1
#190k
90k

#2 93K
Shelled Area
Strength Good

#3 104K

Summary
Thermal cracks are formed when wheel stress
is reversed into TENSION around the
circumference
This is a rare occurrence
Easy to find by trained carmen
However, cannot measure level of stress in the
field

UPRR cannot tolerate the risks associated with

thermal cracks
Much higher likelihood of failure and derailment
FRA exceptions/fines

Current Process
Time Problem MID inspections occur days later
Morning dew is enough to rust the evidence
Hard to find which crack the wheel was pulled for

Proof Problem Only Lathe or Destructive Testing

Training Problem Field Manual still insufficient
UPRR process:
1) Find crack 2) Verify with others 3) Mark the one
4) Verify again with Mag Particle (CYA)

Summary
UPRR believes the root cause of the thermal cracks to be
due mainly to the effects of abusive shoes and
overriding/abnormal shoe positions
It is believed that removal of the abusive shoes or correct
shoe position will eliminate nearly all thermal crack risks
In every case investigated, the standard UP practices for
inspecting and finding thermal cracks have been upheld and
all metallurgical and mechanical tests have proven UP to be
correct in their assessment of thermal cracks
UP will work with MID and with WABL to further improve
rule clarity
UP will continue to work with customers to home shop cars
for significant quantities of repairs