Aar M 101 PDF

03/2011
Association of American Railroads

SAFETY AND OPERATIONS
MANUAL OF STANDARDS
AND
RECOMMENDED PRACTICES
SECTION G
WHEELS AND AXLES
Effective March 2011
Compiled under the direction of the Committees responsible for the subjects shown herein.
Published by
The Association of American Railroads

425 Third Street, SW., Washington, D.C. 20024
Copyright Association of American Railroads
Printed in U.S.A.
03/2011
Copyright 2011 by the Association of American Railroads (AAR)

Safety and Operations
425 Third Street SW.
Washington, D.C. 20024
All rights reserved, including the right to reproduce this book in any form. It is the AARs intention that this publica-
tion be used to promote the objectives of the AAR and its members for the safe, efficient, and uniform interchange of
rail equipment in North America. To this end, only excerpts of a rule or specification may be reproduced by the pur-
chaser for their own use in promoting this objective. No portion of this publication may be displayed or otherwise
made available to multiple users through any electronic distribution media including but not limited to a local area net-
work or the Internet. No portion may be sold or used for advertisement or gain by any entity other than the AAR and
its authorized distributor(s) without written permission from the AAR.
AAR Manual of Standards and Recommended Practices
Wheels and Axles
ORDERING INFORMATION
Copies of the various sections of this manual can be obtained as follows:
ORDERS FOR Publications Department

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Online ordering: http://www.aarpublications.com/
CIRCULAR Subscriptions to Circular Letters of the AAR Safety and Operations Technical Services are available in
LETTER hardcopy or electronic format (online access via AARs Web page at www.aarcirculars.aar.org). Circulars
SUBSCRIPTIONS are issued at least monthly and include industry letter ballots and results, arbitration decisions, notification
of rules and standards revisions, industry early warning and maintenance advisories, and other
information related to mechanical rules and standards. Subscriptions are valid for one year.
For ordering information, contact the following:
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MSRP-A1 The MSRP-A1 Table of Contents is an inclusive index of all MSRP specifications, standards, and
INDEX recommended practices. It is available online at http://www.aar.com/aar_standards-publications.htm This
easy-to-access document is a convenient way to quickly identify in which manual a specific document
resides. The index is updated weekly, enabling the user to see in "real-time" which documents have been
updated via Circular Letter.
TECHNICAL For technical questions regarding this manual, contact the following:
QUESTIONS Technical Committee Coordinator
Transportation Technology Center, Inc.
P.O. Box 11130
55500 DOT Road
Pueblo, CO 81001
Email: wabl@aar.com
Phone: 719-584-0670
Fax: 719-585-1895
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Wheels and Axles
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Wheels and Axles
TO THE USER
Section GWheels and Axles, Manual of Standards and Recommended Practices, covers three
main components: the wrought (or forged) steel wheel, the cast steel wheel, and the steel axle. Be-
cause of the critical functions of all these components, exhaustive details are given on design, met-
allurgy, manufacture, inspection, acceptance, assembly, wear limits, reclamation, and machining
for reuse. Wheels and axles are medium-range carbon steels containing a maximum of less than 1%
manganese and minimal levels of phosphorus, sulfur, and silicon. Wheels subjected to severe ser-
vice conditions have rims heat-treated and quenched to produce wear-resistant surfaces, followed
by overall tempering and controlled cooling. Axles must always be normalized and, when used un-
der high-capacity freight cars, passenger cars, and locomotives, are to be heat-treated, normalized,
quenched, and tempered. A specification included in this volume treats electrochemical metal dep-
osition for restoration of journal surfaces of roller bearing axles. There also are standards and rec-
ommended practices for dimensions, marking, inspection, gauges, condemning limits, wheel
mounting, and manufacturing tolerances.
USERS GUIDE
Section G contains three specifications, twenty-one standards, and thirteen recommended practic-
es. It consists of the following:
Preface: A listing of the subjects covered in the 25 individual sections, the volumes mak-
ing up this manual. This preface is part of each section.
Table of ContentsAlphabetical: An alphabetical listing of the specifications (M pre-
fix), standards (S prefix), and recommended practices (RP prefix).
Table of ContentsNumerical: A numerical listing of the specifications (M prefix),
standards (S prefix), and recommended practices (RP prefix).
Section G: A generalized subject listing that indicates applicable specifications, stan-
dards, and recommended practices.
Specifications, Standards, and Recommended Practices: The body of this volume.
RELATED SECTIONS
Section GWheels and Axles, should be used in conjunction with Section G, Part IIWheel and
Axle (shop) Manual. Other sections containing pertinent information are as follows:
Section DTrucks and Truck Details
Section HJournal Bearing and Lubrication
Section H, Part IIRoller Bearing (Shop) Manual
Section H, Part IIILubrication Manual
Section JSpecifications for Quality Assurance, M-1003
RESPONSIBILITY
The coverage of Section GWheels and Axles, is the responsibility of the AAR Wheels, Axles, Bear-
ings, and Lubrication Committee.
03/2011 Giii
Wheels and Axles
PREFACE
The Manual of Standards and Recommended Practices of the Safety and Operations Depart-
ment, Association of American Railroads, is issued by authority of the Management Committee of
the Division and includes all regularly adopted specifications, standards, and recommended prac-
tices of the Association of American Railroads.
The manual is composed of the following sections:
Section ASAdministrative Supplement serves as a suplement to all MSRP sections (this
is available as a free download at http://www.aar.com/aar_standards-publications.htm)
Section ATable of Contents, Alphabetical and Numerical Index of Sections B through S
inclusive (this is available as a free download at http://www.aar.com/aar_standards-publications.htm)
Section BCouplers and Freight Car Draft Components (100 Series)
Section CCar ConstructionFundamentals and Details (200 and 2000 Series)
Section C, Part IIDesign, Fabrication, and Construction of Freight Cars, M-1001
Section C, Part IIISpecifications for Tank Cars, M-1002
Section DTrucks and Truck Details (300 and 3000 Series)
Section EBrakes and Brake Equipment (300, 400, and 4000 Series)
Section E, Part IIElectronically Controlled Brake Systems
Section FSensors
Section GWheels and Axles (600 Series)
Section G, Part IIWheel and Axle (Shop) Manual (600 Series)
Section HJournal Bearings and Lubrication (700 Series)
Section H, Part IIRoller Bearing (Shop) Manual (700 Series)
Section H, Part IIILubrication (Shop) Manual (700 Series)
Section IIntermodal Equipment Manual
Section JSpecification for Quality Assurance, M-1003
Section KRailway Electronics (5700 Series)
Section K, Part IIRailway Electronics (5800 Series)
Section K, Part IIIRailway Electronics (5900 Series)
Section LLettering and Marking of Cars (900 Series)
Section MLocomotives and Locomotive Interchange Equipment
Section NMulti-Level Manual
Section SCasting Details
Section S, Part IITruck Details and Casting Codes
Section S, Part IIICoupler and Yoke Details
Specifications are designated with an M prefix (e.g., M-900). Standards are prefixed S (e.g.,
S-900). Recommended Practices carry the prefix RP( e.g., RP-900).
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03/2011 Wheels and Axles
TABLE OF CONTENTSALPHABETICAL
Subject Standard Page

Axle for Passenger Cars (Amfleet) Inboard Roller Bearing S-658 G[S-658]101
Raised Wheel Seat
Axle, WeightMachined Finish, Raised Wheel Seat RP-622 G[RP-622]157
Axles, Carbon Steel, Heat-Treated M-101 G[M-101]1
AxlesManufacturing Facility Inspection By Technical S-649 G[S-649]97
Services
Circumference Measure (Tape) for 27-in. to 38-in. Steel S-612 G[S-612]73
Wheels
Circumference Measure (Tape) for 38-in. to 52-in. Steel S-613 G[S-613]75
Wheels
Electrochemical Metal Deposition for Repairing Roller M-967 G[M-967]61
Bearing Axle Journals
Gauge, AxleMaster Gauge For Verifying Axle Journal and RP-613 G[RP-609]145
Fillet Gauge S-614
Gauge, AxleReference Gauge For Verifying Axle Journal S-616 G[S-616]81
and Fillet Gauge S-614
Gauge, WheelApplication Drawing For AAR 1B Wheel RP-637 G[RP-637]165
Gauges S-661 and S-665
Gauge, WheelApplication Drawing For AAR 1B Wheel RP-636 G[RP-636]163
Gauge, WheelApplication Drawing For Reference Gauge To RP-638 G[RP-638]167
Verify Wheel Gauges S-661, S-662, S-663, S-664, S-665, S-
666, S-667, and S-668
Gauge, WheelApplication for Measuring Condemnable RP-630 G[RP-630]161
Overheated Wheels
Gauge, WheelCombination Gauge For Wheel S-627 G[S-627]87
Measurements
Gauge, WheelCombination Gauge For Wheel S-628 G[S-628]89
Measurements Including Locomotive Flange Limit Of
0.875 In.
Gauge, Wheelfor Measuring Condemnable Overheated RP-629 G[RP-629]159
Wheels
Gauge, WheelFormer Standard 1976 S-618 G[S-618]85
Gauge, WheelFormer Standard 1980 S-617 G[S-617]83
Gauge, WheelMaster Gauge For Verifying Wheel Gauges S- RP-614 G[RP-614]151
617 and S-618
Gauge, WheelMaximum Flange Thickness, Height, and S-661 G[S-661]109
Throat Radii Gauge for AAR-1B Narrow-Flange Steel
Wheel
Gauge, WheelMaximum Flange Thickness, Height, and S-665 G[S-665]117
Throat Radii Gauge for AAR-1B Wide-Flange Steel Wheels
Gauge, WheelMinimum Flange Thickness, Height, and S-662 G[S-662]111
Wheel
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Subject Standard Page

Gauge, WheelMinimum Flange Thickness, Height, and S-667 G[S-667]121
Gauge, WheelReference Gauge For Verifying Combination S-629 G[S-629]91
Wheel Gauge S-627
Gauge, WheelReference Limit Gauge For Verifying AAR 1B S-663 G[S-663]113
Narrow Flange Wheel Gauge S-661
Wide Flange Wheel Gauge S-665
Analytic Evaluation of Locomotive Wheel Designs S-669 G[S-669]125
Gauge, WheelReference Master Disk For Verifying Wheel RP-608 G[RP-608]143
Circumference Gauges S-612 and S-613
Gauge, WheelSimplified RP-615 G[RP-615]153
Gauge, WheelStandard S-630 G[S-630]95
Inspection Stand for Use with Master Disks RP-609 G[RP-609]145
Mounting Pressures for Wrought and Cast Steel Wheels on RP-612 G[RP-612]147
Gear-Driven and Idler Axles of Locomotives Other than
Steam
Reference Groove for Multiple-Wear Diesel Wheels RP-619 G[RP-619]155
Wheel DefectWorn Journal Collar and Journal Fillet Gauge S-614 G[S-614]77
Wheel DefectWorn Journal Collar and Journal Fillet Gauge S-615 G[S-615]79
Wheel Designs, Locomotive and Freight CarAnalytic S-660 G[S-660]103
Evaluation
Wheel, Passenger Car (Amfleet) S-657 G[S-657]99
Wheels, Carbon Steel M-107/M-208 G[M-107/M-208]21
WheelsManufacturing Facility Inspection By Technical S-601 G[S-601]69
Services
WheelsMeasuring Wheel Circumference (Tape) Using S-611 G[S-611]71
Wheel Gauges S-612 and S-613
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TABLE OF CONTENTSNUMERICAL
Standard Subject Page

M-101 Axles, Carbon Steel, Heat-Treated G[M-101]1
M-107/M-208 Wheels, Carbon Steel G[M-107/M-208]21
M-967 Electrochemical Metal Deposition for Repairing Roller G[M-967]61
Bearing Axle Journals
S-601 WheelsManufacturing Facility Inspection By Technical G[S-601]69
Services
S-611 WheelsMeasuring Wheel Circumference (Tape) Using G[S-611]71
Wheel Gauges S-612 and S-613
S-612 Circumference Measure (Tape) for 27-in. to 38-in. Steel G[S-612]73
Wheels
S-613 Circumference Measure (Tape) for 38-in. to 52-in. Steel G[S-613]75
Wheels
S-614 Wheel DefectWorn Journal Collar and Journal Fillet Gauge G[S-614]77
S-615 Wheel DefectWorn Journal Collar and Journal Fillet Gauge G[S-615]79
S-616 Gauge, AxleReference Gauge For Verifying Axle Journal G[S-616]81
and Fillet Gauge S-614
S-617 Gauge, WheelFormer Standard 1980 G[S-617]83
S-618 Gauge, WheelFormer Standard 1976 G[S-618]85
S-627 Gauge, WheelCombination Gauge For Wheel G[S-627]87
Measurements
S-628 Gauge, WheelCombination Gauge For Wheel G[S-628]89
Measurements Including Locomotive Flange Limit Of
0.875 In.
S-629 Gauge, WheelReference Gauge For Verifying Combination G[S-629]91
Wheel Gauge S-627
S-630 Gauge, WheelStandard G[S-630]95
S-649 AxlesManufacturing Facility Inspection By Technical G[S-649]97
Services
S-657 Wheel, Passenger Car (Amfleet) G[S-657]99
S-658 Axle for Passenger Cars (Amfleet) Inboard Roller Bearing G[S-658]101
Raised Wheel Seat
S-660 Wheel Designs, Locomotive and Freight CarAnalytic G[S-660]103
Evaluation
S-661 Gauge, WheelMaximum Flange Thickness, Height, and G[S-661]109
Wheel
S-662 Gauge, WheelMinimum Flange Thickness, Height, and G[S-662]111
Wheel
S-663 Gauge, WheelReference Limit Gauge For Verifying AAR 1B G[S-663]113
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Standard Subject Page

S-665 Gauge, WheelMaximum Flange Thickness, Height, and G[S-665]117
S-667 Gauge, WheelMinimum Flange Thickness, Height, and G[S-667]121
S-669 Analytic Evaluation of Locomotive Wheel Designs G[S-669]125
RP-608 Gauge, WheelReference Master Disk For Verifying Wheel G[RP-608]143
Circumference Gauges S-612 and S-613
RP-609 Inspection Stand for Use with Master Disks G[RP-609]145
RP-612 Mounting Pressures for Wrought and Cast Steel Wheels on G[RP-612]147
Gear-Driven and Idler Axles of Locomotives Other than
Steam
RP-613 Gauge, AxleMaster Gauge For Verifying Axle Journal and G[RP-609]145
Fillet Gauge S-614
RP-614 Gauge, WheelMaster Gauge For Verifying Wheel Gauges S- G[RP-614]151
617 and S-618
RP-615 Gauge, WheelSimplified G[RP-615]153
RP-619 Reference Groove for Multiple-Wear Diesel Wheels G[RP-619]155
RP-622 Axle, WeightMachined Finish, Raised Wheel Seat G[RP-622]157
RP-629 Gauge, Wheelfor Measuring Condemnable Overheated G[RP-629]159
Wheels
RP-630 Gauge, WheelApplication for Measuring Condemnable G[RP-630]161
Overheated Wheels
RP-636 Gauge, WheelApplication Drawing For AAR 1B Wheel G[RP-636]163
RP-637 Gauge, WheelApplication Drawing For AAR 1B Wheel G[RP-637]165
RP-638 Gauge, WheelApplication Drawing For Reference Gauge To G[RP-638]167
Verify Wheel Gauges S-661, S-662, S-663, S-664, S-665, S-
666, S-667, and S-668
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REQUIREMENTS FOR WHEELS AND AXLES MANUFACTURED TO AAR

SPECIFICATIONS
The requirements of these standards, recommended practices, and specifications represent the
minimum acceptable requirements. All manufacturers of wheels and/or axles are urged to exceed
the intent of these requirements as much as possible. These specifications have been developed on
the basis of extensive field experience and tests. Each specification contained herein should be read
as including an additional requirement for satisfactory performance under a field test if such test
is deemed appropriate after consideration by the Assistant Vice President of Technical Services and
Chief of Technical Standards, working with the appropriate technical committee(s).
Normally, periodic inspections of manufacturers facilities will be conducted by AAR personnel ap-
proximately every year. These periodic inspections will include wheel mounting facilities, where ap-
plicable.
When inspection of manufacturing processes or facilities of companies manufacturing wheels and/
or axles for use on cars in interchange service involve travel, the out-of-pocket expenses involved to
conduct such required inspections will be paid by the company offering such products for this ser-
vice. Expenses will be prorated when more than one facility is visited in the same geographic area.
03/2011 Gix
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M-101
AXLES, CARBON STEEL, HEAT-TREATED
Specification
M-101
Adopted: 1914; Last Revised: 20

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 FDouble normalized and tempered. (All freight axles over 6 1/2 in. nominal di-
ameter at center shall be Grade F.)
Grade GQuenched and tempered.
Grade HNormalized, quenched, and tempered.
Grades F, G, and HAxles 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. Proposed changes to material or manufacturing processes must be submitted to the AAR
for consideration. Approval of a new material or process may include meeting the requirements
stated in Appendix C.
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 rolling 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.
03/2011 G [M-101] 1
M-101
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 manufacturers 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.
G [M-101] 2 03/2011
M-101
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 purchasers 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
03/2011 G [M-101] 3
M-101
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.
G [M-101] 4 03/2011
M-101
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.
03/2011 G [M-101] 5
M-101
16.0 ULTRASONIC TESTING (NEW AXLES ONLYRADIAL 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 Axialanytime during production following axle end facing and center drilling, but before
drilling cap screw holes.
16.2.2 Radialanytime 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 0.751.00 in. diameter or 1.00 in.2
16.3.2 Radial Transducers

Frequency Range 1.05.0 MHz
Size/shape 0.501.00 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)
G [M-101] 6 03/2011
M-101
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 inspectors 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 Calibration1/8-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
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.
03/2011 G [M-101] 7
M-101
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 CalibrationThe 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.
G [M-101] 8 03/2011
M-101
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 manufacturers 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-
chasers 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.
03/2011 G [M-101] 9
M-101
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 manufacturers 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 manufacturers 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.
G [M-101] 10 03/2011
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.
03/2011 G [M-101] 11
APPENDIX A M-101
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.
G [M-101] 12 03/2011
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)
03/2011 G [M-101] 13
APPENDIX C M-101
APPENDIX C
QUALIFICATION OF MANUFACTURERS 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 applicants 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 03/2011
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
03/2011 G [M-101] 15
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 STAMPFOR 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. MANUFACTURERS 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 UTD, THEN STAMP IMMEDIATELY FOLLOWING AXLE
GRADE = R.
Manufacturers Name or Brand

AXIS AXIS LLC Paragould AR QRSS Qiqihar Railway Rolling Stock Ltd. Qiqihar, P.R.C.
BF Bumar-Fablock S.A. Chrzanow. Poland RW S. C. SMR S.A. Bals, Romania
BSa/ Bethlehem Steel Corporation Johnstown, PA SCOTa/ Scot Forge Clinton, Wisconsin
CAF Construcciones y Auxiliar de Ferrocarriles (CAF) Beasain, Spain SFC or Sa/ Standard Forgings
CBa/ Cobrasma Brazil SMI Sumitomo Metal Industries LTD. Osaka, Japan
CCC CNR Changchun Railway Vehicle Facilities Jilin Province, SPTa/ British Steel Templebourough
Co.,Ltd. China Works, England
CF Valdunes (formerly Creusot-Loire) Dunkerque, France SSD Standard Steel LLC. Burnham,
Pennsylvania
CHB Baotou Baotou Inner
Mongolia PRC SW SWASAP Works Germiston, South
Africa
CHT Jinxi Axle Company LTD. (Formerly Norinco Jinxi) Taiyuan, Shanxi
Province, P.R.C Ta/ British Steel Trafford Park
Works, England
DDAP DDAP/RAX Dneprderzhinsk,
Ukraine THM or TZ Taiyuan Heavy Industries Company LTD. Taiyuan, Shanxi
Province, P.R.C
DSS JSC Dneprospetsstal, Zaporozhye (DSS) Zaporozhye,
Ukraine TW plus a/ Hawker Siddeley Trenton Canada
HM Huta Gliwice-Osie Sp. zo.o Gliwice, Poland UF Ural Forge Chebarkul, Russia
JAW Standard Forged Products Johnstown, PA USS-Fa/ United States Steel Corp. Fairfield Works
KWa/ Klockner West Germany USS-Ga/ United States Steel Corp. Gary Works
L Lucchini Sidermeccanica SpA (Formerly Temi) Lovere, Italy USS-Ha/ United States Steel Corp. Homestead Works
LCKZ LugCentroKuZ Lugansk, Ukraine V Valdunes (formerly Creusot-Loire) Valenciennes,
France
LP Huta L. W. (Formerly Lucchini Poland) Warsaw, Poland
WAP Rail Wheel Factory Indian Railways (Formerly Yelahanka,
MKa/ Makrotek Mexico
Wheel and Axle Plant) Bagalore, India
MRF Standard Forged Products McKees Rocks,
ZB Bonatrans a.s. (Formerly ZAD) Bohumin, Czech
Pennsylvania
Republic
MW MWL Rodas & Eixos LTDA (Formerly Mafersa) Cacapavz, Sao
Paulo, Brazil a/ No Longer in Production
Fig. C.2 AAR standard marking requirements

Paragraph 20.0
G [M-101] 16 03/2011
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 in.
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 in. MAX. MATERIAL AAR SPECIFICATION
1"
1"
M101
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 IN. 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. 5.27.
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 IN., IF GROUND OR TURNED ONLY. IF TURNED
AND ROLLED, THE TURNED FINISH MUST NOT EXCEED 125 IN., AND THE ROLLED FINISH ENLARGED VIEW SHOWING
MUST NOT EXCEED 16 IN. CONDITION AT FILLET JOINING
BODY PORTION OF AXLE TO
INSIDE EDGE OF WHEEL SEAT.
Fig. C.3 Axle for freight car roller bearingraised wheel seat (page 1 of 2)
Standard 1963; Revised 1984, 1998; Effective March 1, 1985
Paragraph 17.5 and Paragraph 25.2
03/2011 G [M-101] 17
APPENDIX C
03/2011
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 1/16" 1 1/4" 28"
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" 28"
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" 28"
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" 415"
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 68 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 79 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 bearingraised wheel seat (page 2 of 2)
M-101
03/2011
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 68 3.8750 6 11/16 5.695 2 5/8 .850
M 79 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
03/2011 G [M-101] 19
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 60 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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M-107/M-208
WHEELS, CARBON STEEL
Specification
M-107/M-208

1.0 SCOPE
These specifications cover one-wear, two-wear, and multiple-wear wrought and cast carbon steel
wheels for locomotives and carsClasses L, A, B, C, and D (heat-treated) wheels used in inter-
change service. All freight car wheels manufactured for AAR interchange service must be
heat-treated and of a low-stress design.
1.1 Class B, C, or D wheels must be used for freight cars in interchange service.
1.2 Class B, C, or D wheels are recommended for use on locomotives.
1.3 For passenger car service, the various classes are intended generally as follows:
Class L High-speed service with more severe braking conditions than other classes and light
wheel loads.
Class AHigh-speed service with severe braking conditions, but with moderate wheel loads.
Class BHigh-speed service with severe braking conditions and heavier wheel loads.
Class C(1) Service with light braking conditions and heavy wheel loads.
(2) Service with heavier braking conditions where off-tread brakes are employed.
2.0 DESIGN
2.1 Standard wheel types and tread and flange contours for freight car and locomotive steel
wheels shall be as shown in this specification. Interchangeability requirements and tolerances and
tread and flange contours for the authorized wheel types are shown in Figs. B.8 through B.14. The
interchangeability requirements and tolerances are generally limited to those required to ensure
the wheel is compatible with the standard axles, bearings, side frames, and track. In the event
that design constraints other than these are shown, the wheel producer may request an exception
or change by application, with supporting data, to the AAR Technical Services Division (hereinaf-
ter termed AAR). Staff will, in turn, submit the application to the Wheels, Axles, Bearings, and
Lubrication (WABL) Working Committee (hereinafter referred to as the Committee) for review.
2.2 In the event any company feels there is a need for a wheel type not currently listed, an appli-
cation, with supporting data, should be made to the AAR, who will obtain the decision of the Com-
mittee.
3.0 Authorization for delivery for interchange use of any AAR wheel type must be obtained from
the AAR as described in Appendix A.
4.0 Qualification as a manufacturer of wheels for use in AAR interchange service must be in
accordance with Appendix B. Qualification is effective until revoked for cause by the Committee.
Failure to maintain reasonable quality standards in manufacturing is an example of cause.
03/2011 G [M-107/M-208] 21
M-107/M-208
5.0 MANUFACTURE
5.1 Discard
A sufficient discard shall be made from the steel used for the manufacture of all steel wheels to
ensure freedom from piping and undue segregation.
5.2 Temperature Control
During manufacture of all wheels, necessary care in the regulation of temperature gradients shall
be exercised to prevent the development of internal defects or injurious stresses.
6.0 HEAT TREATMENT
6.1 All wheels must be rim-quenched and tempered.
6.2 Rim-Quenching Treatment
All wheels shall be allowed to cool to a temperature below the critical range and uniformly
reheated to the proper temperature to refine the grain, and then the rims shall be quenched. Fol-
lowing quenching, the wheels shall be charged into a furnace for tempering to meet the require-
ments of paragraph 10.0 and subsequently cooled under controlled conditions.
7.0 SHOT PEENING
7.1 Scope
This section covers shot peening of steel wheels to provide improvement in plate fatigue strength.
7.2 Requirements
7.2.1 Shot
The shot shall be SAE No. 550 or larger hardened steel as specified in SAE J827.
7.2.2 Shot Size Control
The peening machines shall be equipped with a separator for continuously removing broken shot.
Sufficient new shot shall be added to ensure that a minimum of 85% of No. 550 or larger shot is
maintained in the machines at all times.
7.2.3 Peening Intensity
The peening intensity shall be sufficient to produce an average arc height of not less than
0.008 (.0075 +) Almen C on the front plate near the hub fillet and on the back plate near the rim
fillet of wheels of the standard design and at back plate hub fillet and front plate rim fillet of the
reverse plate design. The area to be peened is defined as the plate area extended approximately
one-half of the way into the hub and rim fillet radii on the front and on the back of the wheel.
7.2.3.1 Arc Height Measurement
Measurements of arc height shall be made in accordance with SAE Standards J442 or SAE Recom-
mended Practice J443.
7.2.4 Coverage
The minimum peening time shall be sufficient to ensure that full coverage is attained on the
Almen C strip as defined in SAE Recommended Practices J443, Alternate Procedure, or
MIL-S-13165 C, Paragraph 6.11
7.2.5 Sequence
Shot peening will be performed on all wheels and after any corrective surface preparation on the
plate area. Plate area is defined in paragraph 7.2.3. Peening may be performed prior to inspection.
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M-107/M-208
7.2.6 Portable Peeners

A portable peening device may be used to re-peen small reconditioned areas (no larger than 6 in.2)
on wheel plate surfaces, excluding the critical fillet areas (front hub and back rim fillets of wheels
of standard designs and back hub and front plate fillets of wheels of reverse plate design). The por-
table equipment must be capable of peening an Almen C strip to develop the required average arc
height of not less than 0.008 in. with a reasonable time of peening. Peening time of wheel plates
must be at least as long as the time required to develop the 0.008-in. arc height. The equipment
must be tested on an Almen C strip each 8-hour shift that the portable peener is used. A record of
the Almen C test results shall be maintained.
7.3 Quality Assurance Provisions
7.3.1 Wheel Surface Condition
The peened appearance of rim and hub shall not be cause for rejection.
7.3.2 Frequency of Test
Arc height determinations shall be made on Almen C strips attached to a test wheel at the begin-
ning and end of each production run but not less than once in each eight operating hours.
7.3.3 Retest
If a test fails to meet the arc height requirements of 0.008 Almen C, two retests will be made.
These retests shall be averaged with the first determination. The average shall be not less than
0.008, and no more than one value of the three shall be less than 0.008.
7.3.4 Repeening
When test values fail to meet the provisions of paragraph 7.3.3, corrective action shall be initiated
and satisfactory test values secured before proceeding with production peening. If the average
Almen value of the unsatisfactory test is 0.006 or 0.007, the last half of the wheels peened prior to
the unsatisfactory test (but subsequent to a satisfactory test) shall be repeened with at least 1/2
exposure time. If the average Almen value is less than 0.006, all the wheels peened since the last
satisfactory test shall be repeened with full exposure.
03/2011 G [M-107/M-208] 23
M-107/M-208
8.0 LADLE ANALYSIS

8.1 The steel shall conform to the following chemical requirements:
Table 8.1 Chemical requirements
Ladle Analysis (%)
Element
Class L Class A Class B Class C
Carbon 0.47 max. 0.470.57 0.570.67 0.670.77
Manganese 0.600.90 0.600.90 0.600.90 0.600.90
Phosphorous 0.030 max. 0.030 max. 0.030 max. 0.030 max.
Sulfur 0.0050.040 0.0050.040 0.0050.040 0.0050.040
Silicon 0.151.00 0.151.00 0.151.00 0.151.00
Residual Elements
Nickel 0.25 max.a/ 0.25 max.a/ 0.25 max.a/ 0.25 max.a/
Chromium 0.25 max.a/ 0.25 max.a/ 0.25 max.a/ 0.25 max.a/
Molybdenum 0.10 max.a/ 0.10 max.a/ 0.10 max.a/ 0.10 max.a/
Vanadium 0.040 max.a/ 0.040 max.a/ 0.040 max.a/ 0.040 max.a/
Copper .35 max. .35 max. .35 max. .35 max.
Aluminum 0.060 max. 0.060 max. 0.060 max. 0.060 max.
Titanium 0.03 max. 0.03 max. 0.03 max. 0.03 max.
Colunbium (niobium) 0.05 max. 0.05 max. 0.05 max. 0.05 max.
a/ If the manufacturer chooses to vary from the above limits for nickel, chromium, molybdenum,
and vanadium, the following formula must be met:
930 [570 % carbon] [80 % manganese] [20 % silicon] 50 % chromium] [30 % nickel] [20 % molybdenum + % vanadium] > 390
8.2 An analysis of each heat of steel shall be made by the manufacturer to determine the percent-
age of the elements specified in paragraph 8.1. This analysis shall be made on a test specimen
taken during the pouring of the heat. The chemical composition thus determined, together with
such identifying records as may be desired, shall be reported to the purchaser or purchasers repre-
sentative and shall conform to the requirements specified in paragraph 8.1.
8.3 Chemical Analysis
Chemical analysis of each heat of steel shall be made by one of the test methods listed below. All
analyses should note which method is used for the carbon and/or chemical determinations.
8.3.1 Test Method 1
The carbon determinations should be one of the following test methods:
8.3.1.1 Total carbon by the combustion gravimetric method, ASTM E-350 Standard Test Meth-
ods for Chemical Analysis of Carbon Steel, Low-Alloy Steel, Silicon Electrical Steel, Ingot Iron,
and Wrought Iron.
8.3.1.2 Total carbon by the combustion thermal conductivity method, ASTM E-1019 Standard
Test Methods for Determination of Carbon, Sulfur, Nitrogen, Oxygen, and Hydrogen in Steel and
in Iron, Nickel, and Cobalt Alloys.
8.3.1.3 Total carbon by combustion, followed by quantitative infrared analysis, ASTM E-1019
Standard Test Methods for Determination of Carbon, Sulfur, Nitrogen, Oxygen, and Hydrogen in
Steel and in Iron, Nickel, and Cobalt Alloys.
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M-107/M-208
8.3.2 Test Method II

ASTM E-415 Standard Test Method for Optical Emission Vacuum Spectrometric Analysis of Car-
bon and Low-Alloy Steel.
8.4 Check Analysis
An analysis may be made by the purchaser from a sample furnished by the manufacturer that rep-
resents the heats, from a wheel block, or from finished wheels selected by the purchaser from each
heat in question. Samples from wheel blocks must be drilled from the end of the block midway
between the center and outside. When a finished wheel is used, the sample must be obtained from
the rim face or the hub in a manner that will not impair the usefulness of the wheel. No drilling of
the finished wheel plate is permitted. Each sample must be thoroughly mixed together and must
be clean and free of oil, scale, and other foreign substances.
8.4.1 Sampling Method
When wheel blocks or whole wheels are not available for chemical analysis, the laboratory con-
ducting the chemical analysis shall follow a standard sampling method. This standard method of
sampling shall be ASTM E-1806, Standard Practice for Sampling Steel and Iron for Determina-
tion of Chemical Composition. Then use either ASTM E-350, E-1019, or ASTM E-415 as specified
in paragraph 8.3 for chemical analysis of the sample.
9.0 INTERIOR CONDITION/MICROCLEANLINESS STANDARDS
9.1 Sample Frequency
The metallurgical cleanliness of the wheel steel shall be determined from samples taken from ran-
domly selected finished wheels representing the heat. A minimum of one 33-in. wheel and one
36-in. wheel of different heats produced quarterly per facility shall be tested.
Facilities that produce only 33-in. or 36-in. wheels shall test two wheels of different heats
quarterly.
Facilities producing different size wheels to AAR specifications during a quarter shall test
at least two wheels of different heats during the subject quarter.
Facilities not producing wheels to AAR specifications during four successive quarters shall,
at a minimum, test at least two wheels from a heat specially produced to AAR specifica-
tions for the scheduled facility certification continuation inspection once a year.
The purchaser reserves the right to more frequent testing should it be deemed necessary by
mutual agreement between the purchaser and producer.
9.2 Sample Size and Location
A minimum of six samples shall be taken from each wheel tested approximately equidistant
around the circumference of the wheel. Each sample shall be 7/8 in. long in the circumferential
direction (the rolling direction), 3/4 in. wide in the axial direction (the rim width), and 1/2 in. thick
in the radial direction (the rim thickness). The circumferential surface for microcleanliness evalu-
ation shall be located 1/2 in. below the wheel tread and 2 1/2 in. to 3 1/4 in. from the back rim face.
Dimension tolerances are 1/8 in.
03/2011 G [M-107/M-208] 25
M-107/M-208
9.3 Sample Preparation and Evaluation

9.3.1 Each 7/8 in. 3/4 in. 1/2 in. sample shall be carefully prepared and evaluated to ASTM
Standard Practice E1245. The flicker method shall be used to establish the correct setting of the
gray-level threshold limits.
9.3.2 The total area evaluated for each sample shall be not less than 1/4 in.2 or 161 mm2. All
inclusions greater than 2.5 m shall be counted. The WABL Committee must approve alternates
to this method.
9.3.3 Effective January 1, 2008, average and worst field area percentage oxides, voids, and sul-
fides will be recorded. The AAR shall be advised quarterly when the six samples representative of
the heat tested average more than 0.100% oxide plus voids; or the worst field area percentage of
any one sample is more than 0.750% oxide plus voids; or 0.750% sulfides. If AAR is advised in two
successive quarters, the provisions of AAR Manual of Standards and Recommended Practices,
Administrative Standards, Standard S-060, paragraph 5.3, shall apply. In such cases, a special
facility inspection may be required to demonstrate that the root cause has been identified and
addressed.
9.3.4 Each sample shall be permanently marked according to heat and wheels represented and
retained for a period of 1 year after the wheels are shipped. Records of test results shall be kept for
10 years after the wheels are shipped. Inspection results will be available for review by the AAR or
other interested parties. AAR or other interested parties may have the test samples evaluated by
other accredited laboratories at their expense.
10.0 BRINELL HARDNESS
10.1 The hardness of the rim, when measured in accordance with the requirements of
paragraph 10.2, shall show the following values:
Table 10.1 Brinell hardness of rim
Class Minimum Hardness Maximum Hardness
L 197 BHN 277 BHN
A 255 BHN 321 BHN
B 302 BHN 341 BHN
C 321 BHN 363 BHN
D 341 BHN 415 BHN
Note: Class D alloy steel wheels must meet all chemical requirements for Class C wheels and have
approval of the AAR WABL Committee.
10.2 Method of Measurement
Measurement must be made in accordance with ASTM E-10 (latest revision) on the front face of
the rim with the edge of the impression not less than 3/16 in. from the radius joining face and
tread. Before making the impression, any decarburized metal shall be removed from the front face
of the rim at the point chosen for measurement. The surface of the wheel rim shall be properly pre-
pared to permit accurate determination of hardness.
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M-107/M-208
11.0 NUMBER OF TESTS

11.1 Where continuous heat-treating furnaces are used, BHN measurements shall be made on
10% of the wheels from each heat. Where batch-type heat-treating furnaces are used, BHN mea-
surements shall be made on 10% of the wheels from each heat-treatment lot. For batch-type
heat-treating, at least one wheel from each heat in the heat-treatment lot must be tested. For
either heat-treatment process, BHN measurements must be made on a minimum of one wheel in a
heat or heat-treatment lot of 10 or less, and on a minimum of 2 wheels in a heat or heat-treatment
lot of 11 to 20.
11.2 If all the wheels tested meet the requirements of paragraph 10.0, all of the wheels repre-
sented shall be accepted.
11.3 If any wheel tested fails to meet the requirements of paragraph 10.0, it shall be checked by
making two additional hardness measurements, one on each side of the point first measured and
each approximately 1 in. from that point. If both of these check measurements meet the require-
ments of paragraph 10.0, the wheel shall be considered to have met the requirements of
paragraph 10.0.
11.4 When continuous heat-treating furnaces are used, should any of the wheels tested fail on
check test to meet the requirements of paragraph 10.0, the manufacturer may test for individual
hardness measurements all of the wheels of that heat in the lot submitted for inspection, and
those meeting the requirements of paragraph 10.0 shall be accepted. Where batch heat-treating
furnaces are used, should any of the wheels tested fail on check test to meet the requirements of
paragraph 10.0, the manufacturer may test all of the wheels in the heat-treatment lot for individ-
ual hardness measurement, and those meeting the requirements of paragraph 10.0 shall be
accepted.
11.5 On new wheel designs or existing designs to which process changes are made, hardness
gradient tests shall be performed on a minimum of one wheel from each of the first five heats of
steel produced. The hardness shall be taken per Fig. 11.1 utilizing an approved hardness test
machine. Values shall meet the requirements as shown in Table 11.1.
Table 11.1 Acceptable hardness ranges
Class Minimum Maximum
285 HB 341 HB
B
28 Rc 40 Rc
301 HB 363 HB
C
30 Rc 42 Rc
321 HB 415 HB
D
32 Rc 44 Rc
If values do not meet the requirements in Table 11.1, an additional five wheels from five heats
shall be tested. All five wheels must meet the requirements in Table 11.1. If one or more wheels
fail to meet the requirements in Table 11.1, testing per paragraph 11.5 shall be repeated after a
process and/or design change is made. All wheels from heats that have a test wheel that failed to
meet the requirements in Table 11.1 shall be reheat-treated, and one wheel from the heat shall be
tested. If this wheel fails to meet the requirements in Table 11.1, all wheels from the heat shall be
scrapped. Only one reheat treatment shall be allowed.
03/2011 G [M-107/M-208] 27
M-107/M-208
Fig. 11.1 Hardness mapping locations

12.0 RETREATMENT
Any wheel failing to meet the requirements of paragraph 10.0 may be retreated and tested in
accordance with paragraph 11.0.
13.0 MATING
Wheels shall be measured and marked to the lower tape number until the next graduation is
reached. Wheels shall be shipped in pairs of the same measured tape size.
14.0 GAUGES
The gauges and tapes shall conform to and be used as required by the standards of the AAR Tech-
nical Services Division Alternate tape gauging will meet or exceed the AAR measurement stan-
dard for taping wheels. The repeatability and reproducibility of all alternate gauges must be
demonstrated.
15.0 PERMISSIBLE VARIATIONS
15.1 The wheels shall conform to the dimensions with tolerances as specified in Figs. B.8, B.9,
B.11, and B.12 for freight car wheels and in Figs. B.8 and B.10 for locomotive wheels.
15.2 Where Figs. B.9 and B.10 allow a certain percentage of the wheels to vary from standard
dimensions for tape size by a given amount, the percentage of such wheels shipped by any manu-
facturer shall not exceed this percentage during a calendar year. No individual purchaser may
receive more than this percentage of his daily shipments of such wheels except by agreement with
the manufacturer.
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M-107/M-208
16.0 FINISH
16.1 Wheels shall be rough bored and shall not have black spots in the rough bore. Front hub face
of wheels (1-W, 2-W, and MW) shall be parallel to the plane of the vertical reference line and may
be smooth forged, cast, or machined. The back hub face may be smooth forged, cast, or machined.
16.2 The contour of tread and flange shall be as shown in Figs. B.11, B.12, or B.13 as applicable.
Wrought steel wheels must be machined and finished smooth without excessive tool chatters. Cast
steel wheels shall be as cast, machined, or ground, at the option of the manufacturer. Minimum and
maximum flange thickness, height, and throat radii gauges shown in Standards S-661 and S-662
shall be used to check proper profile. Wheels that do not meet the criteria must be scrapped or recon-
toured.
16.3 Wheels must be free of all condemnable in-service defects. As-produced surfaces must be
free from abrupt changes in surface contours. Spot grinding or machining to remove surface
defects must not exceed a depth of 1/8 in. (0.125 in.; 3.2 mm). Sectional properties must meet all
dimensional requirements following repair of surface defects. Repaired surfaces must have a max-
imum surface roughness of 500 in. prior to final shot peening. Repaired surfaces must provide a
uniform transition to the as-produced surfaces.
16.4 Wheels shall not be covered with any substance to such an extent as to hide defects.
16.5 Wheel profile is to be checked using wide flange profile gauge shown in Fig. B.14. There will
be no more than 1/32-in. variation from the profile.
17.0 MARKING
17.1 Identification markings shall be legibly stamped as shown in Figs. B.4 or B.5. Wheels for
freight service must be hot stamped or cold stamped on the back hub face. If any stamped charac-
ters are missing or illegible, these shall be replaced by cold stamping in the proper place in the
marking sequence. Passenger car wheels may be hot stamped or cold stamped on front or back (as
specified by purchaser) hub face. When ordered, locomotive wheels may be hot or cold stamped on
the back rim face; or hot or cold stamped on the front hub face; or hot or cold stamped on the back
hub face providing finish machining will completely remove the markings on the back hub face.
Locomotive wheels that are to receive final hub machining by the purchaser may be ordered with
markings paint stenciled on the wheel plate. After final machining, the purchaser will cold stamp
the markings on the front hub face. For wheels having raised cast-on markings, the markings shall
be legible characters and be as shown in Fig. B.7. For all wheels, stamping should be centered
approximately on the hub. No wheel manufactured after May 1, 2009, may be bored and applied
with any portion of the wheel manufacturers hub stamp closer than 1/8 in. from the inner hub
diameter and no closer than 1/8 in. from the outer hub diameter. No wheel manufactured before
May 1, 2009, may be bored and applied with any portion of the wheel manufacturers hub stamp
breaking over the edge of the inner or outer hub diameter.
17.2 The tape size of all wheels shall be paint stencilled on back plates in characters at least 1 in.
high. An H shall also be paint stencilled on the front plate at least 1 in. in height on those wheels
of curved plate, heat-treated configuration. Stencil paint must be white and have a minimum ser-
vice life of 1 year.
03/2011 G [M-107/M-208] 29
M-107/M-208
18.0 INSPECTION
18.1 The inspector representing the purchaser shall have free entry, at all times while the work
on the purchasers contract is being performed, to all parts of the manufacturers works that con-
cern the manufacture of wheels ordered. The manufacturer shall afford the inspector, free of
charge, all reasonable facilities and necessary assistance to satisfy the inspector that the wheels
are being furnished in accordance with these specifications. Internal defects are usually detected
by ultrasonic testing. Such test shall be used in the manufacture of all wheels. The method to be
followed and the equipment to be used shall comply with the requirements as shown in
paragraph 18.4. Tests and inspection shall be made at the place of manufacture prior to shipment,
unless otherwise specified.
18.2 The purchaser may make tests to govern the acceptance or rejection of the wheels in pur-
chasers own laboratory or elsewhere. Such tests shall be made at the expense of the purchaser.
18.3 All tests and inspections shall be so conducted so as not to interfere unnecessarily with the
operation of the works.
18.4 Ultrasonic Inspection
For detecting internal discontinuities in the rim of all steel wheels, ultrasonic inspection shall be
made by following either the procedures shown below or an AAR-approved equivalent. Equipment
used in these procedures shall comply with the following requirements.
Each manufacturer shall maintain a documented test method and procedures for ultrasonic
inspection of all railroad wheels manufactured under this specification.
18.4.1 Equipment
18.4.1.1 The instrument shall have a pulse echo receiver and shall operate at frequencies of 2 to
5 MHz required for the test method and type of equipment used.
18.4.1.2 The transducers shall be of the type whose composition and dimensions are appropriate
for the test method used.
18.4.1.3 The ultrasonic inspection shall be performed with an automated scanning system. An
automatic flaw alarm system shall be used in conjunction with the ultrasonic instrumentation.
18.4.1.4 A suitable couplant shall be used between the test surface and the transducer. The cou-
plant shall be free of air bubbles. Rust inhibitors, softeners, and wetting agents may be added to
the couplant.
18.4.2 Time of Inspection
Inspection shall be performed after final thermal processing.
G [M-107/M-208] 30 03/2011
M-107/M-208
18.4.3 Calibration
18.4.3.1 Calibration shall be conducted using a reference standard of a wheel or portion of a
wheel rim containing simulated defects or other AAR-approved procedure. The instrument sensi-
tivity level should be adjusted to produce an approximate full-scale reflection from the reference
standards of paragraphs 18.4.3.2, 18.4.3.3, 18.4.3.4, and 18.4.3.5.
18.4.3.2 For axial testing of all wheels, the reference standard shall be a 1/8-in.-diameter flat-bot-
tom hole generated perpendicular to the rim face and to a depth of 1 1/2 in. (1/16 in.) at the
mid-thickness of the rim. See Fig. B.1
18.4.3.3 For radial testing, the reference standard shall be a 1/8-in.-diameter flat-bottom hole
generated from the inside diameter of the rim perpendicular to the tread surface, and shall be a
minimum of 1 1/4 in. from the tread surface. See Fig. B.2.
18.4.3.4 A distance amplitude correction (DAC) shall be used for axial and radial testing of
wheels. To ensure detection, the DAC will be generated for each testing direction in the following
manner.
Holes shall not be located close to each other so as to impede the response from each hole individu-
ally.
18.4.3.4.1 Axial
As a minimum, two additional 1/8-in.-diameter flat-bottom holes shall be generated at whatever
depth the manufacturer chooses. The creation of the DAC shall be accomplished using the refer-
ence standard and the response(s) from additional holes. Typical depths for the three holes could
be 1 1/2, 2 1/2, and 3 1/2 in. All holes should be generated from the front or back rim face. See
Fig. B.1. Individual depth standards shall be permitted.
18.4.3.4.2 Radial
To facilitate creation of a DAC, as a minimum, one additional 1/8-in.-diameter flat-bottom hole
shall be generated in one-wear and two-wear wheels, and, as a minimum, two additional
1/8-in.-diameter flat-bottom holes shall be generated in multi-wear wheels. Calibration shall be
accomplished using the reference standard, and the response(s) from the additional holes shall be
used to create the DAC. Table B.1 shows the depth of reference standard holes for the different
wheel types. See Fig. B.2. Individual depth standards shall be permitted.
18.4.3.5 Alternate calibration standards may be used when authorized by the AAR WABL Com-
mittee. Manufacturer shall document and demonstrate the correlation between the 1/8-in.-diame-
ter flat-bottom hole and the proposed alternate standard.
18.4.3.6 An alternate method for axial testing of cast steel wheels is to use loss of back reflection.
The reference standard shall be a 3/8-in.-diameter concave bottom hole generated to a depth of
1/8 in. at the front rim face. See Fig. B.3.
18.4.3.7 Reference standards for the inspection of wheels shall be made from rim-treated wheel
steel made by the same process as the wheels being inspected, i.e., wrought or cast. Reference
standard need not be the same AAR design as the wheels being inspected.
18.4.3.8 Recalibration
Conduct ultrasonic calibration to ensure system conformance to required specifications. Check the
ultrasonic system and calibration of the instrument per documented procedures using a calibra-
tion standard when any of the following occurs:
Damage to any part of the ultrasonic system
Change in transducers, cables, and other accessories
Loss of power or equipment malfunction
Whenever ultrasonic instrumentation is first turned on
03/2011 G [M-107/M-208] 31
M-107/M-208
18.4.3.9 System Verification and Test Results Validation

18.4.3.9.1 Conduct ultrasonic calibration checks to ensure system conformance to required speci-
fications.
18.4.3.9.2 System calibration shall be verified per documented procedures using a calibration
standard at least every 8 hours of operation. If the results from system verification are outside of
system tolerance, assessment of previous inspections must be made and appropriate action taken.
Action taken shall be supported by wheel reinspection data.
18.4.3.9.3 Records shall be maintained of system calibration and system verification.
18.4.4 Scanning
18.4.4.1 Wheels shall be inspected axially from either the front or back rim face and radially from
the tread surface.
18.4.4.2 One or more transducers shall be designed and located to give maximum volumetric cov-
erage of the rim cross-section both radially and axially.
Each manufacturer shall ensure optimum volumetric coverage for the test method and manufac-
turing process. Optimization of coverage is verified by using supplemental reference standard
holes located in different areas of the rim, as shown in Figs. B.3.1 and B.3.2.
18.4.4.3 Scanning speed shall permit detection of reference standards at calibration level.
18.4.5 Rejection
18.4.5.1 Any wheel with a flaw indication equal to or larger than 25% of the reference standard
at the estimated discontinuity depth shall be cause for rejection.
18.4.5.2 Any indication from discontinuity giving a loss of back reflection equal to or greater than
the reference standard (covered in paragraph 18.4.3.6) during axial scanning shall be cause for
rejection.
18.4.5.3 Ultrasonic indications that result from wheel geometry or spurious electrical signals
shall not be valid cause for rejection.
18.4.5.4 The final disposition of rejectable wheel may be determined by manual testing of ques-
tioned areas. Wheel records and test results shall be maintained for wheels found to be conforming
under this paragraph.
18.5 Magnetic Particle Inspection
18.5.1 Purpose
To supplement visual inspection of the surface of new wheels by detecting discontinuities that may
be harmful to wheel service.
18.5.2 Scope
This test method covers the wet fluorescent magnetic particle inspection of the plates of wheels
ordered to this specification.
G [M-107/M-208] 32 03/2011
M-107/M-208
18.5.3 Equipment
18.5.3.1 Magnetizing Apparatus
The magnetizing apparatus shall be capable of inducing suitable magnetic fields within the entire
plate area of the wheel to facilitate the disclosure of both circumferentially and radially oriented
discontinuities. The magnetizing currents used shall be large enough to induce magnetic fields of
sufficient intensity to disclose surface discontinuities 1/4 in. long. The use of prod-type contacts is
prohibited.
18.5.3.2 Lighting Apparatus
The inspection shall be performed in a darkened booth with the area of the wheel to be inspected
illuminated with properly filtered black light. The black light shall have a predominant wave-
length of 4000 to 3400 , and the intensity of the black light, measured at the surface to be
inspected, shall be a minimum of 75 footcandle at point of inspection.
18.5.3.3 Inspection Medium
18.5.3.3.1 The bath or solution should be prepared using a suitable carrier fluid and fluorescent
magnetic particles and renewed monthly or more often if contamination is noted in weekly tests.
Each time the bath is renewed, the bath container should be cleaned out and the agitation and cir-
culation system should be flushed with 1 or 2 gal of clean carrier. Filtering screens should be
removed and cleaned by blowing with air. In preparing the new bath, only recommended materials
should be used. The amount of powder should be carefully weighed out in accordance with the
material manufacturers recommendation and be added directly to the bath containing the correct
amount of carrier. It is recommended that powder be added directly over the sump so that it will be
drawn quickly into the pump and circulated. The amount of carrier and powder used and the date
of preparation should be recorded on a regular form set up for this purpose, as outlined in
paragraph 18.5.3.3.6.
18.5.3.3.2 Concentration and contamination of the bath solution should be tested weekly as fol-
lows: pump and agitation system should be operated for 20 minutes and then the solution should
be run through a hose and nozzle for 30 seconds. Using a regular 100-mL centrifuge tube, fill the
centrifuge tube with 100 mL of the solution. Allow the bath solution to settle for the time recom-
mended by the manufacturer of the type of powder used, making sure that the tube is not sub-
jected to excessive vibration during the settling period. Each horizontal division represents
0.1 mL, and a correct reading in volume of particles must be as stipulated by the powder manufac-
turer. The check also should note contamination caused by dirt, chips, or other foreign matter set-
tling with the powder. Contamination also is indicated when the carrier appears to acquire more
than usual fluorescence or when the magnetic particles appear to have lost fluorescent qualities.
This condition can be readily observed when the settling tube is exposed to ultraviolet light. The
readings obtained are to be shown on the regular report form as outlined in paragraph 18.5.3.3.6.
18.5.3.3.3 The ultraviolet light should be tested weekly using a light meter, such as a type having
75-footcandle scale with a 10 multiplying disc or equivalent or a meter that responds specifically
to the ultraviolet range of 3650 (365 nm). The latter type meters are calibrated in microwatts
per square centimeter. The meter should be held a fixed distance of 15 in. from the light source
(from the black light filter surface to the meter-sensing element) and should have a minimum
meter reading of 525 W/cm2.
18.5.3.3.4 The conversion factor from footcandles (for light meters) to microwatts per square cen-
timeter is 5.7 times the footcandle reading (at 15 in. distance).
18.5.3.3.5 The maximum allowable footcandles will be left to the discretion of the user dependent
on the degree of brilliance desired to obtain satisfactory inspection conditions. Before taking read-
ings, it should be known that the glass black light filters are clean. Reports of this test are to be
shown on regular form as outlined in paragraph 18.5.3.3.6.
03/2011 G [M-107/M-208] 33
M-107/M-208
18.5.3.3.6 A regular form should be prepared embodying the information to be shown on monthly
and weekly tests as outlined above, and this form should be on hand at the wheel shop and avail-
able to AAR inspectors.
18.5.3.3.7 Prepackaged, self-contained solutions, including aerosol sprays, may be used provided
that the following conditions are met:
18.5.3.3.7.1 The solution is agitated frequently to ensure that magnetic particles remain in solu-
tion.
18.5.3.3.7.2 A detectability test is performed daily on each package in use and a record is kept
per paragraph 18.5.3.3.6. The test consists of inspection of a test wheel with a known crack of at
least 1/4 in. long or an equipment manufacturers approved test piece that will indicate and verify
the following:
Proper brilliance of ultraviolet light
Proper concentration of bath solutions
Proper magnetic power source and operation of equipment
Note: Test wheel or test piece must be thoroughly cleaned of the last test indicators before testing.
This must be verified by ultraviolet light before the test is started.
18.5.4 Preparation for Inspection
The surface shall be scale free before magnetic particle inspection.
18.5.5 Detection of Discontinuities
This inspection shall be performed to detect discontinuities whose axes may be in any direction.
Continuous or residual magnetization shall be used with adequate coverage by the inspection
medium.
18.5.6 Time of Inspection
The magnetic particle inspection shall be performed following final machining or grinding on wheel
plate.
18.5.7 Rejection
Rejection of magnetic particle discontinuity indications must take place if any plate surface indica-
tion is 1/4 in. in length or longer in any direction. Discontinuities may be removed by machining or
grinding where sufficient stock remains. Such wheels shall be retested by magnetic particle
inspection.
18.6 Personnel Requirements for Ultrasonic Inspection
18.6.1 All personnel engaged in ultrasonic operations will be qualified to NDT Level I according
to the qualification requirements as defined by the American Society for Nondestructive Testing,
Recommended Practice SNT-TC-1A, latest edition.
18.6.2 All personnel conducting inspection setups and machinery setups will be trained and qual-
ified to meet the criteria for NDT Level II for ultrasonic testing as defined by the American Society
for Nondestructive Testing, Recommended Practice SNT-TC-1A, latest edition.
18.6.3 Each manufacturer will employ the services of an individual who will be trained and qual-
ified to meet the criteria for NDT Level III for ultrasonic testing as defined by the American Soci-
ety for Nondestructive Testing, Recommended Practice SNT-TC-1A, latest edition.
19.0 CERTIFICATION
At the purchasers request, a certification shall be made the basis of acceptance of the material.
This shall consist of a copy of the manufacturers test report that the material has been sampled,
tested, and inspected in accordance with the provisions of the specification. Each certificate so fur-
nished shall be signed by an authorized agent of the supplier or manufacturer.
G [M-107/M-208] 34 03/2011
M-107/M-208
20.0 REJECTION
20.1 Wheels represented by samples that fail to conform to the requirements of these specifica-
tions will be rejected.
20.2 Wheels that show injurious defects subsequent to original inspection and acceptance at the
manufacturers works, or elsewhere, will be rejected, and the manufacturer shall be notified.
21.0 REHEARING
Samples tested in accordance with this specification that represent rejected wheels shall be held
for a period of 14 days from date of the test report. In case of dissatisfaction with the results of the
tests, the manufacturer may make claim for a rehearing within that time.
22.0 This specification includes Appendices A and B; and Figs. B.1 through B.14.
03/2011 G [M-107/M-208] 35
APPENDIX A M-107/M-208
APPENDIX A
AUTHORIZATION FOR DELIVERY OF WHEELS FOR AAR INTERCHANGE
SERVICE
1.0 Each manufacturer must obtain an authorization for delivery of wheels for AAR interchange
use from the Committee prior to delivery.
2.0 The manufacturer applying for delivery authorization must provide the AAR with an
electronic copy of the following documentation.
2.1 A descriptive drawing of the wheel type as it will be produced. The descriptive drawing will
provide the following information:
2.1.1 A full-scale drawing showing the wheel cross-section from center of the hub to top of the
flange. The drawing may show either a single profile with tolerances or, preferably, two profiles,
with one depicting the minimum inner tolerances and the other the maximum outer tolerances in
such a way that a wheel section laid on the drawing would fall between the two profiles. This
would allow analysis of wheels produced to this drawing.
2.1.2 A notation of the wheel type and heat-treatment classes of the wheels to be produced.
2.2 A brief description of the design analysis method and the results of the analysis. The pre-
ferred analytic procedure is that covered in S-660. If there is no design analysis, a statement
should be made to this effect along with a summarization of the design considerations. If the appli-
cant would like the AAR to perform the S-660 design analysis on a contract basis, the applicant
should request details from the AAR.
2.3 A statement advising the specific areas in which the wheel design may not be compatible with
normal shop machinery and handling equipment, standard storage facilities, and wheel transport
cars in general use.
3.0 Authorization for the delivery of a wheel type will be approved by the Committee if deemed
suitable for interchange service based on a review of wheel data submitted by the manufacturer.
The initial authorization will be for the delivery of 32,000 wheels. If the manufacturer requests
additional delivery authorizations, the second will be for 20,000 wheels (52,000 total) and the third
will be for 20,000 wheels (72,000 total). Additional allotments or unconditional approval for
unlimited quantities will be given after that, provided all required conditions are met.
3.1 A new wheel type (such as CH-36, CJ-36, or J-33) that is made for the first time by the
requesting manufacturer will require the following prior to being granted unconditional approval.
If necessary, WABL will designate a sponsor railroad to assist the manufacturer in meeting these
requirements.
3.1.1 A minimum of 5,000 wheels installed from the first allotment will have been tracked to
provide mileage and will have achieved 200,000 miles in service.
3.1.2 Ultrasonic testing to wheelshop requirements for turned wheels will be performed for 30 or
more wheels with at least 200,000 miles of service and with sufficient rim metal to be reapplied.
Provided all other criteria are met, upon successful completion of ultrasonic testing, conditional
approval, unlimited quantity will be granted. The 30 wheels will then be placed in service and
tracked. Ultrasonic testing to wheelshop requirements of turned wheels will be performed for 10 of
the 30 wheels reapplied after 100,000 miles additional service. Provided all other criteria are met,
upon successful completion of the ultrasonic testing, unconditional approval will be granted. Test
costs will be paid by the proponent, and data provided in the form of C-scans will be captured with
an AAR observer present and provided to WABL.
G [M-107/M-208] 36 03/2011
M-107/M-208 APPENDIX A
3.1.3 At least one out of every 1,000 wheels produced in the initial allotment will be tested for
microcleanliness according to paragraph 9.0 of this specification. Results will be reported to the
Wheels, Axles, Bearings, and Lubrication Committee Manager within 90 calendar days. Electronic
reporting is preferred. Send results to
Email: wabl@aar.com
Facsimile: 719-585-1895
Mail: AAR WABL Committee Manager
Transportation Technology Center Inc.
P.O. Box 11130
Pueblo, Colorado 81001
3.2 Each authorization after the initial authorization will be granted only after satisfactory
performance is indicated by a review of service data submitted on the wheel by the manufacturer
as well as service data from AAR records. Authorization may be withdrawn if service performance
so dictates.
4.0 Changes to any wheel design by the producer must be reviewed by the Committee before
delivery authorization may be granted.
03/2011 G [M-107/M-208] 37
APPENDIX B M-107/M-208
APPENDIX B
QUALIFICATION OF MANUFACTURERS PLANT AS A PRODUCER OF
WHEELS 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 wheels. 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 review of the data submitted with the application, the Committee will authorize the
applicant to contact the AAR for information concerning product testing. Normally this will consist
of the applicant furnishing three wheels, at applicants 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 the plant where the wheels are to be produced for proper equipment
and, if mounted wheels are to be provided, an AAR inspection will be arranged for the wheel shop.
These inspections will require that all out-of-pocket expenses be borne by the applicant. These
inspections can be arranged concurrently with the test program if the applicant so requests.
4.0 All plants desiring to maintain their status as an AAR-approved manufacturer of wheels for
use in AAR interchange service must be inspected yearly with costs of inspection to be borne by
the wheel producer. Every effort will be made to inspect all plants in a given area at one time to
minimize costs, which will be prorated among the companies inspected.
5.0 In the event that a facility ceases production for less than 1 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 wheels 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. In the event a plant ceases production of wheels 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. An AAR inspection of the plant will be required, and
normally, the provisions of Appendix A will apply for all wheel designs that have been given an
authorization in accordance with the procedure outlined in paragraph 2.0 and subparagraphs. The
Committee may elect to require testing of wheels in accordance with Appendix B, paragraph 2.0.
6.0 In addition to the foregoing, wheel manufacturers must meet the requirements of the AAR
Manual of Standards and Recommended Practices, Section J, Specification M-1003, Specification
for Quality Assurance.
7.0 All plants desiring to maintain their status as an AAR-approved manufacturer of wheels for
use in AAR interchange service must also have their steel suppliers, shot peening, 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.
8.0 Wheel manufacturers using a native language other than English are responsible for the
accurate communication of all applicable AAR and customer requirements within the plant.
8.1 Plant practices and the final product must conform to the English language versions of any
applicable standards or specifications.
8.2 Critical records are defined as the standards, internal procedures, and forms necessary to
demonstrate compliance with this Specification M-107/M-208 and with MSRP Section J, Specifica-
tion M-1003. Critical records must be kept up to date with production and be maintained in Eng-
lish.
G [M-107/M-208] 38 03/2011
M-107/M-208 APPENDIX B
Fig. B.1 Typical reference standard for rim face ultrasonic test
Paragraphs 18.4.3.2 and 18.4.3.4
Hole #1 reference hole
Holes #2 and #3 used for distance amplitude correction (DAC)
03/2011 G [M-107/M-208] 39
Fig. B.1.1 Axial rim test

Paragraphs 18.4.3.2 and 18.4.3.4.1
Alternate configuration for distance amplitude correction
G [M-107/M-208] 40 03/2011
Table B.1
Distance below Tread Surface
Wheel Design Reference Hole #1 Hole #2 Hole #3
One-wear two holes 1 1/4 in. 3/4 in.
Two-wear two holes 1 1/4 in. 3/4 in.
Multi-wear three holes 1 1/4 in. 3/4 in. 2 1/4 in.
Fig. B.2 Typical reference standard for rim tread ultrasonic test
Paragraphs 18.4.3.3 and 18.4.3.4.2
Hole #1 reference hole
Hole #2 and #3 used for distance amplitude correction (see Table B.1)
03/2011 G [M-107/M-208] 41
Fig. B.3 Axial rim test

Paragraph 18.4.3.6
G [M-107/M-208] 42 03/2011
Fig. B.3.1 Tread rim test

Paragraph 18.4.4.2
03/2011 G [M-107/M-208] 43
Fig. B.3.2 Axial rim test

Paragraph 18.4.4.2
G [M-107/M-208] 44 03/2011
MONTH
SERIAL NUMBER YEAR
MFGR.
CLASS
/8"
1
13/8"
1" MIN.
TAPE SIZE
Note 1 Stamping is to consist of manufacturers serial number, date of manufacture, manufacturers identification, and
class of heat treatment. Stamping is limited to 14 characters, and the design designation shall be stencilled on
the back plate with paint using characters at least 1 in. in height.
Note 2 Stamping is to be spaced a minimum of 1/8 in. between characters and 1 3/8 in. between groups. The stamping
shall be located not less than 1/4 in. from the inner edge of the rim.
Note 3 Dies used to produce characters shall be not less than 3/8 in. in nominal height at crest, and hot stamping shall
be nominally 3/32 in. in depth. Italicized characters (sloping upward to right) shall be used.
Note 4 All wheels will be marked for class using letters L, A, B, C, or D, as appropriate.
Note 5 All stamped characters must be stamped with a low-stress die design to a minimum depth of 0.015 in. or an
AAR-approved alternative.
Fig. B.4 Marking of locomotive wheels rim stamping

Paragraph 17.1
03/2011 G [M-107/M-208] 45
160 TAPE SIZE

1' MIN.
MFGR.
CLASS
YEAR
/8"
/8"
3
3
MONTH GK
77 B
12
1 3/8
"
38
/"
MI
N.
54
J33
18
.
MIN
89
SERIAL NUMBER DESIGN

/18"
Note 1 When ordered, locomotive wheels and wheels for passenger service may be ordered stamped on the front or
back hub face. Wheels for freight service are stamped on the back hub face.
Note 2 Stamping is to consist of manufacturers serial number, date of manufacture, manufacturers identification, class
of heat treatment, and design designation in the order shown above. The hub stamping of locomotive wheels
may be applied by the purchaser after final machining of the hub. Wheels that are to be marked by the purchaser
should be furnished with all marking stencilled on the front plate with paint using characters at least 1 in. in height.
Note 3 Stamping is to be spaced a minimum of 1/8 in. between characters and a minimum of 1 3/8 in. between groups
and located approximately central of the hub face. No wheel manufactured after May 1, 2009, may be bored and
applied with any portion of the wheel manufacturers hub stamp closer than 1/8 in. from the inner hub diameter
and no closer than 1/8 in. from the outer hub diameter. No wheel manufactured before May 1, 2009, may be
bored and applied with any portion of the wheel manufacturers hub stamp breaking over the edge of the inner
or outer hub diameter.
Note 4 Stamps used to produce characters shall be not less than 3/8 in. in height and shall not have sharp edges.
Note 5 All wheels will be marked for class using letters L, A, B, C, or D, as appropriate.
Note 6 The three groups (1) design; (2) serial number; and (3) date of manufacture, manufacturer, and class will be
spaced approximately equidistantly around the hub face.
Note 7 All stamped characters must be stamped with a low-stress die design to a minimum depth of 0.015 in. or an
AAR-approved alternative.
Fig. B.5 Marking of carbon steel wheels hub stamping

Paragraph 17.1
G [M-107/M-208] 46 03/2011
Manufacturers Cast or No Longer

Manufacturer Location
Identification Wrought in Production
TW Adtranz UK W X
A Armco W X
BV B.V.V. (Formerly VSG) Bochum, Germany W
BW Bethlehem W X
DW Bonatrans a.s. (Formerly ZDB) Bohumin, Czech Republic W
P British Steel UK W X
ZW Canadian Steel Wheel Canada W X
QW Construcciones y Auxiliar de Ferrocarriles (CAF) Beasain, Spain W
FW Creusot-Loire France W X
EW Edgewater Steel LTD Oakmont, Pennsylvania W X
KW Klockner Germany W X
LW Lucchini Sidermeccanica SpA (Formerly Gruppo Lucchini) Lovere, Italy W
HW Maanshan Iron and Steel Co. LTD Anhui, Province, P.R.C. W
MW MWL (Formerly Mafersa) Cacapavz, Sao Paulo, Brazil W
NW Niznedneprovssky Tube Rolling Plant (NTRP) Dnepropetrovsk, Ukraine W
CS OneSteel Rail and Forge Waratah NSW, Australia W
RW S. C. SMR S.A (Formerly SMR/MECANO) Bals, Romania W
SW Standard Steel LLC Burnham, Pennsylvania W
JW Sumitomo Metal Industries LTD Osaka, Japan W
TY or TZ Taiyuan Heavy Industries Company LTD Taiyuan, Shanxi Province, PRC W
(TY not used after 10/ 06)
CW U.S. Steel Pittsburg, Pennsylvania W X
G U.S. Steel Gary, Indiana W X
VW Valdunes Dunkerque & W
Valenciennes, France
VK Vyksa Steel Works Nizhegorodsky Region, Russia W
SO ABC Rail (formerly Abex) Calera, Alabama C X
C Abex Rail ** Calera, Alabama C X
S Abex ** St. Louis, Missouri C X
SJ Abex Johnstown, Pensylvania C X
T Abex ** Toledo, Ohio C X
CZ Amsted Maxion (Formerly Iochpe-maxion S.A.) Cruzeiro, Brazil C
CO Datong ABC Castings Company LTD Datong, Shanxi Province, China C
FM FM Fundiciones de Hierro y Acero Mexico C X
GB Griffin Wheel Company Bensenville, Illinois C X
GC Griffin Wheel Company Columbus, Ohio C
GI Griffin Wheel Company Kansas City, Kansas C
GK Griffin Wheel Company Keokuk, Iowa C
GL Griffin Wheel Company Colton, CA C X
GS Griffin Wheel Company Bessimer, Alabama C X
GT Griffin Wheel Company Winnipeg, Canada C
GY Griffin Wheel Company St. Hyacinthe, Canada C X
WI Rail Wheel Factory (Formerly Wheel and Axle Plant) Yelahanka, Bagalore, India C
AW Scaw Metals Germiston, South Africa C
RZ Tianrui Group Foundry Co. Ltd Ruzhou, Henan Province, PRC C
TA Tonghe Wheel Company Xinyang City, Henan C
Province, PRC
** The letters C, S, or T directly precede the wheel serial number for wheels manufactured prior to about April 1978
Fig. B.6 AAR-approved manufacturers
03/2011 G [M-107/M-208] 47
SERIAL NUMBER
09 7511
MONTH
08
DESIGN YEAR
CJ-33
78 S0 C
MFGR.
CLASS
TRADEMARK
Note 1. Characters to be cast on the back plate of wheels shall, at least, show the manufacturers serial number, date of
manufacture, manufacturers identification, class, and design designation.
Note 2. Cast markings shall be legible characters, at least 1 in. high and so spaced to allow related characters to be readily
distinguished as a group.
Note 3 All wheels shall be marked for class using letters L, A, B, C, or D, as appropriate.
Note 4 The three groups (1) design; (2) serial number; and (3) date of manufacture, manufacturer, and class must be clearly
separate.
Fig. B.7 Raised markings on cast carbon steel wheels

Paragraph 17.1
G [M-107/M-208] 48 03/2011
Standard Standard
Wide Flange Narrow Flange
Dimensions and Dimensions and
Tolerances Tolerances
1 + 16 1 + 16
1 1
A
0 0
1 38 + 32
1 + 116
B 1 532
32
3 0
L 5 2332 18 5 2332 18
(5 12 18 alternate)
Pa/ 7 14 See Note
R2 2 12 18 See Note
K 0.0865 0.0663
a/ Except A-28 = 7 18
Fig. B.8 Standard dimensions and tolerances and permissible variations

Paragraphs 2.1 and 15.1
Note: For standard wheel types and for dimensions and other data not shown above, see Figs. B.9
through B.14.
03/2011 G [M-107/M-208] 49
9.0 PERMISSIBLE VARIATIONS IN DIMENSIONS NOT SHOWN BY TOLERANCES ON

FIGS. B.9 THROUGH B.14
9.1 Inside DiameterFront Face of Rim
The inside diameter of the rim at the front face of the wheel shall not differ from that at the back
face of the wheel by more than 1/4 in.
9.2 Thickness of Rim
In any wheel, the radial thickness of the rim shall not vary more than 1/8 in. around the wheel.
9.3 Corner at Inside Diameter of Back Face
A sharp corner is preferable to facilitate measurement. In any case, the radius of the corner shall
not exceed 1/8 in.
9.4 Plane of Back Face
When wheels are gauged with a straight edge applied to the back face of the rim, no point on the
back face of narrow-flange wheels more than 1 1/4 in. from the inside edge of the rim shall be more
than 1/32 in. from the straight edge. For wide-flange wheels, no point on the back face of the rim
shall be more than 1/32 in. from the straight edge. For narrow- and wide-flange wheels, the back
face of the rim measured on the circumference at a distance 1 1/4 in. inward from the apex of the
flange must be in plane within 0.040 in. Total Indicator Reading (TIR) with respect to the plane of
the front face of the rim.
9.5 Hub Wall Thickness
The thickness of the hub wall in any one wheel measured at any two points equidistant from the
face of the hub shall not vary by more than 3/8 in. if the hub is not machined, nor by more than
1/8 in. if the hub is machined.
9.6 Rotundity
Tread when gauged with a ring gauge must not have an opening between tread and gauge at any
point over .022 in.
9.7 Diameter of Bore
The diameter of rough bore shall not vary more than 1/16 in. over nor more than 1/16 in. under the
dimensions specified by the purchaser.
9.8 Eccentricity of Bore
Eccentricity between the rough bore and tread, measured in the plane of the taping line, shall not
exceed .0625 in. TIR, except that no more than 5% of wheels delivered may be over .0625 in. TIR
and these must not exceed .09375 in. TIR.
G [M-107/M-208] 50 03/2011
L
TAPING
LINE B
D R
O1 O2
P
C
L
STANDARD AAR WHEEL TYPESWIDE-FLANGE CONTOURFOR FREIGHT CAR SERVICECARBON STEEL
AAR A-28 E-28 A-30 J-33 M-33 P-33 H-36 J-36 K-36 B-38 C-38 D-38
TYPE CA-28 CA-28 CA-30 CJ-33 CM-33 CP-33 CH-36 CJ-36 CK-36 CB-38 CC-38 CD-38
STATUS STND STND STND STND STND STND STND STND STND STND STND
DATE 1952 1985 1946 1956 1961 1984 1962 1962 1962 1964 1964
EFFECTIVE
DATE 1971 7/1/85 1971 1968 1968 3/1/85 10/1/72 1968 1968 9/1/73 1968
TREAD
TYPE M-W 1-W M-W 1-W 2-W M-W 1-W 2-W M-W 1-W 2-W M-W
INTENDED
AXLE F, K E F, K D, E D, E D, E, F, G F F F G G G
CLASS
MAX. CAP.
PER WHEEL 32,875 24,375 32,875 27,500 27,500 32,875 35,750 35,750 35,750 39,375 39,375 39,375
(LB)
DIMENSION AND TOLERANCESALL ENTRIES IN INCHES, EXCEPT TAPES

28 + 14 28 + 14 30 + 14 33 + 14 33 + 14 33 + 14 36 + 14 36 + 14 36 + 14 38 + 14 38 + 14 38 + 14
D TAPES TAPES TAPES TAPES TAPES TAPES TAPES TAPES TAPES TAPES TAPES TAPES
(5%5) (5%5) (5%5) (5%5) (5%5) (5%5) (5%5) (5%5) (5%5) (5%5) (5%5) (5%5)
G (MIN) 21/2 11/2 21/2 11/4 2 21/2 11/2 2 21/2 11/2 2 21/2
N (MIN) 3/4 5/8 3/4 5/8 5/8 3/4 3/4 3/4 3/4 7/8 7/8 7/8
+1 +1 +1 +1 +1 +1 +1 +1 +1 +1 +1 +1
01 111/80 105/80 111/80 105/80 105/80 117/80 111/80 111/80 111/80 121/80 121/80 121/80
+1 +1 +1 +1 +1 +1 +1 +1 +1 +1 +1 +1
02 111/80 105/80 111/80 105/80 105/80 117/80 111/80 111/80 111/80 121/80 121/80 121/80
MAX FINISH
BORE 87/8 83/8 87/8 83/8 83/8 95/8 87/8 87/8 87/8 95/8 95/8 95/8
MIN HUB
WALL 11/8 11/8 11/8 11/8 11/8 11/8 11/8 11/8 11/8 11/4 11/4 11/4
P1 71/8 71/4 71/4 71/4 71/4 71/4 71/4 71/4 71/4 71/4 71/4 71/4
R 21/2 1/8 21/2 1/8 21/2 1/8 21/2 1/8 21/2 1/8 21/2 1/8 21/2 1/8 21/2 1/8 21/2 1/8 21/2 1/8 21/2 1/8 21/2 1/8
NOTES:
1. HUB LENGTH TOLERANCE IS BASED ON FINISHED DIMENSION.
2. 5 1/2 10 AXLE ALSO STANDARD FOR J-33 AND M-33; 5 1/2 10, 6 11, AND 6 1/2 12 AXLES ALSO STANDARD FOR P-33
Fig. B.9 Standard AAR wheel typeswide-flange contourfor freight car service
Paragraphs 2.1, 15.1, and 15.2
03/2011 G [M-107/M-208] 51
L
TAPING
LINE B
D R
O1 O2
P
C
L
STANDARD AAR WHEEL TYPESNARROW-FLANGE CONTOURFOR DIESEL LOCOMOTIVE

AAR F-36 A-38 E-40 A-41 A-42 A-43 C-42 D-42 E-42
TYPE CF-36 CA-38 CE-40 CA-41 CA-42 CA-43 CC-42 CD-42 CE-42
STATUS STND STND STND STND STND STND STND STND STND
DATE 1946 1947 1982 1997 1946 1997 1946 1997 1997
EFFECTIVE 8/1/46 1947 3/1/83 1997 8/1/46 1997 1947 1997 1997
DATE
TREAD
M-W M-W M-W* M-W* M-W* M-W* M-W* M-W M-W
TYPE
DIMENSION AND TOLERANCESALL ENTRIES IN INCHES, EXCEPT TAPES,

SEE Fig. B.8 FOR DIMENSIONS A, B, C, and L FOR ALL NARROW-FLANGE WHEEL TYPES
36" 38" 40" 41" 42" 43" 42" 42" 42"
TAPES TAPES TAPES TAPES TAPES TAPES TAPES TAPES TAPES
D
+ 14 + 14 + 14 + 14 + 14 + 14 + 14 + 14 + 14
0 0 0 0 0 0 0 0 0
G (MIN) 21/2 21/2 21/2 3 3 3 21/2 21/2 31/2
N (MIN) 3/4 7/8 1 1 1 1 1 1 1
+1 +1 +1 +1
01 130 103/40 121/2 1/8 121/2 1/8 111/20 121/2 1/8 131/20 121/2 1/8 121/2 1/8
02 +1 +1 +1 +1
130 103/40 131/4 1/8 131/4 1/8 111/20 131/4 1/8 131/20 131/4 1/8 131/4 1/8
P 61/2 1/8 71/8 61/2 1/8 61/2 1/8 71/8 61/2 1/8 61/2 1/8 61/2 1/8 61/2 1/8
R1 413/16 1/8 55/16 1/8 413/16 1/8 413/16 1/8 45/16 1/8 413/16 1/8 413/16 +1/8 413/16 1/8 413/16 1/8
R2 111/16 f 111/16 f 111/16 f 111/16 f 211/16 1/8 111/16 f 111/16 f 111/16 f 111/16 f
MAX FINISH 101/4 81/2 915/16 915/16 91/4 915/16 103/4 915/16 915/16
BORE
MIN HUB **
13/8 11/8 11/8 11/8 11/8 13/8 11/8 11/8
WALL 11/8
NOTES:
1. WHERE DIMENSION R2 IS MARKED F, EXTRA STOCK OF 1/16 IN. TO 3/16 IN. OVER SPECIFIED DIMENSION MAY BE LEFT FOR MACHINING OF EACH FINISHED
SURFACE OR WHEEL MAY BE FURNISHED FINISHED TO EXACT DIMENSION SHOWN. HUB LENGTH TOLERANCE IS BASED ON FINISHED DIMENSION.
* REFERENCE GROOVE REQUIREDSEE RP-619
** HUB WALL THICKNESS MAY BE REDUCED AS NECESSARY FOR APPLICATION OF ROLLER BEARING WATER GUARD.
Fig. B.10 Standard wheel types for locomotive service

G [M-107/M-208] 52 03/2011
Wheels and Axles
AAR-1B WIDE PROFILE CENTERS OF

RADII RELATIVE TO GAUGE POINT
POINT X Y
A 1.196896 1.149921
B 0.589000 0.249600
C 0.589000 0.312100
D 0.362211 0.097100
E 0.580300 0.007500
F 1.060300 0.812800
AAR-1B WIDE PROFILE INTERSECTION OF POINTS

RELATIVE TO GAUGE POINT
POINT X Y
1 1.375000 0.624585
2 1.147435 0.031070
3 0.589000 0.375400
4 0.091706 0.162616
5 0.000000 0.000000
6 0.035442 0.132273
7 0.291159 0.474998
8 0.631437 0.624585
9 0.989517 0.685529
Detail A
Fig. B.11 AAR-1B wide-flange contour for freight car wheels
03/2011 G [M-107/M-208] 53
Wheels and Axles
AAR-1B NARROW PROFILE CENTERS

OF RADII RELATIVE TO GAUGE POINT
POINT X Y
A 0.204400 0.641800
B 0.562500 0.312500
C 0.562500 0.000000
D 0.370581 0.065876
E 0.571971 0.038692
F 1.052000 0.844000
AAR-1B NARROW PROFILE INTERSECTION OF

POINTS RELATIVE TO GAUGE POINT
POINT X Y
1 1.156300 444011
2 0.853075 0.237046
3 0.562500 0.375000
4 0.140565 0.230296
5 0.008400 0.031335
6 0.028575 0.106659
7 0.278542 0.441210
8 0.748621 0.625000
9 0.977100 0.654129
Detail A
Fig. B.12 AAR-1B narrow-flange contour for freight car wheels
G [M-107/M-208] 54 03/2011
Wheels and Axles
NOTE: WHEN WHEEL RIMS ARE REDUCED IN THICKNESS TO SUCH AN EXTENT THAT LATHE DOGS INTERFERE WITH THE 5/8-IN. RADIUS AT THE OUTER RIM
FACE, THIS RADIUS MAY BE REDUCED AS NECESSARY OR A CHAMFER USED. FREIGHT LOCOMOTIVE WHEEL RIMS SHALL BE MACHINED WITH A
MAXIMUM RADIUS OF 5/8 IN. ON THE OUTER RIM FACE. A CHAMFER IS ALLOWED TO EXTEND PAST THE RADIUS AT 45, BUT MUST BE NO LONGER THAN
0.4375 IN. MEASURED ALONG ITS LENGTH.
Fig. B.13 Cylindrical tread contour for narrow-flange wheels

03/2011 G [M-107/M-208] 55
Wheels and Axles
6.500
3
8 " 1.469
3
8 "
A 4.000
WHEEL CONTOUR ACCEPTANCE GAUGE
FOR AAR 1B NARROW & WIDE FLANGE
INTERSECTION POINTS
1 (0.0841873, -1.49764) R1.500
2 (0.4289, -1.4374) B 5 1.094
3 (0.769141, -1.2878) 2.8624 4
4 (1.02338, -0.950724)
5 (1.0603, -0.8128) BASELINE 3
1 2 R.5625
CENTERS OF RADII
A (0.000, 0.000) 1.987
B 0.480, -0.8053)
VERIFY WITH CONTOUR MAPPING MATERIAL:
MAX MANUFACTURE DEVIATION: .003" STAINLESS STEEL 17-7
8 " THICKNESS
1
MAX RECERTIFICATION DEVIATION: .005"
HARDENED
.750
Fig. B.14 Tread contour gauge for AAR-1B wheels

Paragraph 16.5
G [M-107/M-208] 56 03/2011
Wheels and Axles
M-107/M-208 APPENDIX C
APPENDIX C
AUTHORIZATION FOR CLASS D WHEEL TEST ALLOTMENT
1.0 Each manufacturer must obtain an authorization for Class D test wheels from the Committee
prior to delivery. All requirements of the M-107/M-208 wheel specification and associated
appendixes apply to Class D wheels.
1.1 The intent of Class D is to provide wheel materials with superior resistance to tread damage
when compared to Class C wheels, without compromising any other safety performance character-
istics.
2.0 Class D wheel applicants must submit results from laboratory material tests as described in
paragraph 3.0 of this appendix, Material Testing. Upon acceptance of the laboratory test results,
the WABL Committee will authorize a test allotment of 5,000 wheels for field service testing in
interchange service.
3.0 MATERIAL TESTING
3.1 The following material testing is required. The applicant must contact the WABL Committee
to schedule an AAR observer. Three sample wheels must be tested. Unless otherwise approved by
WABL, an AAR observer is required. All costs for the tests and the observer are to be paid by the
applicant. Wheel materials should meet the minimum properties listed in Table 3.1.
3.1.1 Tension testing shall be conducted on two specimens at ambient temperature and two spec-
imens at 1,000 F. Specimens shall be taken from as close to the tread as possible (at least 1/8 in. of
the original wheel tread must remain visible at the ends of the test specimen) in the circumferen-
tial direction. Ultimate tensile strength, 0.2% offset yield strength, percentage elongation, and
percentage reduction of area shall be determined. Tests must be conducted per ASTM E21
(1,000 F) and ASTM A370 (ambient temperature), latest edition.
3.1.2 The microstructure shall be classified in the report and should be free of martensite. Six
microstructural specimens (1/2 in.2 section) shall be taken in the radial plane direction adjacent to
the microcleanliness specimens and must include the tread surface. The intent is to classify all
microstructures in the specimen, to include the tread surface. The report should contain sufficient
photographic evidence to support the conclusions.
3.1.3 Absence of tensile hoop stress shall be documented by a radial saw cut made to a depth at
least 1 in. deeper than the rim inner diameter. No opening of the cut shall be present at the conclu-
sion of the cut.
3.1.4 Hardness mapping of the test wheels shall be performed per M-107/M-208, Section 11.5. In
addition, Brinell hardness measurements shall also be taken along the centerline of the plate to
the hub inner diameter at approximately 1/2 in. spacing and reported for reference only.
03/2011 G [M-107/M-208] 57
Wheels and Axles
APPENDIX C M-107/M-208
3.1.5 Fracture toughness type testing shall be determined for two samples per test wheel at
70 F to 75 F according to ASTM E 399, latest edition. The sample shall be taken as shown in
Fig. 3.1. If a valid KIC is not obtained, then report the KQ value.
2.4" MIN
1" MIN
2.5
"M
IN
Fig. 3.1 Fracture toughness test sample

3.1.6 The manufacturer must provide lab data demonstrating the relative wear and shelling per-
formance as compared to Class C. The manufacturer must specify the test methods used for the
comparison. The following test conditions are recommended. Testing protocols may be changed if
better methods can be demonstrated.
3.1.6.1 To demonstrate performance no worse than Class C, comparative accelerated rolling load
wear tests shall be conducted. Tests shall be performed using two discs constructed of the proposed
wheel material.
3.1.6.1.1 Test conditions shall be as follows:
Contact pressure = 319,500 psi
0.75% slip
Duration = 500,000 cycles
3.1.6.1.2 The result must be calculated wear rates for Classes C and D.
3.1.6.2 To demonstrate performance superior to Class C, an accelerated rolling load shelling test
shall be conducted using two discs.
3.1.6.2.1 Test conditions shall be as follows:
Contact pressure = 159,750
0.3% slip
Duration = onset of shelling as determined using a vibration sensor
3.1.6.2.2 The result must compare cycles to shelling onset for Classes C and D.
Table 3.1 Minimum material properties
Ambient (65 F80 F) 1,000 F
Hardness 341 HB415 HB NA
UTS (psi) >157,000 >70,000
Yield (psi) (0.2% offset method) >110,000 >50,000
% Elongation in 2 in. >14 >20
Reduction of Area (%) >15 >40
Fracture toughness (KIc or Kq) >35 ksi sq root in.
G [M-107/M-208] 58 03/2011
Wheels and Axles
M-107/M-208 APPENDIX C
4.0 FIELD SERVICE TEST ALLOTMENT

4.1 Upon Committee review of the laboratory test program, an allotment of 5,000 wheels shall be
granted. The manufacturer shall inspect all wheels in service and report to the Committee the
cause for any removals. Manufacturer shall select a service that is expected to accumulate at least
50,000 miles per year.
5.0 FIELD SERVICE TESTING
5.1 It is the responsibility of the manufacturer to monitor the performance of the test wheels in
service and report results to the WABL Committee. Reduction of removals for tread damage (as
compared to Class C) must be demonstrated. The field service test shall include the following:
Monitoring a minimum of 1,000 wheels in 286k service
Documenting car numbers and location of all test wheels
100% trackingfor removal causes
Visual inspections and sample wear monitoring (30% of test wheels) at the following inter-
vals:
At least 25,000 miles
400,000 miles
5.2 The field service report shall include the following:
Removal causes
Reduction of tread defect removals compared to Class C in the same service
Percentage of test wheels remaining in service after 300,000 miles
6.0 ADDITIONAL ALLOTMENTS
6.1 A second test allotment of 5,000 wheels may be applied for after the 300,000-mile report.
6.2 After the 400,000-mile test report is accepted by the WABL Committee, additional allotments
may be approved per Appendix A.
03/2011 G [M-107/M-208] 59
Wheels and Axles
APPENDIX C M-107/M-208
G [M-107/M-208] 60 03/2011
M-967
ELECTROCHEMICAL METAL DEPOSITION FOR REPAIRING ROLLER

BEARING AXLE JOURNALS
Specification
M-967

1.0 SCOPE
This document describes the certification requirements, equipment, materials, personnel require-
ments, quality control, and utilization of the electrochemical metal deposition process for repairing
roller bearing axle journals.
2.0 PROCESS DESCRIPTION
The electrochemical metal deposition process is an electrochemical metallizing process in which
the high current density technology of arc welding is applied to a concentrated electrolyte solution,
thus depositing metal without the use of either heat or immersion tanks. The solution is held in, or
pumped through, an absorbent material attached to an inert electrode (anode) that, in turn, is
attached to a DC power pack. The cathode lead of the power pack is attached to the workpiece, and
a current is passed through the solution. The result is a rapid deposition of metal onto the area
contacted by the anode. The process requires neither the pre-machining of base metal nor the sub-
sequent stress relief and embrittlement relief of the metal deposit. A motion between the anode
and the workpiece is required to produce high quality, uniform deposits.
3.0 APPLICATIONS
The electrochemical metal deposition process can be used effectively on specific surfaces, as listed
in the AAR Manual of Standards and Recommended Practices, Section G-II, paragraph 1.2.7,
where a metal deposit is required for restoration of original dimensions on roller bearing axle jour-
nals and dust guards.
4.0 GENERAL REQUIREMENTS
4.1 Equipment
Equipment used with the electrochemical metal deposition process and supplied by the process
manufacturer incorporates certain safety features commensurate with handling electrodes and
electrolytes. No equipment shall be used that does not have these safety features and that is not
certified by the process manufacturer as having been designed specifically for electrochemical
metal deposition.
4.1.1 Power Pack
4.1.1.1 The DC output ranges of power packs used for electrochemical metal deposition processes
shall be determined by the process manufacturer. The capacity of the power pack is directly
related to the size of the surface on which metal is being deposited and the thickness of that
deposit.
03/2011 G [M-967] 61
M-967
4.1.1.2 The following are features that shall be integral parts of the power pack:
Voltmeter
Dual-range ammeter with automatic switching or dual ammeters
Digital amp-hour meter
Polarity reversing switch
Overload protection
Infinitely variable voltage control
Instantaneous (1/2 cycle) safety cutout switch
Controlled ripple
4.1.2 Handles and Anodes
Handles for the process are conductive, must be matched to the amperes drawn for a given appli-
cation, should aid in dissipating heat, and must provide operator protection as well as ease of oper-
ation. The anodes must be of a material chemically inert to the electrolyte solution. The only
materials considered universally inert to all electrolytes used in the electrochemical metal deposi-
tion process are high-density, high-purity graphite or platinum with up to 11% iridium alloy. Other
anode materials may be used with a specific compatible solution; however, both the anode and
solution must be approved in writing by the process manufacturer. This written approval must
also be provided to the AAR. Where graphite anodes are used, graphite shall have less than 1%
metallics by volume, of a grade approved, in writing, by the process manufacturer for each electro-
lyte being used. This written approval must also be submitted to the AAR.
4.2 Solutions
4.2.1 The solutions used in the electrochemical metal deposition process are highly concentrated
water base chemicals. These include preparatory solutions for cleaning and activating the surface
to be coated, metal deposition solutions for coating, and metal removal solutions for polishing and
stripping. All metal deposition solutions must carry a batch number and be traceable to the manu-
facturers control batch and the axle repaired.
Note: Although several sources for electrochemical metal deposition solutions may be developed,
compatibility of the chemicals in the process is mandatory for process integrity. Therefore, in no
case will solutions, either preparatory or metal deposition, of different manufacturers be inter-
mixed or substituted into a buildup procedure.
4.3 A solution certified by the process manufacturer and annually verified by the axle recondi-
tioner as capable of depositing nickel with minimum C50 Rockwell or 500 Knoop hardness tested
per ASTM B-578 with a 50-g load must be used when repairing roller bearing axles. Documenta-
tion of the hardness test must include the test method and batch number(s) and be kept on record.
5.0 TECHNICAL REQUIREMENTS
5.1 Operator Qualification
The electrochemical metal deposition process is operator dependent and, therefore, only certified
personnel shall be permitted to process interchange equipment. Certification may be obtained in
any of the following manners:
5.1.1 Completion of a manufacturers theoretical course of instruction and a demonstrated ability
to repair axles consistently to the manufacturers process procedures.
5.1.2 Completion of a theoretical course certified by the process manufacturer and a demon-
strated ability to repair axles consistently to the manufacturers process procedures.
5.1.3 Completion of theoretical and hands-on training under direct supervision of a certified oper-
ator for a period as stipulated in the facilitys AAR Manual of Standards and Recommended Prac-
tices, Section J, Specification M-1003, Specification for Quality Assurance, to include a
demonstrated ability to repair axles.
G [M-967] 62 03/2011
M-967
5.1.4 The course shall provide the operator proficiency in the electrochemical metal deposition
process including the following:
Inspection and preparation of metal surfaces for electrochemical metal deposits
Selection of proper tools
Calculation of deposit thickness
Application of metal deposit
Proper finishing techniques
5.1.5 The demonstration of ability shall consist of properly repairing at least two journals with
each of the following defects:
For status code 3A:
a. Undersized journal greater than .003 in. below minimum
b. Seal wear ring groove greater than .008 in. deep
c. Water etch in cone area greater than .001 in. deep
d. Undersized journal and ring groove combination
e. Undersized journal and water etch combination
f. Undersized journal that has been previously rebuilt (nickel de-
posited to nickel over the entire journal)
For status code 3B:
a. Undersized journal greater than .003 in. below minimum
For status code 3C:
a. Undersized dust guard greater than 0.003 in. below minimum
5.1.6 Proper repairing shall be determined by testing 100% of the repaired journals in accordance
with paragraphs 5.2.1, 5.2.2, 5.2.3, and 5.2.4, except in the case of dust guard repairs where
paragraph 5.2.3 does not apply.
5.1.7 Adequate records to document the above demonstration of operator proficiency for certifica-
tion shall be maintained. Operator recertification is required annually and shall include the abil-
ity to demonstrate qualification by written examination and/or practical application as stipulated
in the facilitys quality assurance manual required by AAR Manual of Standards and Recom-
5.2 Inspection Procedure
The quality of an electrochemical metal deposition deposit is most readily proven when secondary
processing such as machining or grinding is accomplished. However, since the process obtains sig-
nificant cost reduction when secondary processing is not required and the part is built to size,
other inspection procedures are available.
5.2.1 Visual Inspection
All deposits shall be smooth, uniform in color, and free of blisters, pits, nodules, porosity, excessive
edge build-up, and other defects that would affect the functional use of the axle. The deposit sur-
face of the repaired journal shall be free of burnings and stress concentrations. Burning is defined
as rough, coarse grained, or dark deposits caused by localized high current density or arcing.
Highly stressed deposits will normally be indicated by cracks or crazing. The above defects are
cause for rejection.
5.2.2 Adhesion Test
Each axle journal repaired by the electrochemical metal deposition process shall have an adhesion
test performed. The adhesion test is accomplished using Scotch #250 tape or an equivalent
high-tack-strength, pressure-sensitive tape as approved by the AAR. The adhesion test is accom-
plished as follows:
03/2011 G [M-967] 63
M-967
5.2.2.1 Thoroughly clean and dry the processed surface with a method that will not adversely
affect tape adhesion.
5.2.2.2 Cut a piece of 1-in.-wide unused tape approximately 6 in. longer than the width of the pro-
cessed area.
5.2.2.3 Stick the tape longitudinally across the width of the processed area of the journal so that
approximately 1/2 in. of the base metal on each side is taped to ensure coverage of both edges of
the processed area. Tamp the tape down to ensure thorough adhesion.
5.2.2.4 Grip the loose end of the tape and rip rapidly upward (at a right angle to the surface),
removing the tape with a single jerk.
5.2.2.5 Inspect the tape and processed surface area. Any deposit nickel adhering to the tape and
part of the processed area visually lifted is cause for rejection.
5.2.3 Burnishing
5.2.3.1 The deposit is suspect if moderate burnishing will cause a nonadhering deposit to lift,
peel, or flake; therefore, an inspection sampling derived from ANSI/ASQC Z1.91993 shall be bur-
nished and retested in accord with paragraphs 5.2.1 and 5.2.2 with a minimum daily inspection of
5%.
5.2.3.2 Each active operator shall have at least one axle inspected for compliance with this para-
graph for each week of production.
5.2.3.3 A moderate burnishing shall be that which creates a 0.0001-in. to 0.0002-in. reduction in
journal diameter after being burnished.
5.2.4 Surface Finish
5.2.4.1 The deposit surface finish on the repaired journal must not exceed 63 in.
5.2.4.2 The deposit finish on the repaired dust guard must not exceed 125 in.
5.2.5 Dimensional Inspection
When restoration of the entire length of the journal is required, average journal diameters must be
within the prescribed tolerances for new axles except for the restored area of the journal diameter
outside the area bounded by the inboard edge of the seal wear ring contact area, to the outboard
edge of the outboard cone. The average journal diameter may be used to meet journal diameter
requirements for the AAR Manual of Standards and Recommended Practices, Section G-II,
Fig. 4.1. The radius of the journal fillet must meet the new axle dimensions. When restoring the
dust guard for use in fitted applications, the diameter of the repaired dust guard must be within
the prescribed tolerances for new axles.
6.0 GENERAL REQUIREMENTS
The requirements of the AAR Manual of Standards and Recommended Practices, Section G, Part
II, Wheel and Axle Manual, pertaining to axle repairs by this process and to facility certification
must be met. In addition to the foregoing, those facilities maintaining or requesting certification in
accord with M-967 must meet the requirements of the AAR Manual of Standards and Recom-
G [M-967] 64 03/2011
M-967 APPENDIX A
APPENDIX A
QUALIFICATION OF APPLICANTS FACILITY FOR REPAIRING AXLES BY
ELECTROCHEMICAL METAL DEPOSITION PROCESS
1.0 The applicant must provide the Technical Services Division with an application for approval,
as described in the AAR Manual of Standards and Recommended Practices, Administrative
Standards, Standard S-060. Applications shall be provided in electronic file format and must
include brochures, material safety data sheets, and any other information that provides a general
description of the facility equipment and process to be used in the electrochemical metal deposition
repair of axles.
2.0 After determining that the application is consistent with the requirements of this
specification, the Committee will authorize the applicant to contact the AAR for information
concerning product testing.
3.0 All costs are to be paid upon notification of the testing charges. Product testing shall consist
of the applicants furnishing a minimum of three axles with journals electrochemically repaired
and shall include (as required by the applicable status code number) the following:
3.1 Two journals having had only seal wear ring grooves greater than 0.008 in. repaired.
3.2 Two journals undersize greater than 0.003 in. below minimum with full length of journal
restored.
3.3 Two journals with full length of journal restored over repaired water etch greater than
0.001 in. on the outboard cone seat. This must reflect nickel over nickel restoration.
3.4 Two dust guards having the dust guards greater than 0.003 in. below minimum restored.
4.0 The following tests shall be performed at or under the observation of the AAR with the test
results being provided to the Committee.
4.1 Microhardness test as per ASTM-B-578, latest revision. Microhardness for electroplating on a
minimum 0.002-in. deposit material on a seal wear ring groove. Minimum microhardness should
be C50 Rockwell or 500 Knoop tested per ASTM B-578 with a 50-g load.
4.2 Visual inspection as per paragraph 5.2.1.
4.3 Adhesion test as per paragraph 5.2.2.
4.4 All journals and dust guards must be measured and meet dimensional requirements as per
paragraph 5.2.5.
4.5 All journals and dust guards must be measured and meet the surface finish requirements per
paragraph 5.2.4.
4.6 Mounting and removal of a bearing three times on journals with full length restored with a
minimum interference fit of 0.002 in. All journals must meet the requirements of paragraph 5.2.2.
4.7 Journals must meet burnishing and testing specifications per paragraph 5.2.3. Photographic
documentation will be developed to confirm compliance with paragraphs 4.1, 4.2, and 4.3 of this
appendix. Subsequent to performance of the test referenced in paragraph 4.6 of this appendix,
inspection will be performed in accordance with paragraphs 4.2 and 4.3 thereof.
4.8 Mounting and removal of a fitted backing ring three times on restored dust guards.
03/2011 G [M-967] 65
APPENDIX A M-967
5.0 Subsequent to the satisfactory completion of the tests and approval of the test results by the
Committee, the AAR Technical Services Division will inspect the facility where the axles are to be
repaired for proper procedures and equipment, including a demonstration of the ability to meet
the requirements of this specification. These inspections will require a certification fee as per the
AAR Field Manual of Interchange Rules, Rule 120. These inspections may be arranged
concurrently with the test program.
6.0 It is considered necessary that each qualified applicant have enough axles in AAR
interchange service to develop meaningful performance data. Therefore, the applicant will be
required to deliver at least 150 axles during the first 2 years after receipt of AAR approval and at
least 1500 axles within any consecutive 5-year period for use in AAR interchange service. When
data to support the number of deliveries is not available to the AAR, the applicant will be asked to
provide this information by listing the required number of axles delivered and to which customers
delivery was made. In the event the delivery requirement is not met and upon notification by the
AAR, the applicant will be required to requalify.
7.0 Requalification will require at least a current plant inspection by the AAR and a certification
by the applicant that repaired axles are of the same process and material, subject to compliance
with the latest version of this specification, as previously approved by the Committee. The
Committee may elect to require verification of any or all of the provisions of Appendix A of this
specification for requalification.
8.0 In the event that a plant ceases production for more than 60 days but no more than 1 year,
the AAR must be notified no less than 2 weeks prior to reopening. In the event that a plant ceases
production for more than 1 year, requalification will be required prior to delivery of any items for
use in AAR interchange service. The Committee may elect to require testing of axles in accordance
with paragraph 2.0 of Appendix A.
G [M-967] 66 03/2011
M-967 APPENDIX B
APPENDIX B
AUTHORIZATION FOR DELIVERY OF AXLES REPAIRED BY THE
ELECTROCHEMICAL METAL DEPOSITION PROCESS FOR AAR
INTERCHANGE SERVICE
1.0 Each applicant must obtain an authorization for delivery of repaired axles for AAR
interchange use from the Committee prior to delivery.
2.0 Authorization for delivery of repaired axles will be approved after review of the tests and of
the AAR Field Manual of Interchange Rules Rule 120 inspection report required by Appendix A.
Authorization may be withdrawn if service performance so dictates.
03/2011 G [M-967] 67
APPENDIX B M-967
G [M-967] 68 03/2011
S-601
WHEELSMANUFACTURING FACILITY INSPECTION BY TECHNICAL

SERVICES
Standard
S-601

1.0 SCOPE
1.1 This document became effective March 1, 1980.
1.2 An AAR Technical Services Division inspector will periodically inspect steel wheel manufac-
turing facilities to ensure that control practiced by manufacturers is effective in maintaining a
constant standard of quality to meet the requirements of AAR specifications and service conditions
to which the wheels are subjected.
2.0 GENERAL
Current operating conditions on railroads make it imperative that high quality is maintained in
all wheels. Processes used by individual manufacturers differ in many details, but all have been
developed to produce wheels that will meet the specification requirements.
3.0 DUTIES
The following shall be the duties of an inspector:
3.1 To obtain definite information concerning plant facilities and manufacturing processes and
obtain a general knowledge of the manufacturing procedure. This should not imply that the
inspector should require detailed information of melting practice or of any other processes adopted
by a manufacturer. The inspector should determine the following:
If steel is basic or acid
If steel is melted in electric or open-hearth furnaces or by basic oxygen process
Chemical analysis procedures
Pouring practice
If ingots produce individual or several wheels
Method of converting ingots to billets or blocks
Type of heating furnaces
Method of forging, rolling, and casting
Method of cooling and heat treatment
Frequency of furnace instrumentation calibration
Frequency of calibration of furnace temperature monitoring equipment
Type of machines
Operation of shot peening equipment
Inspection procedures, including
Operation of magnetic particle inspection equipment
Operation of ultrasonic inspection equipment
Condition and calibration of equipment for mechanical property determinations and
dimensional measurements
Shipping procedures
Adequacy manufacturing records
03/2011 G [S-601] 69
S-601
3.2 To inspect typical wheels that the manufacturer has released for shipment.
3.2.1 The inspections shall be in accordance with the requirements outlined in the AAR Manual
of Standards and Recommended Practices, Section G, Part II, Wheel and Axle Manual and in
M-107/M-208 of this manual.
3.2.2 Table 3.1 lists in detail defects that, through past experience, have been found to be detri-
mental to the performance of wheels in service:
Table 3.1 Defects detrimental to wheel performance
Defects Rims Plates Hubs
Inclusions (sand/slag) x x x
Cracks (hot tears/cold shut) x
Laps/seams x x x
Deep or numerous pits (insufficient stock) x x x
Deep chuck marks (extending to edge of back rim) x
Abrupt change in section x
Poorly blended machine sections x x x
Improper stamping x
3.3 To report to the AAR Technical Services Division and manufacturer on the results of the
inspection.
G [S-601] 70 03/2011
S-611
WHEELSMEASURING WHEEL CIRCUMFERENCE (TAPE) USING WHEEL

GAUGES S-612 AND S-613
Standard
S-611
Adopted: 1893, 1973; Last Revised: 2004

1.0 These wheel circumference measures are used for taping wheels to ensure that wheels
mounted on the same axle shall be of the same diameter and that new wheels are within the
specification limits.
2.0 The measures are calibrated by 1/8-in. circumference and 1/2 tape sizes interpolated.
3.0 For new wheels, tape 283 (S-612) represents a wheel of exactly 38-in. diameter.
4.0 The tape size of a wheel is considered to be that of the lower graduation until the next
graduation is reached.
5.0 The four lugs that contact on the face of the flange are to hold the tape in the center of the
treads. These lugs should preferably have ribs pressed into them to reduce a tendency to bend out
of shape.
6.0 In use, the tape should lie flat on the treads all the way around, including the handle and lug.
Kinks in tape are not tolerated.
7.0 The wheel circumference gauge (S-613) may be used not only for taping new wheels but for
taping worn wheels of large diameter. Because this tape is calibrated in increments of 1 in. from a
35-in.-diameter wheel to a 52-in.-diameter wheel, it may be used for checking the worn diameter of
any of the intermediate size wheels.
8.0 All wheel tapes should be checked periodically on a master ring of known accuracy.
03/2011 G [S-611] 71
Wheels and Axles
S-611
G [S-611] 72 03/2011
S-612
CIRCUMFERENCE MEASURE (TAPE) FOR 27-IN. TO 38-IN. STEEL WHEELS
Standard
S-612

Note: For master gauge, see RP-608 and RP-609.
NOTE:
THE SCALE ON THE WHEEL TAPE CAN HAVE A TOLERANCE OF .005
BETWEEN ANY TWO POINTS ON THE SCALE WITH NO ACCUMULATIVE
VARIATION. LINEAR DIMENSIONS SHOWN REPRESENT
MEASUREMENTS OF ACTUAL CIRCUMFERENCE OF THE WHEEL AND
NOT STRAIGHT LENGTH OF THE TAPE. GRADUATIONS ARE TO BE
SPACED 1/8 IN. APART WITH THE TAPE LAID FLAT.
03/2011 G [S-612] 73
Wheels and Axles
S-612
G [S-612] 74 03/2011
S-613
Part 1
CIRCUMFERENCE MEASURE (TAPE) FOR 38-IN. TO 52-IN. STEEL WHEELS
Standard
S-613

1.0 SCOPE
1.1 This standard became effective July 1, 1980.
1.2 See S-611.
NOTE 1:
MARK WHEEL DIAMETERS IN 1/8-IN.
FIGURES ON TAPE AS SHOWN ABOVE
AND AS INDICATED IN THE FOLLOWING
TABLE:
WHEEL DIA. TAPE SIZE
35 207
36 233
37 258
38 283
39 308
40 333
41 358
42 385
43 409
44 434
45 459
46 484
47 509
48 534
49 559
50 584
51 610
52 636
NOTE 2:
THE SCALE ON THE WHEEL TAPE CAN
HAVE A TOLERANCE OF .005
BETWEEN ANY TWO POINTS ON THE
SCALE WITH NO ACCUMULATIVE
VARIATION. LINEAR DIMENSIONS
SHOWN REPRESENT MEASUREMENTS
OF ACTUAL CIRCUMFERENCE OF THE
WHEEL AND NOT STRAIGHT LENGTH
OF THE TAPE. GRADUATIONS ARE TO
BE SPACED 1/8 IN. APART WITH THE
TAPE LAID FLAT.
03/2011 G [S-613] 75
Wheels and Axles
S-613
G [S-613] 76 03/2011
S-614
WHEEL DEFECTWORN JOURNAL COLLAR AND JOURNAL FILLET

GAUGE
Standard
S-614

Note: See RP-613 for the master gauge and S-616 for the limiting wear condemning gauge.
MATERIAL: ASTM A-576, Grade 1020

HARDEN AND GROUND ON ALL GAUGING SURFACES. CHROMIUM-PLATED FINISH
03/2011 G [S-614] 77
Wheels and Axles
S-614
G [S-614] 78 03/2011
S-615
WHEEL DEFECTWORN JOURNAL COLLAR AND JOURNAL FILLET

GAUGE
Former Standard
S-615

1.0 SCOPE
1.1 This gauge can be used for 7/8-in. or less flange on locomotive wheels.
1.2 This standard became effective April 1, 1981.
Gauge No. 34401A

MATERIAL: .093 STAINLESS STEEL
UNLESS OTHERWISE STATED, ALL TOLERANCES ARE .010 in.
03/2011 G [S-615] 79
Wheels and Axles
S-615
G [S-615] 80 03/2011
S-616
GAUGE, AXLEREFERENCE GAUGE FOR VERIFYING AXLE JOURNAL

AND FILLET GAUGE S-614
Former Standard
S-616

1.0 SCOPE
This gauge applies to Gauge No. 34401 described in S-614.
03/2011 G [S-616] 81
Wheels and Axles
S-616
G [S-616] 82 03/2011
S-617
GAUGE, WHEELFORMER STANDARD 1980
Former Standard
S-617

Note: For the master gauge, see RP-614.
03/2011 G [S-617] 83
Wheels and Axles
S-617
G [S-617] 84 03/2011
S-618
GAUGE, WHEELFORMER STANDARD 1976
Former Standard
S-618
Adopted: 1976
Note: Steel Wheel Gauge1976 is to be suitably marked on the back side of the gauge in approx-
imately 1/8-in. letters. For the master gauge, see RP-614.
MATERIAL: .093-in. STAINLESS STEEL FOR BODY OF GAUGE AND .050-in. STAINLESS STEEL OF SUITABLE HARDNESS FOR GAUGE FINGER. TOLERANCES ON DECIMAL
DIMENSIONS TO BE .005 in. AND ON DIMENSIONS IN COMMON FRACTIONS TO BE 1/64 in. UNLESS OTHERWISE SPECIFIED. REMOVE BURRS AND SHARP EDGES.
03/2011 G [S-618] 85
Wheels and Axles
S-618
G [S-618] 86 03/2011
S-627
GAUGE, WHEELCOMBINATION GAUGE FOR WHEEL MEASUREMENTS
Standard
S-627
Adopted: 1998
Note: For the limiting wear condemning gauge, see Standard S-629.
Notch Detail
A B
0 3/16 1/4
1/4 1/8 1/8
1/2 1/8 3/16
3/4 1/8 1/8 Material: Stainless steel 304
Thickness: 3/32
1 3/16 1/4
1 1/4 1/8 1/8
1 1/2 1/8 3/16
1 3/4 1/8 1/8
2 3/16 1/4
2 1/4 1/8 1/8 NOTES:
1. UNLESS OTHERWISE SPECIFIED, MANUFACTURE TOLERANCES ARE .010.
2 1/2 1/8 3/16 2. BOXED DIMENSIONS ARE MINIMUM CHARACTERISTICS TO BE VERIFIED FOR RECERTIFICATION.
3. RECERTIFICATION TOLERANCE IS .015 IN.
03/2011 G [S-627] 87
Wheels and Axles
S-627
G [S-627] 88 03/2011
S-628
GAUGE, WHEELCOMBINATION GAUGE FOR WHEEL MEASUREMENTS

INCLUDING LOCOMOTIVE FLANGE LIMIT OF 0.875 IN.
Standard
S-628
Adopted: 1998
Notch Detail
A B
0 3/16 1/4
1/4 1/8 1/8
Material: Stainless steel 304
1/2 1/8 3/16 Thickness: 3/32
3/4 1/8 1/8
1 3/16 1/4
1 1/4 1/8 1/8
1 1/2 1/8 3/16
1 3/4 1/8 1/8
NOTES:
2 3/16 1/4 1. UNLESS OTHERWISE SPECIFIED, MANUFACTURE TOLERANCES ARE .010.
2. BOXED DIMENSIONS ARE MINIMUM CHARACTERISTICS TO BE VERIFIED FOR RECERTIFICATION.
2 1/4 1/8 1/8 3. RECERTIFICATION TOLERANCE IS .015 IN.
4. THIS GAUGE CAN BE USED FOR 7/8-IN. OR LESS FLANGE ON LOCOMOTIVE WHEELS.
2 1/2 1/8 3/16
03/2011 G [S-628] 89
Wheels and Axles
S-628
G [S-628] 90 03/2011
S-629
GAUGE, WHEELREFERENCE GAUGE FOR VERIFYING COMBINATION

WHEEL GAUGE S-627
Standard
S-629
Adopted: 1998
Verify using contour mapping Material: Stainless steel 17-7

Maximum manufacture deviation from nominal: .003 in. Thickness: 3/16 in.
Maximum recertification deviation from nominal: .005 in.
03/2011 G [S-629] 91
S-629
Application Drawings (page 1 of 2)
G [S-629] 92 03/2011
S-629
Application Drawings (page 2 of 2)
03/2011 G [S-629] 93
Wheels and Axles
S-629
G [S-629] 94 03/2011
S-630
GAUGE, WHEELSTANDARD
Standard
S-630
Adopted: 1998
Finger radii Centers
X Y
0.3125 0.00 0.00
0.251A 0.00 0.00
0.251B 0.755726 0.685488
1.3125 0.0536604 0.999073
0.7656 0.29881 0.573978
1.562 0.00 0.00
0.126 0.00 1.49899
Wide Flange Markings
0.5625 0.0332779 0.874367 (Optional)
0.1875 1.24331 0.610423
Material:
Rivet and thumb knob:
303 stainless steel
Body and finger:

stainless steel 17-7
Hardened
Manufacture tolerance: .005

Recertification tolerance: .010
03/2011 G [S-630] 95
S-630
A
0 at 5 1.375
0 at 4 1.313
0 at 3 1.250
0 at 2 1.188
0 at 1 1.125 Wide Flange Markings
0 at 0 1.063 (Optional)
At B At C
0 1.264 0 1.483
2 1.210 2 1.408
3 1.168 3 1.364
4 1.120 Manufacture tolerance: .005 4 1.323
5 1.070 Recertification tolerance: .010 5 1.283
6 1.034 6 1.248
7 0.995 7 1.203
8 0.951 8 1.142
9 0.894 9 1.077
10 0.997
11 0.896
G [S-630] 96 03/2011
S-649
AXLESMANUFACTURING FACILITY INSPECTION BY TECHNICAL

SERVICES
Standard
S-649

1.0 OBJECTIVE
An AAR Technical Services Division inspector will periodically inspect manufacturing facilities
and processes pertaining to production of steel car and locomotive axles. This will include such
necessary inspection of the product to ensure that controls practiced by the manufacturers are
adequate to minimize defects that might result in service failures.
2.0 GENERAL
The procedures followed by the inspector will include a review and written record of practices and
facilities starting with the axle bloom immediately after rolling or forging and continuing through
the cooling practice of the axles. Heat-treating practices also will be reviewed. Extensive inspec-
tion of finished axles will not ordinarily be required. This should not imply that the inspector will
require detailed information of processes adopted by a manufacturer.
3.0 DUTIES
3.1 The following are some details of the practices that will be reviewed by the inspector:
Axle bloom handling, including cooling practice immediately after rolling or forging
Axle bloom heating practice, including furnace controls and type of furnace
Reduction practice, including facilities
Straightening practice
Axle cooling practice
Heat-treatment facilities and controls
Quality controls, tensile testing, and records
Ultrasonic testing
Determining if equipment and procedures for machining axles are adequate to meet AAR
specifications for the finished product
3.2 The inspections shall be in accordance with the requirements outlined in M-101.
3.3 A report will be made to the AAR Technical Services Division and the manufacturer on the
results of the inspection.
03/2011 G [S-649] 97
Wheels and Axles
S-649
G [S-649] 98 03/2011
S-657
WHEEL, PASSENGER CAR (AMFLEET)
Standard
S-657
Adopted: 1980
1.0 SCOPE
This standard became effective April 1, 1981.
NOTES:
1. MATERIAL: AAR MANUAL OF STANDARDS AND RECOMMENDED
PRACTICES,SECTION G, SPECIFICATION M-107/M-208. CLASS B.
2. DESIGN: AAR STEEL PASSENGER CAR WHEEL M-36 OR CM-36, MULTIWEAR
TREAD, NARROW FLANGE CONTOUR.
3. MARKING: MSRP SPECIFICATION M-107/M-208.
4. TREAD: MSRP SPECIFICATION M-107/M-208 FIG. B.13, EXCEPT 1:40 TAPER.
5. PERMISSIBLE VARIATION IN DIMENSIONS: PER MSRP SPECIFICATION
M-107/M-208, FIG. B.8, EXCEPT AS SHOWN.
6. MACHINING:
A. MSRP SPECIFICATION M-107/M-208 AND AS SHOWN.
B. INNER FACE OF WHEEL HUB SHALL BE SQUARE WITH CENTERLINE OF
FINISHED WHEEL BORE WITHIN .002 TOTAL INDICATOR READING (TIR.)
C. WHEEL SHALL BE MACHINED ALL OVER.
D. MAXIMUM DYNAMIC UNBALANCE AT THE OUTSIDE DIAMETER OF THE RIM
SHALL NOT EXCEED 0.6 LB. STAMP UNBALANCE IN OUNCES ON THE INSIDE
FACE OF THE RIM AT THE HEAVIEST POINT. AS AN ALTERNATIVE, IT IS
ACCEPTABLE TO MACHINE THE WHEELS ON ALL SURFACES TO WITHIN A
DIMENSIONAL TOLERANCE OF .005 IN.
E. SURFACE FINISH ON ID OF RIMS, WEB, AND OD OF HUB SHALL BE 250 IN.
MAXIMUM AND SHALL BE 350 IN. MAXIMUM FINISH ON THE TREAD,
FLANGE, AND RIM FACES.
7. WHEEL PLATE AREA, ID OF RIM, AND OD OF HUB SHALL BE SHOT PEENED IN
ACCORDANCE WITH MSRP SPECIFICATION M-107/M-208.
8. WHEEL SHALL BE ULTRASONICALLY TESTED AND MAGNETIC PARTICLE
INSPECTED AFTER MACHINING IN ACCORDANCE WITH MSRP SPECIFICATION
M-107/M-208.
9. THE VENDOR SHALL FURNISH AMTRAK WITH WHEELS IN PAIRS WITH THE
SAME TAPE SIZE. IN ADDITION TO MSRP SECTION G, WHEELS AND AXLES,
TAPE SIZE MARKING REQUIREMENTS, THE TAPE SIZE ALSO SHALL BE
STENCILED ON THE WHEEL TREAD IN 1-IN. (MINIMUM HEIGHT) LETTERS.
10. THE WORD AMTRAK SHALL BE STENCILED ON THE INSIDE PLATE IN 1-IN.
(MINIMUM HEIGHT) LETTERS, COLOR WHITE.
11. WHEELS ARE FOR USE WITH TRUCKS HAVING INSIDE JOURNAL ROLLER
BEARINGS.
Dimensions and Tolerances

A B C D G L N1 N2 O1 O2 P R1 R2
1 +1/16 1 5/32 +1/16 11/16 1/16 36 +14 tapes 2 3/4 min. 5 1/2 1/8 in. 3/4 min. 1 min. 10 3/4 +1/4 10 3/4 +1/4 7 1/8 8 5/8 1/8 1.625 +.000
0 0 0 tapes 1/8 1/8 .028
03/2011 G [S-657] 99
Wheels and Axles
S-657
G [S-657] 100 03/2011

S-658
AXLE FOR PASSENGER CARS (AMFLEET)

INBOARD ROLLER BEARINGRAISED WHEEL SEAT
Standard
S-658

1.0 SCOPE
This standard became effective March 1, 1983.
+.03
.13 .00
.06 FINISHED AXLE
1.50
+.06
.44 .00 DIA. BEARING SEAT TO BE UNIFORM
CL AXLE DIAMETER THROUGHOUT. TAPER NOT TO
2.00 EXCEED .001 PER FOOT ON DIAMETER.
DIA.
1.94 SYMMETRICAL ABOUT CL (TYPICAL)
6.135 DIA.
1.63 DIA. 6.125 6.31 .015
DIA.
60 6.1915 DIA. .88 R TYP
6.6260 DIA.
DETAIL A 6.1905 WHEEL SEAT
6.6240 6.25 DIA. (TYPICAL)
END FACES MUST BE

SQUARE WITH O.D. (TYP) A .03 TYP
.015 B 3.00 R 5.90 C

5.69 DIA. .38 TYP
.015 6.502 DIA. 1.25 7.00
5.81 DIA. 6.500 .015
.015
17.75
35.50
.19 R 15.95
46.00 JOURNAL CENTERS REF
5 71.00 +.052
.046
.50 R
.078
.19 .19
.265 5.90 REF. .19 .19
LABORATORY
DETAIL B ACCEPTANCE
STAMP MFG. NAME OR MO. & YR. WHEELS
BRAND MOUNTED
PART NO.
.25
COLD ROLL RELIEF GROOVES OVER
GRADE OF AXLE 4.00 DIA. 4.00 DIA.
REGION SHOWN WITH ROLLER HAVING CONTOUR OF
.19 RADIUS. USE 1200 POUNDS ROLLER PRESSURE. F FOR F
5.81 DIA. .25 +.00
.05R START ROLLING AT
CHEMISTRY ONLY .
REF. HEAT NO. MONTH
.88 R THESE POINTS. ROLL DOWN GROOVE AND OVERLAP & YEAR
AT BOTTOM. WHERE MOUNTED
METHOD OF COLD-ROLLING RELIEF GROOVES STAMPING ONE END OF AXLE STAMPING OTHER END OF AXLE
.44
DETAIL C
NOTES: LABORATORY ACCEPTANCE, MANUFACTURERS NAME OR

1. MATERIAL: AAR M-101, GRADE F. THE AXLE OTHERWISE BRAND, MONTH AND YEAR, HEAT NUMBER, SERIAL
MUST BE IN COMPLIANCE WITH AAR MANUAL OF NUMBER, GRADE OF AXLE, AND PART NUMBER ARE TO
STANDARDS AND RECOMMENDED PRACTICES, SECTION BE STAMPED ON ONE END OF THE AXLE TUBE BY THE
G, M-101, LATEST REVISION. MANUFACTURER AND TRANSFERRED TO THE FINISH
2. ROUGH MACHINED AXLE IS TO BE SUBCRITICALLY AXLE IN THE PRESENCE OF THE RAILROAD COMPANY
QUENCHED FROM 1000 F TO 1050 F IN WATER. ALLOW INSPECTOR UNLESS WAIVED BY THE RAILROAD
.187 IN. OVER FINISHED DIAMETERS. RELIEF GROOVES COMPANY.
ARE TO BE MACHINED AND COLD-ROLLED AFTER DATE OF APPLICATION AND PLACE WHERE MOUNTED ARE TO
SUBCRITICAL QUENCHING. BE STAMPED ON THE OPPOSITE END OF THE AXLE BY
3. FINISH MARKS WERE REMOVED IN THE 1982 REVISION. THE BUILDER OR RAILROAD COMPANY.
03/2011 G [S-658] 101

Wheels and Axles
S-658
G [S-658] 102 03/2011

S-660
WHEEL DESIGNS, LOCOMOTIVE AND FREIGHT CARANALYTIC

EVALUATION
Standard
S-660

1.0 OBJECTIVE
1.1 The ultimate objective of this procedure is to provide an additional method to help evaluate a
given wheel design to perform satisfactorily under normal railroad operating service conditions.
This objective will be attained by comparing the results of stress analyses of different wheel
designs. The database contains wheel designs demonstrating either satisfactory field performance
or unsatisfactory service with high failure rates.
1.2 The first step is to ensure that the computations will be of sufficient accuracy and reproduc-
ibility, regardless of where and by whom they are made. This procedure permits the use of all cal-
culational techniques that can be demonstrated to provide accurate results and that permit the
analyses to be made under a standard set of assumptions (i.e., material property data and loading
conditions).
1.3 This procedure shall be operative under M-107/M-208, Appendix A, paragraph 2.2.
2.0 BACKGROUND
2.1 Several computer codes can calculate wheel stresses, and these results can help in the evalu-
ation of the suitability of the wheel design. If stress comparisons are to be made among wheels of
different design, however, the magnitude and manner of design load application to the wheel must
be specified, as well as the accuracy requirements for the computational technique, if consistent
results are to be obtained.
2.2 The designated mechanical and thermal loads are not intended to indicate the maximum pos-
sible loads that might occur under service conditions, nor are they necessarily representative of
specific service conditions. The values selected represent levels that would be expected to be
exceeded only a very small percentage of the time. Load levels above these values may occur under
certain special conditions and would not necessarily lead to failure of the wheel.
3.0 LIMITATIONS
Stress calculations are limited to elastic analyses. The results of an elastic analysis will give some
indication of the quality of the wheel design. The thermal input (as subsequently defined) is lim-
ited, which permits the use of simpler equations to describe the mechanical and physical proper-
ties.
4.0 RESULTS
4.1 The results of the temperature calculation shall be displayed on a contour plot. The maxi-
mum temperature shall be indicated. Isotherms at even 100 F intervals are required.
4.2 The results of the stress calculation will be expressed in terms of effective stresses. The effec-
tive, or von Mises, stress is calculated from the principal stresses by the following equation:
1 2 2 2
eff = ------- ( 1 2 ) + ( 2 3 ) + ( 3 1 )
2
where 1, 2, and 3 are the principal stresses.
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S-660
4.3 While it is recognized that the thermal load cannot exist alone, it will not be advisable to
include combined mechanical (vertical and/or lateral) and thermal loads in the rim stress calcula-
tion because there are analytic complexities in calculating stresses close to the point of load appli-
cation. This leads to the following set of desired information:
4.3.1 A maximum effective stress on the surface of the plate, resulting from the individual or
combined action of vertical, lateral, and thermal loads.
4.3.2 Maximum effective stresses at designated points on the surface of the rim, resulting from
only a thermal load.
The maximum stress shall be found, regardless of wheel orientation. If the maximum stress occurs
at an orientation other than 0, the orientation must be specified in the tabulation of the results.
Data shall be provided in both tabular and graphical (contour) form. Constant stress contours
shall be labeled, and their spacing shall be chosen for clarity.
5.0 WHEEL LOADS
Load magnitudes should be a function of the maximum static rail load. The mechanical load mag-
nitudes are currently twice the maximum static rail load for a vertical load and the maximum
static rail load for a lateral load. The thermal loads also are proportional to the maximum static
rail load. Examples of currently approved loads are given in Table 5.1.
Table 5.1 Wheel load parameters
Thermal Load
Wheel Types Vertical Load (lb) Lateral Load (lb) (HP for 20 min.,
100% into wheel)
125 ton: 38-in. diameter 78,750 39,375 41.92
110 ton: 36-in. diameter 71,500 35,750 38.00
100 ton: 28-, 30-, 33-in. diameter 65,750 32,875 35.00
70 ton: 33-in. diameter 55,000 27,500 29.28
One Wear 28-in. diameter 48,750 24,375 25.95
Locomotive: 40-in. diameter and over 70,000 35,000 37.00
Note: Mechanical loads shall be introduced at several alternative locations.
5.1 Vertical (e.g., 71,500 lb for 36-in.-diameter wheel)

Two different positions for the line of action of the vertical load shall be considered. A load V1 shall
be imposed in the flange throat, such that the line of action of the load passes through a point
1/8 in. horizontally removed from the gauging point on the flange. (This requirement becomes
1 1/2 in. from the back rim face for wide-flange wheels and 1 9/32 in. for narrow-flange wheels.) An
edge load, V2, shall have a line action 1 in. from the front rim face.
5.2 Lateral (e.g., 35,750 lb for 36-in.-diameter wheel)
The line of action of the lateral load, L1, shall be imposed at the same point of action as V1,
described in paragraph 5.1 (see Fig. 11.1).
5.3 Thermal (e.g., 38.0 hp for 20 minutes for 36-in.-diameter wheel)
The thermal load, Th, shall be introduced axisymmetrically around the tread of the wheel. The
load shall be applied evenly over the area 1 11/16 in. on either side of a line centered 3 7/16 in.
from the back face of the rim for wide-flange wheels and 1 11/16 in. on either side of a line centered
3 7/32 in. for narrow-flange wheels, as shown in Fig. 11.1. Simultaneously the convective load shall
be applied to each of the elements in the above area.
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6.0 LOAD COMBINATIONS

Possible load combinations are given for the separate consideration of plate and rim stresses. One
must limit the number of load combinations in order to keep the total calculation time within rea-
sonable limits. Experience will show what combinations lead to the most critical stresses.
6.1 Plate Stress Results
Calculate maximum effective surface stress under the following combinations:
Vertical Load V1 + Lateral Load L1,

Vertical Load V2,
Thermal Load Th,
V2 + Th, and
V1 + L1 + Th.
6.2 Rim Stress ResultsThermal Only
Calculate the maximum effective surface stresses at the tread, back and front rim faces (including
corners), and the flange. These shall be shown on the contour plot.
7.0 WHEEL CONFIGURATION
7.1 New Condition
7.1.1 The wheel configuration used in the analysis shall conform to the requirements listed in
M-107/M-208. The minimum rim thickness and the normal rim width given in the AAR specifica-
tions for new wheels shall be used. If necessary, it shall be obtained by translating the new wheel
tread and flange geometry radially inward to bring the taping line position to the minimum rim
thickness position. The original plate and rim fillet contours and locations shall be retained.
7.1.2 The calculation shall be made at the mean of the envelope dimensions required by
M-107/M-208, Appendix A, paragraph 2.1.1.
7.1.3 In the data summary, the source of the wheel profile (drawing or wheel measurement) shall
be stated. The plate thickness (N) shall be stated. The exact diameter at the taping line before and
after translation and the amount of translation of the tread-flange geometry (to bring the taping
line to the minimum specified rim thickness position) also shall be stated if it is necessary to
reduce the rim thickness for the purpose of the calculation.
7.2 Condemning Limit Rim Thickness
7.2.1 The wheel configuration (at the condemning limit) is quite sensitive to the development of
large thermal stresses. The assumed worn wheel configuration shall be obtained by translating
the new wheel tread-flange geometry radially inward to bring the tape line position to the rim
thickness designated as the thin rim condemning limit (AAR Field Manual of Interchange Rules,
Rule 41, Section A.1.h). The original plate and rim fillet contours and locations shall be retained.
7.2.2 Calculations shall be made for the Th and V2 + Th cases; all data required in paragraph 6.2
also shall be furnished. The exact diameter at the taping line before and after translation, and the
amount of translation of the tread-flange geometry (to bring the taping line to the thin rim con-
demning limit), also shall be stated.
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S-660
8.0 MATERIAL PROPERTIES AND BOUNDARY CONDITIONS

Material properties and boundary conditions are specified so that the results of various calcula-
tional techniques are comparable.
8.1 Data Required for Temperature Calculations
Initial Temperature: Assume 75 F
Density: Assume 0.283 lb/in.3
Specific Heat: Assume the linear function:CP= 0.102 + 0.000052 T (BTU/lbF)
Thermal Conductivity: Assume the linear function:K= 28.1 0.0060 T (BTU/hftF)
Convection Coefficient: Assume a constant: h = 4 BTU/hft2F
Emissivity: None required. The effect of radiated heat transport from the surface of the wheel is
to be neglected in these calculations.
8.2 Data Required for Stress Calculations
Modulus of Elasticity: Assume 29,000,000 psi
Poissons Ratio: Assume 0.30
Coefficient of Thermal Expansion:Assume the linear function:alpha = [6.0 + 0.002 (T-75) ] in./in.F
8.3 Boundary Conditions:
Fix all hub bore nodes in the radial and axial directions at a radius of 1 in.
9.0 ACCURACY OF CALCULATIONAL TECHNIQUE
Any candidate analytical procedure for stress calculations must be shown to provide accurate
results. The results must be both accurate and convergent. Accuracy can be defined with respect to
a standard set of calculated results. Convergence must be examined to ensure that the use of
smaller element sizes or more terms in the series representations will not appreciably change the
results of the calculations.
9.1 Qualification of Code
Qualification of an analytical procedure shall include a demonstration that the results of the finite
element analyses are convergent.
9.2 Comparison with Standard Solution
The code shall be used to calculate wheel stresses for a standard problem. A specific wheel config-
uration with a given set of loads shall be defined. Stress and temperature predictions must fall
within a specified tolerance.
10.0 REQUIRED DATA
In addition to the data required in paragraphs 6.0 and 7.0, all data necessary to permit a knowl-
edgeable individual to repeat the calculation must be reported. Reference to this procedure for the
loads and mechanical/physical properties is sufficient. The intent is to permit one program user to
check the results of another user.
11.0 RESPONSIBILITY
11.1 Once an analytical procedure has been qualified, it shall be the responsibility of the vendor
to inform the AAR if he deviates from the conditions under which he qualified. The vendor must
then demonstrate that the new code still qualifies.
11.2 In auditing the analyses done by vendors, the AAR may, at its discretion, require any vendor
to rerun the standard solution in its entirety or in part. Failure on the part of the vendor to comply
shall be grounds for disqualification.
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5 23/32" 1/8"
+ 1/32"
- 3/32"
V1 13/8"
GAUGING POINT 1
/8"
V2
1" L1
Th
3 3/8"
3 7/16"
Fig. 11.1 Locations of assumed loadings for wide-flange, steel, freight car wheels
(not to scale)
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S-661
GAUGE, WHEELMAXIMUM FLANGE THICKNESS, HEIGHT, AND THROAT

RADII GAUGE FOR AAR-1B NARROW-FLANGE STEEL WHEEL
Standard
S-661
Adopted: 1991
1.0 SCOPE
1.1 This standard became effective March 29, 1991.
1.2 This standard supersedes MSRP S-602.
Notes:
1. Unless noted, all other tolerances are 0.0250.
2. Hanging holes optional.
3. Minimum 0.120-in. steel with minimum 55 RC hardness.
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S-662
GAUGE, WHEELMINIMUM FLANGE THICKNESS, HEIGHT, AND THROAT

RADII GAUGE FOR AAR-1B NARROW-FLANGE STEEL WHEEL
Standard
S-662
Adopted: 1991
1.0 SCOPE
Notes:
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S-663
GAUGE, WHEELREFERENCE LIMIT GAUGE FOR VERIFYING AAR 1B

NARROW FLANGE WHEEL GAUGE S-661
Standard
S-663
Adopted: 1991
1.0 SCOPE
Notes:
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S-664

NARROW FLANGE WHEEL GAUGE S-662
Standard
S-664
Adopted: 1991
1.0 SCOPE
Notes:
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S-665
GAUGE, WHEELMAXIMUM FLANGE THICKNESS, HEIGHT, AND THROAT

RADII GAUGE FOR AAR-1B WIDE-FLANGE STEEL WHEELS
Standard
S-665
Adopted: 1991
1.0 SCOPE
Notes:
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S-666

WIDE FLANGE WHEEL GAUGE S-665
Standard
S-666
Adopted: 1991
1.0 SCOPE
Notes:
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S-667
GAUGE, WHEELMINIMUM FLANGE THICKNESS, HEIGHT, AND THROAT

RADII GAUGE FOR AAR-1B WIDE-FLANGE STEEL WHEELS
Standard
S-667
Adopted: 1991
1.0 SCOPE
Notes:
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S-668

WIDE FLANGE WHEEL GAUGE S-667
Standard
S-668
Adopted: 1991
1.0 SCOPE
Notes:
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S-669
ANALYTIC EVALUATION OF LOCOMOTIVE WHEEL DESIGNS
Standard
S-669
Adopted: 2011
1.0 OBJECTIVE
The objective of this procedure is to provide a method, using the AAR Manual of Standards and
Recommended Practices Standard S-660 as a basis, to evaluate the performance of a proposed loco-
motive wheel design under normal railroad operating service conditions. The objective will be
achieved by comparing the results obtained from the application of this procedure to a fatigue cri-
terion and prescribed vibration performance limits.
The first step is to ensure that the computations will be of sufficient accuracy and reproducibility
where and by whom they are made. This procedure permits the use of all computational techniques
that can be demonstrated to provide accurate results and that permit the analysis to be performed
under a standard set of assumptions (i.e., material property data and loading conditions).
This procedure shall be operative under MSRP Specification M-107/M-208, Appendix A,
paragraph 2.2.
This standard applies to new wheel designs that have not yet received approval for use in service
pursuant to the requirements of Standard S-660.
2.0 BACKGROUND
Computational finite element methods may be applied to obtain the results required by this stan-
dard. These results form the basis of the AAR evaluation of the wheel design. Because the evalua-
tion process consists of comparisons of results for wheels of different designs, the magnitude and
manner of design load application to the wheel as well as the accuracy requirements for the compu-
tational technique must be specified if consistent, comparable results are to be obtained.
3.0 ANALYST AND CODE QUALIFICATION
To ensure accuracy and consistency of the results of an analysis, analysts and software must be
qualified by the AAR. Qualification shall be obtained by performing a benchmark analysis of a pre-
scribed wheel design and heat-treatment schedule (identifying the initial temperature, quench du-
ration, quenched region, and annealing temperature and duration) that shall be obtained from the
committee coordinator of the Wheels, Axles, Bearings, and Lubrication (WABL) Committee. The
analysis shall be conducted using the procedures and material properties provided herein, and a
report of the results obtained shall be submitted to the committee coordinator.
4.0 RESULTS
Specific results reporting requirements are described below. Stress results must be reported in
pounds per square inch (psi) at each nodal location.
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5.0 SOLUTION QUALITY AND REQUIRED ANALYSES

5.1 Solution Quality and Analysis Overview
The analytical procedures applied to produce the results required by this standard must be accurate
and convergent. Accuracy can be determined by comparison with a standard set of calculated re-
sults. Convergence must be examined to ensure that the choice of finite element size and density or
the number of terms in the series representations (if employed) do not appreciably affect the results
of the calculations. For the purpose of compliance with the requirements of this standard, conver-
gence is achieved when the maximum von Mises effective stress predicted by the analytical proce-
dure employed is less than 500 lb/in.2 (psi) for successive complete mesh refinements.
Five analyses are required to evaluate the conditions described in this standard as described in
paragraphs 5.2 to 5.6 and paragraphs 7.0 and 8.0.
The first analysis is performed according to the current requirements in Standard S-660 (with ad-
ditions) as described in paragraph 5.2 and consists of an elastic analysis of the wheel in the new
and worn (to the condemning limit) conditions. This analysis may be performed using a two- or
three-dimensional finite element model.
The second analysis consists of an elastic-plastic simulation of the wheel heat treating process as
described in paragraph 5.3 and may be performed using a two- or three-dimensional finite element
model. This analysis also considers the wheel in the new and worn (to the condemning limit) condi-
tions. Mechanical properties for this analysis are specified in paragraph 10.0. Because the purpose
of this analysis is for comparison of wheel designs only, analysts who wish to extend this analysis
to consider conditions not specified here may wish to apply different properties for such analyses.
The third analysis involves calculation of the elastic stresses resulting from the wheel-to-axle inter-
ference fit as described in paragraph 5.4 and may be performed using a two- or three-dimensional
finite element model. This analysis also considers the wheel in the new and worn (to the condemn-
ing limit) conditions.
The fourth analysis identifies fatigue-prone locations in the proposed wheel design through appli-
cation of the Sines criterion as described in paragraph 5.5. This is accomplished by combining se-
lected results from the three analyses described above according to the procedure outlined in
paragraph 7.0.
The fifth analysis requires determination of certain vibration characteristics of the proposed wheel
design as described in paragraph 5.6 A three-dimensional model of the wheel is necessary to per-
form this elastic analysis (for the full-thickness rim condition only) according to the procedures out-
lined in paragraph 8.0.
To simplify the task of manipulating and interpreting the results, the cross-sectional finite element
mesh (in the radial-axial plane) of all models used to satisfy the requirements of this standard for
a particular wheel design must be identical.
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5.2 S-660 Analysis

An analysis pursuant to the requirements in Standard S-660 (most recent version) shall be com-
pleted. Compliance with this standard expands the requirements of Standard S-660 paragraph 7.2
to include the V1+L1 and V2 load cases for the worn rim condition.
Two types of finite element models may be used to perform the Standard S-660 analysis. The first
model type consists of a mesh of structural or thermal elements as required. The structural element
will have three displacement degrees of freedom at each node, and the thermal element will have a
single degree of freedom (temperature) at each node.
The second model type that may be utilized to perform the Standard S-660 analysis comprises a
mesh composed of harmonic structural or thermal elements. The structural element will have three
displacement degrees of freedom at each node, and the thermal element will have a single degree
of freedom (temperature) at each node. The difference is, with this type of element, the structural
and thermal loads are characterized by Fourier series approximations. Compared with the first
model type, run times are faster and file sizes are smaller using harmonic elements. If this tech-
nique is employed, a sufficient number of terms must be considered in the Fourier series represen-
tation of the loading to obtain an accurate solution.
5.3 Heat-Treatment Analysis
The state of residual stress in the wheel following wheel rim heat treatment (quenching, tempering,
and cool down) shall be determined. The heat-treatment analysis shall be performed independently
of all other analyses required by this standard. The complete thermal and stress transient history,
beginning at the start of the quench process (assuming a uniform temperature) and ending when
the wheel reaches ambient thermal conditions, shall be calculated. Viscoelastic creep effects shall
be accounted for in the heat-treatment analysis. Because the fatigue analysis methodology requires
combining results from different analyses at particular nodal locations, the same model used to per-
form the Standard S-660 analysis must be used for the heat-treatment analysis. Results of the
heat-treatment analysis shall be presented as four contour plots depicting the axial, radial, circum-
ferential (hoop), and in-plane shear stress components individually for the new and worn rim con-
ditions.
5.4 Interference Fit Analysis
An interference fit of 0.010 in. (referenced to the diameter) between the wheel bore and axle shall
be applied. The interference fit analysis shall be performed independently of all other analyses re-
quired by this standard. Because the fatigue analysis methodology requires combining results from
different analyses at particular nodal locations, the same model and material properties used to
perform the Standard S-660 analysis must be used for the interference fit analysis. Results of the
interference fit analysis shall be presented as four contour plots depicting the axial, radial, circum-
ferential (hoop), and in-plane shear stress components individually for the new and worn rim con-
ditions.
5.5 Fatigue Analysis
The fatigue analysis specified in this standard shall be performed by applying the Sines criterion
to the results obtained from the preceding analyses. In the Sines criterion context, the live (alter-
nating and mean) stresses are those that occur as a result of the applied loading, and the as-man-
ufactured residual stresses and the stresses due to interference fit represent the static stresses. The
analytically-determined stresses are combined with certain material constants to evaluate the
Sines criterion at each node in the model. The outcome of this evaluation determines whether the
proposed wheel design is likely to experience fatigue failure before its desired lifetime.
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5.6 Vibration Analysis

The objective of this analysis is to evaluate the dynamic performance of the proposed wheel by sim-
ulating the dynamic reaction between the wheel and the track.
A 360 model of the wheel, as shown in Fig. 5.1, shall be created using solid (brick) elements with
a minimum of eight nodes. The use of higher-order solid elements is permitted. If a two-dimensional
(axisymmetric) model is used to perform the analyses described in paragraphs 5.2, 5.3, and 5.4, that
model shall be revolved as described below to generate the three-dimensional model. The portion of
the S-660 compliant model that represents the hollow axle shall be retained. The elastic material
properties prescribed in Standard S-660 (most recent version) shall be used in the vibration analy-
sis. Interference pressure between the hollow axle and wheel hub shall be ignored in this analysis.
90
180 0
270
Fig. 5.1 3-D rendering of locomotive wheel identifying angular reference positions (view is of front face of wheel)
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The elements generated in the hoop direction shall have a maximum angular length of 10 or less.
The model shall have a plane of nodes at 45. The angular length of the elements on either side of
the 45 plane shall extend in the hoop direction by no more than 5. These requirements are illus-
trated in Fig. 5.2. The 0 plane is the plane on which the specified loads are applied. The 45 plane
is the plane at which the stress results are reported.
Note: Shaded sectors represent minimum 10 arc length segments.

Black and white segments represent minimum 5 arc length segments on
opposite sides of 45 plane. Red arrow indicates direction of tractive load
applied to tread surface.
Fig. 5.2 Illustration of 3-D model created by revolution of 2-D axisymmetric model (view is of front face of wheel)
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6.0 LOADING CONDITIONS

6.1 Standard S-660 Stress Results
Obtain the orthogonal (normal) stresses for the following loading combinations from the Standard
S-660 analysis (using the material properties defined therein) for all nodes in each model (new and
worn rim conditions):
Vertical Load V1 + Lateral Load L1
Vertical Load V2.
Orthogonal (normal) stresses at each node in the region identified in Fig. 6.1 for each model shall
be retained.
Fig. 6.1 Portion of model (red regions) in which stresses due to applied loads (L1 + V1 and V2) must be retained for
fatigue analysis of the new and worn rim conditions
6.2 Heat-Treatment Residual Stresses
The heat-treatment schedule shall be provided by the AAR WABL Committee for the benchmark
analysis to be performed for analyst qualification. The schedule identifies initial temperature,
quench duration and extent, annealing temperature and duration, and any dwell time that may ex-
ist between any steps in the heat-treatment process. Convective and radiative heat transfer shall
be accounted for on all exterior surfaces of the wheel as described in paragraph 10.0. All other sub-
missions to the WABL Committee according to this standard must utilize the heat-treatment sched-
ule proposed for the actual wheel design for which approval is sought.
6.2.1 New Rim Geometry
The purpose of this analysis is to establish the state of residual stress for the new rim geometry due
to the heat-treatment process including cool-down to room temperature. In a decoupled analysis,
the temperature history at each node shall be calculated first using thermal elements. Time begins
(t = 0) when the wheel exits the austenizing furnace at a uniform elevated temperature. The mate-
rial is considered to be strain-free at this point in time. The analysis ends (t = tn) when the wheel
reaches ambient temperature at the end of the cool-down period. This condition is satisfied when
the temperature at all nodes is within the range of ambient temperature plus 5 F.
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In the second part of the decoupled analysis, the time-dependent nodal temperatures are applied to
the structural elements to obtain the residual stresses.
The relevant temperature-dependent material property data in paragraph 10.0 shall be used. At
the conclusion of the heat-treatment simulation, orthogonal (normal) stresses at each node in the
model in the region identified in Fig. 6.1 shall be retained.
6.2.2 Worn Rim Geometry
To determine the residual stress distribution in the worn wheel, elements are removed from the
model described above to arrive at the worn rim geometry. Element removal alters the residual
stress distribution. This technique involves modifying the stiffness matrix.
The relevant temperature-dependent material property data in paragraph 10.0 shall be used. After
removal of the rim material, orthogonal (normal) stresses at each node in the model in the region
identified in Fig. 6.1 shall be retained.
6.3 Interference Fit Analysis
The interference fit shall be accomplished by inserting a hollow axle stub into the wheel bore. A
nominal interference of 0.010 in. referenced to the diameter is assumed. For convenience, the hol-
low axle geometry shown in Fig. 5.2 (in which the axle bore diameter is 2 in.) may be used. The in-
terference fit stresses shall be determined for the new and worn rim conditions. The element
removal technique described above may be used to obtain the interference fit stresses for the worn
rim geometry.
Material properties for the wheel and axle shall be as defined in Standard S-660 (current version).
Orthogonal (normal) stresses at each node in each model in the region identified in Fig. 6.1 shall be
retained.
6.4 Required Stress Results
The analyses performed according to paragraphs 6.1, 6.2, and 6.3 yield eight sets of stress results,
or eight load cases, as shown in Table 6.1.
Table 6.1 Summary of load cases
Load Case Required Result at Each Node Condition
1 Orthogonal normal stresses under load V1+L1, new (full) rim
(SxL, SyL, SzL, TxyL, TyzL, TxzL)
2 Orthogonal normal stresses under load V2, new (full) rim
3 Orthogonal normal stresses under load V1+L1, worn rim
4 Orthogonal normal stresses under load V2, worn rim
5 Orthogonal normal stresses Heat-treatment residual stresses, new (full) rim
(SxR, SyR, SzR)
6 Orthogonal normal stresses Heat-treatment residual stresses, worn rim
(SxR, SyR, SzR)
7 Orthogonal normal stresses Interference-fit stresses, new (full) rim
(SxP, SyP, SzP)
8 Orthogonal normal stresses Interference-fit stresses, worn rim
(SxP, SyP, SzP)
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7.0 FATIGUE ANALYSIS ACCORDING TO SINES CRITERION

Combinations of static or residual stress with superimposed alternating stress were examined by
Sines [1, 2, 3, 4] and it was found that the permissible alternation of stress is a reasonably linear
function of the orthogonal normal static stresses expressed as follows:
J 2 A ( J 1M + J 1R + J 1P ) Equation (1)
in which J'2 represents the octahedral shear stress and is defined as follows:
1---
1 2 2 2 2
J 2 = --- [ ( S x S y ) + ( S y S z ) + ( S z S x ) + 6 ( T xy
2 + T2 + T2 )]
yz xz Equation (2)
3
which, for the purposes of this standard, is characterized by the amplitudes of the stresses due to
the applied load as derived from the stress states on the load application plane (at 0) and on a ra-
dial plane located 180 from the load application plane. The amplitude of each nodal stress compo-
nent (Si, Tij) in Equation (2) is defined as follows:
1 1
S i = --- [ ( S iL ) 0 ( S iL ) 180 ] and T ij = --- [ ( T ijL 0 ) ( T ijL 180 ) ] Equation (3)
2 2
in which the subscripts 0 and 180 denote the value of each stress component on the respective
model planes (the regions identified in Fig. 6.1), and the superscript L denotes the stresses due to
the applied loads. These stresses are obtained from the analysis performed according to
paragraph 6.1.
J1M is the mean of the sum of the orthogonal (normal) components of the alternating stresses (SiL)
at each node as determined by the analysis performed according to paragraph 6.1 and is defined as
follows:
1
J 1M = --- [ ( S xL + S yL + S zL ) 0 + ( S xL + S yL + S zL ) 180 ] Equation (4)
2
in which (SxL + SyL + SzL)0 are the orthogonal (normal) stress components at the nodes on the ra-
dial plane upon which the load is acting (at 0), and (SxL + SyL + SzL)180 are the orthogonal (nor-
mal) stress components at the nodes on a radial plane 180 away (the regions identified in Fig. 6.1),
and
J1R is the sum of the orthogonal (normal) components of the residual (static) stresses (SiR) at each
node as determined by the analysis performed according to paragraph 6.2 and is defined as follows:
J R 1 = S xR + S xR + S xR Equation (5)
and
J1P is the sum of the orthogonal (normal) components of the interference fit (static) stress (SiP) at
each node as determined by the analysis performed according to paragraph 6.3 and is defined as
follows:
J 1P = S xP + S yP + S zP Equation (6)
The values of the constants (A = 28 ksi and = 0.16) have been experimentally determined [5, 6].
G [S-669] 132 03/2011

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S-669
Equation (1) shall be evaluated at each node in each model in the region identified in Fig. 7.1 for
the four combinations of load cases shown in Table 7.1. If, under any load combination, Equation (1)
evaluates to false (the alternating stresses are greater than the static stresses) at any node in the
model(s), then fatigue is predicted, rendering the design unacceptable.
Note: Area comprises portion of

wheel cross-section between red
lines that connect inboard and
outboard hub outer diameters and
inboard and outboard rim inner
diameters.
Fig. 7.1 Region in which Sines criterion is applied
Table 7.1 Load combinations to which Equation (1) shall be applied

Load Combination J2 J1M J1R J1P
A Load Case 1 Load Case 1 Load Case 5 Load Case 7
B Load Case 2 Load Case 2 Load Case 5 Load Case 7
C Load Case 3 Load Case 3 Load Case 6 Load Case 8
D Load Case 4 Load Case 4 Load Case 6 Load Case 8
03/2011 G [S-669] 133

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7.1 Results
The results obtained by application of the Sines criterion for the four load combinations described
in paragraph 7.0 shall be presented as four contour plots in the plane of the wheel cross-section on
which the mechanical loads act in a format similar to that shown in Fig. 7.2.
Fig. 7.2 Sample contour plot of Sines parameter on portion of

wheel cross-section identified in Fig. 7.1 (legend omitted)
For each of these plots, the value to be contoured at each node location is the Sines parameter, SP,
which is the difference between the left-hand and right-hand sides of Equation (1), or
SP = J 2 [ A ( J 1M + J 1R + J 1P ) ] Equation (7)
Negative contour data (SP less than 0) indicate locations at which the Sines criterion is satisfied.
Positive contour data (SP greater than 0) represent fatigue-prone locations at which the Sines cri-
terion is violated. Fatigue-prone locations are unacceptable, and if identified through application of
this procedure, the proposed wheel design must be revised and the analysis procedure repeated un-
til no Sines criterion violations remain (SP < 0 everywhere in the specified plate region).
The minimum safety factor and the location in the wheel plate at which it occurs shall be reported
for each load combination. The safety factor represents the fatigue margin for the proposed wheel
design and is determined in the following way.
The analysis described in paragraph 7.0 yields a value for the Sines parameter (SP) at each node
for each of the specified nominal loading conditions. The stresses due to the mechanical loads are
recomputed assuming the nominal load (L1, V1, V2) is increased by a load factor n. Because the
model is linearly elastic, the stresses due to the mechanical loads (load cases 1 through 8 in
Table 6.1) increase proportionally.
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The Sines parameter SP is recomputed for each node for each load combination described in
Table 7.1. Each node is now characterized by two values for SP: one due to the nominal load (load
factor = 1) and one resulting from the increased load (load factor = n). The safety factor at each node
is the multiplier (load factor) on the mechanical load necessary to cause the left-hand and
right-hand sides of the Sines criterion to be equal at this location (SP = 0). This concept is graphi-
cally depicted in Fig. 7.3:
Fig. 7.3 Schematic illustrating method for determining safety factor
Table 7.2 Reporting format for fatigue analysis results
Load Loading Maximum

Rim Condition Safety Factor
Combination Description SP
A V1 + L1 NEW <value> <value>
B V2 <value> <value>
C V1 + L1 WORN <value> <value>
D V2 <value> <value>
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S-669
8.0 VIBRATION ANALYSIS

8.1 Modal Analysis
A modal analysis shall be conducted to determine the vibration characteristics (natural frequencies
and mode shapes) in the frequency range of 0 Hz to 500 Hz. The saddle mode of vibration (as shown
in Fig. 8.1) is the subject of this analysis. The natural frequency associated with this mode shall be
used in a harmonic response analysis to determine the stress field in the wheel. Damping is ignored.
0 - 180
reference plane
Fig. 8.1 Wheel in saddle-mode of vibration with reference plane for applied load
8.1.1 Finite Element Model
The three-dimensional model described in paragraph 5.6 shall be used.
8.1.2 Material Properties
Relevant material properties as defined in Standard S-660 (current version) shall be used. Thermal
effects are not considered in this analysis. The modal and harmonic response analyses are per-
formed assuming elastic material behavior.
8.1.3 Boundary Conditions
The outer surface of the hollow axle stub shall be fixed to the inner surface of the wheel hub. Axle
bore nodal degrees of freedom are fixed. Interference pressure between the hollow axle and wheel
hub is ignored in this analysis.
8.1.4 Modal Analysis Results
The lowest frequency at which the wheel vibrates in the saddle-mode shape as shown in Fig. 8.1
shall be reported to a minimum of three decimal places.
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8.2 Harmonic Response Analysis

A harmonic response analysis shall be conducted for the saddle mode of vibration to predict the sus-
tained dynamic behavior and the steady-state response of the wheel to a tractive load that varies
sinusoidally with time. The forcing frequency of the applied load is 0.002% greater than the sad-
dle-mode natural frequency obtained in paragraph 8.1.4 (i.e., f = fn[1+0.00002] to a minimum of
three decimal places). The same model used for the modal analysis shall be used for the harmonic
response analysis.
Three load cases shall be considered. Tractive loads shall be applied in the rail running direction
on the wheel tread surface in the 0 plane identified in Fig. 5.2 at the locations shown in Table 8.1.
A force magnitude of 300 lb is sufficient to provide adequate excitation. Damping is ignored.
Table 8.1 Load locations for harmonic analysis
Load Case Load Location on Wheel Tread
H1 1 in. from front rim face
H2 3 1/16 in. from the back rim face for wide flange wheels
2 27/32 in. from the back rim face for narrow flange wheels
H3 1 1/2 in. from the back rim face for wide flange wheels
1 9/32 in. from the back rim face for narrow flange wheels
8.3 Harmonic Response Analysis Results

For each load case identified in Table 8.1, provide the following graphical results:
A three-dimensional view of the model depicting the wheel in the saddle mode of vibration
as shown in Fig. 8.1
Two-dimensional contour plots of circumferential (hoop), axial, and radial stresses in the
cross-sectional plane located 45 from the 0 plane at which the excitation is applied (as
identified in Fig. 5.2) when the amplitude of the forced vibration is maximum
For each load case identified in Table 8.1, report the following data as shown in Table 8.2:
The maximum residual circumferential (hoop) tensile stress in the wheel rim resulting
from the heat-treatment analysis as identified in Fig. 8.2 (paragraph 6.2)
The circumferential (hoop) stress range due to the forced vibration at the location of maxi-
mum residual circumferential (hoop) tensile stress in the wheel rim (in the cross-sectional
plane located 45 from the 0 plane at which the excitation is applied as identified in
Fig. 5.2) resulting from the heat-treatment analysis (paragraph 6.2)
The maximum circumferential (hoop) tensile stress in the wheel rim (in the cross-sectional
plane located 45 from the 0 plane at which the excitation is applied as identified in
Fig. 5.2) that occurs during the forced vibration analysis (paragraph 8.3)
03/2011 G [S-669] 137

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S-669
Fig. 8.2 Arrow indicates typical location of maximum residual circumferential (hoop) tensile stress in wheel rim fol-
lowing simulated heat treatment. This is referred to as cross-sectional Location X in Table 8.2 (legend omitted)
Table 8.2 Reporting format for stresses due to heat treatment and forced vibration (ksi)
Maximum Rim
Circumferential (Hoop) Circumferential (Hoop) Maximum Rim
Tensile Stress Following Stress Due to Circumferential (Hoop)
Load Case
Simulated Heat Treatment Forced Vibration Tensile Stress Due to
at Location X at Location X Forced Vibration
(see Fig. 8.2)
H1 <value> <value> <value>
H2 <value> <value>
H3 <value> <value>
9.0 RESPONSIBILITY
9.1 Deviations
Once an analytical procedure has been qualified, it shall be the responsibility of the vendor to in-
form the AAR if he deviated from the conditions for which he is qualified. The vendor must demon-
strate that the new code still qualifies.
9.2 Auditing
In auditing the analysis done by vendors, the AAR may, at its discretion, require any vendor to re-
run the standard solution in its entirety or in part. Failure on the part of the vendor to comply shall
be grounds for disqualification.
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S-669
10.0 MATERIAL PROPERTIES

Material properties are specified so that the results of various computational techniques may be
compared.
10.1 Material Properties (Constants) for Heat-Treatment Simulation
Initial temperature (after residual stress calculation): 75 F
Ambient temperature for cool-down portion of residual stress analysis: 75 F
Mass density: 0.283 lbm/in.3
Convection coefficient (wheel to air):
H = 9.6450 10-6 BTU/sec-in.2-F (assume constant) or
H = 5.0 BTU/hr-ft2-F (assume constant)
Convection coefficient (wheel to water) [7]:
H = 1.0417 10-3 BTU/ sec-in.2-F (assume constant) or
H = 540.0 BTU/hr-ft2-F (assume constant)
Stefan-Boltzmann constant: 3.30632716e-15 BTU/sec-in.2-R4
Emissivity: 0.80
View factor: 1.0
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10.2 Material Properties (Temperature-Dependent) for Heat-Treatment Simulation

Table 10.1 Specific heat [8] Table 10.2 Thermal conductivity [7]
Temp (F) (BTU/lbm-F) Temp (F) (BTU/sec-in-F)
0 0.1059 0 0.000672
75 0.1106 75 0.000664
1292 0.1866 392 0.000629
1337 0.4079 1292 0.000403
1382 0.1487 1472 0.000329
1652 0.1309 1800 0.000361
1800 0.1309
10.3 Material Properties (Temperature-Dependent) for Stress Calculations

Table 10.3 Modulus of elasticity (E) and hardening Table 10.4 Poisson's ratio [ 9, 11, 13]
modulus (Etan) Temp (F)
Etan 0 0.2820
E
Temp (F) [9, 10, 11, 12]a/
(kips/in.2) 75 0.2836
(kips/in.2)
514 0.2927
0 29368 2016
752 0.2980
75 29000 2192
932 0.3020
100 28955 2250
1292 0.3200
200 28543 2484
1472 0.3400
300 28130 2719
1800 0.3461
400 27718 2953
500 27306 3187
600 26859 3028 Table 10.5 Coefficient of thermal expansion [8]
700 26407 2804 Thermal
800 25741 2514 Expansion
Temp (F)
900 24784 2151 Coefficient
per F
1000 23553 1790
0 6.22E-06
1100 20542 1431
75 6.22E-06
1200 17531 1071
212 6.22E-06
1300 14424 726
400 8.58E-06
1400 11698 557
1292 8.58E-06
1500 9952 424
1472 9.61E-06
1600 9114 384
1800 9.61E-06
1700 8577 343
1800 7390 303
a/ Temperature-dependent values
for hardening modulus have been
interpolated such that they are
presented for the same tempera-
tures as the modulus of elasticity.
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S-669
Table 10.6 Yield strength Table 10.7 Creep strain rate [7]
53712-
y -----------------
Temp (F) 08 T + 460
(kips/in.2) & = 4.6410 ( eff
12.5 )e
0 80.00 in which
75 80.00 & = the creep strain rate (1/F)
100 79.94
eff = von Mises effective stress (ksi)
200 79.69
T = temperature (F)
300 79.44
400 79.20
500 78.95
600 77.71
700 76.32
800 67.77
900 54.91
1000 41.95
1100 32.77
1200 23.59
1300 14.63
1400 10.50
1500 8.94
1600 7.79
1700 6.63
1800 5.48
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11.0 REFERENCES
1. Sines, G. 1955. Failure of Materials Under Combined Repeated Stresses with Superimposed
Static Stresses. NACA Technical Note 3495.
2. Sines, G. 1969. Elasticity and Strength. Needham Heights:Allyn and Bacon.
3. Sines, G., and J.L. Waisman, eds. 1959. Metal Fatigue. London:McGraw-Hill.
4. Stephens, R.I., A. Fatemi, R.R. Stephens, and H.O. Fuchs. 1980. Metal Fatigue in Engineering,
Hoboken:Wiley and Sons.
5. McKeigan, P.C., F.J. McMaster, and J.E. Gordon. 2002. Fatigue Performance of AAR Grade B
Wheel Steel at Ambient and Elevated Temperatures. ASME Paper IMECE2002-33240.
6. McMaster, F. J., G.P. Robledo. and J.E. Gordon. 2005. Fatigue Performance of AAR Grade A
Wheel Steel at Ambient and Elevated Temperatures. ASME Paper IMECE2005-82519.
7. Kuhlman, C., H. Sehitoglu, and M. Gallagher. 1988. The Significance of Material Properties on
Stresses Developed During Quenching of Railroad Wheels. Proceedings of the 1988 Joint ASME
IEEE Railroad Conference.
8. Metals Handbook. 1948. Vol. 1, 9th edition. Cleveland:American Society for Metals.
9. Slavik, D., and H. Sehitoglu. 1986. Constitutive Models Suitable for Thermal Loading. ASME
J. Eng. Mats. Techn. 108:108-312.
10. Lunden, R. 1991. Contact Region Fatigue of Railway Wheels Under Combined Mechanical Roll-
ing Pressure and Thermal Brake Loading. Wear. 144:57-70.
11. Orringer, O., D.E. Gray, and R.J. McCown. 1993. Evaluation of Immediate Actions Taken with
Cracking Problems Observed in Wheels of Rail Commuter Cars. DOT-VNTSC-FRA. 93:3.
12. Berg, N. A., and R. Alber. 1972. Tread Braking Versus the Wheel. Proceedings of the 64th An-
nual Convention of the Air Brake Association.
13. Metals Handbook. 1948. Vol. 1, 10th edition. Cleveland:American Society for Metals.
G [S-669] 142 03/2011

RP-608
GAUGE, WHEELREFERENCE MASTER DISK FOR VERIFYING WHEEL

CIRCUMFERENCE GAUGES S-612 AND S-613
Recommended Practice
RP-608
49"
29"
1"
/4"
1
11/4"
11/4" 13/8"
3"
21/4"
/4" R.
/4"
1
11/4"
1
/2" R.
1
21/2"
38.002" 35"
37.998" 1
+ /64"
(6-55'-23" APART.)
383/32" -0"
SECTION A-A
1"R.
3"
MAKE MARKS AT 38", 36", 33" AND 30" DIAMETER

A
31/2"
3 6
5 0
/12"
31/2" 31/2"
31/2" 31/2"
MAKE MARKS AS SHOWN 52" DOWN TO 35"
1"R
.
60
/64"
52 3/32 0
1
52.002"
51.998"
51
A
38
L
C
MARK:
52
50
L
C
MASTER DISK FOR CHECKING WHEEL CIRCUMFERENCE

MEASURE OF 35" TO 52" DIAMETER WHEELS.
3
/16" STAMPS
.010"
.012"
MARK:
ENLARGED VIEW MASTER DISK FOR CHECKING WHEEL CIRCUMFERENCE
OF MARK MEASURE OF 27" TO 38" DIAMETER WHEELS.
MATERIAL: ASTM A-47 Grades 32510 or 35018
03/2011 G [RP-608] 143

Wheels and Axles
RP-608
G [RP-608] 144 03/2011

RP-609
INSPECTION STAND FOR USE WITH MASTER DISKS
RP-609
MATERIAL: COLD ROLLED STEEL, CAST IRON
03/2011 G [RP-609] 145

Wheels and Axles
RP-609
G [RP-609] 146 03/2011

RP-612
MOUNTING PRESSURES FOR WROUGHT AND CAST STEEL WHEELS ON

GEAR-DRIVEN AND IDLER AXLES OF LOCOMOTIVES OTHER THAN
STEAM
RP-612
Diameter of Wheel Seat Minimum Desired Mounting Pressure Maximum

(in.) (ton)
6.000 to 6.346, inclusive 75 80 95
6.347 to 6.730, inclusive 75 85 100
6.731 to 7.115, inclusive 75 90 110
7.116 to 7.499, inclusive 75 95 115
7.500 to 7.884, inclusive 80 100 120
7.885 to 8.269, inclusive 85 105 125
8.270 to 8.653, inclusive 90 110 130
8.654 to 9.038, inclusive 90 115 140
9.039 to 9.423, inclusive 95 120 145
9.424 to 9.807, inclusive 100 125 150
9.808 to 10.192, inclusive 105 130 155
10.193 to 10.576, inclusive 110 135 160
10.577 to 10.961, inclusive 110 140 170
10.962 to 11.346, inclusive 115 145 175
11.347 to 11.730, inclusive 120 150 180
11.731 to 12.115, inclusive 125 155 185
12.116 to 12.499, inclusive 130 160 190
12.500 to 12.884, inclusive 130 165 200
12.885 to 13.269, inclusive 135 170 205
13.270 to 13.653, inclusive 140 175 210
13.654 to 14.000, inclusive 145 180 215
Desired mounting pressures are based on 13 ton/in. of diameter, expressed in the nearest 5 ton with
an allowable variation of 20% over and under, except the first three minimum pressures, which are
shown as 75 ton, being considered better practice for these sizes.
03/2011 G [RP-612] 147

Wheels and Axles
RP-612
G [RP-612] 148 03/2011

RP-613
GAUGE, AXLEMASTER GAUGE FOR VERIFYING AXLE JOURNAL AND

FILLET GAUGE S-614
RP-613

1.0 SCOPE
This master gauge applies to Gauge No. 34401, described in the AAR Manual of Standards and
Recommended Practices, S-614.
03/2011 G [RP-613] 149

Wheels and Axles
RP-613
G [RP-613] 150 03/2011

RP-614
GAUGE, WHEELMASTER GAUGE FOR VERIFYING

WHEEL GAUGES S-617 AND S-618
RP-614

1.0 SCOPE
This master gauge applies to the steel wheel gauges described in the AAR Manual of Standards
and Recommended Practices, Standards S-617 and S-618.
MARK: MASTER FOR WHEEL GAUGE (3/32-in. STAMPS)

FINISH: CHROMIUM PLATE
03/2011 G [RP-614] 151

Wheels and Axles
RP-614
G [RP-614] 152 03/2011

RP-615
GAUGE, WHEELSIMPLIFIED
RP-615

1.0 SCOPE
1.1 This gauge can be used for checking high-flange, thin-rim, and grooved tread for all freight
car wheels.
1.2 This recommended practice became effective October 1, 1976.
DETAIL A
(FOR GROOVED TREAD MEASUREMENT)
MATERIAL: .093-in. STAINLESS STEEL. UNLESS OTHERWISE STATED. ALL TOLERANCES ARE .010 in. REMOVE BURRS AND SHARP EDGES.
03/2011 G [RP-615] 153

Wheels and Axles
RP-615
G [RP-615] 154 03/2011

RP-619
REFERENCE GROOVE FOR MULTIPLE-WEAR DIESEL WHEELS
RP-619
DESIGN D (in.)a/
CH 33 29
H 33 29
CA 34 30
NOTE:
THIS REFERENCE GROOVE IS OPTIONAL AND IS MACHINED AT A 34 30
THE REQUEST OF THE CUSTOMER UNLESS SPECIFIED AS
REQUIRED. CF 36 32
F 36 32
CA 38 34
A 38 34
CE 40 36
E 40 36
CA 42 38
A 42 38
CC 42 38
C 42 38
a/ TOLERANCE = 1/32 IN.
03/2011 G [RP-619] 155

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RP-619
G [RP-619] 156 03/2011

RP-622
AXLE, WEIGHTMACHINED FINISH, RAISED WHEEL SEAT
RP-622
Nominal Weight (lb)

Classification Size of Journal Rough-Turned Journal and
of Axles (in.) Wheel Seats
Freight Car Passenger Car
D 5 1/2 10 810 840
E 6 11 975 1005
F 6 1/2 12 1175 1220
Roller
G 7 12 1415
Bearing
K 6 1/2 9 1168
L 68 900
M 79 1325
03/2011 G [RP-622] 157

Wheels and Axles
RP-622
G [RP-622] 158 03/2011

RP-629
GAUGE, WHEELFOR MEASURING CONDEMNABLE OVERHEATED

WHEELS
RP-629

Note: See RP-630 for application.
MATERIAL: 16 GAUGE BLACK STEEL
03/2011 G [RP-629] 159

Wheels and Axles
RP-629
G [RP-629] 160 03/2011

RP-630
GAUGE, WHEELAPPLICATION FOR MEASURING CONDEMNABLE

OVERHEATED WHEELS
RP-630

Note: See RP-629 for gauge drawing.
4"
03/2011 G [RP-630] 161

Wheels and Axles
RP-630
G [RP-630] 162 03/2011

RP-636
GAUGE, WHEELAPPLICATION DRAWING FOR AAR 1B WHEEL GAUGES

S-662 AND S-667
RP-636
Adopted: 1991
1.0 SCOPE
This recommended practice can be used when checking with the following gauges: S-667 (wide
flange) and S-662 (narrow flange).
CONTACT
REQUIRED
FLANGE HEIGHT THROAT RADII
CONTACT
REQUIRED
FLANGE THICKNESS
03/2011 G [RP-636] 163

Wheels and Axles
RP-636
G [RP-636] 164 03/2011

RP-637
GAUGE, WHEELAPPLICATION DRAWING FOR AAR 1B WHEEL GAUGES

S-661 AND S-665
RP-637
Adopted: 1991
1.0 SCOPE
This recommended practice can be used when checking with the following gauges: S-665 (wide
flange) and S-661 (narrow flange).
CONTACT
REQUIRED
FLANGE HEIGHT THROAT RADII
CONTACT
REQUIRED
FLANGE THICKNESS
03/2011 G [RP-637] 165

Wheels and Axles
RP-637
G [RP-637] 166 03/2011

RP-638
GAUGE, WHEELAPPLICATION DRAWING FOR REFERENCE GAUGE TO

VERIFY WHEEL GAUGES S-661, S-662, S-663, S-664, S-665, S-666, S-667, AND
S-668
RP-638
Adopted: 1991
1.0 SCOPE
This recommended practice can be used when checking with the following gauges:
Maximum Flange Thickness, Height and Throat Radii Gauges: S-665 and S-661
Maximum Limit Wear Gauges: S-663 and S-666
Minimum Flange Thickness, Height and Throat Radii Gauges: S-667 and S-662
Minimum Limit Wear Gauges: S-664 and S-668
CONTACT
REQUIRED
CONTACT
REQUIRED
FLANGE HEIGHT FLANGE THICKNESS
03/2011 G [RP-638] 167

RP-638
G [RP-638] 168 03/2011

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03/2011

Association of American Railroads

WHEELS AND AXLES

Effective March 2011

The Association of American Railroads

Copyright 2011 by the Association of American Railroads (AAR)

ORDERS FOR Publications Department

THIS PAGE LEFT BLANK INTENTIONALLY

Subject Standard Page

Subject Standard Page

Standard Subject Page

Standard Subject Page

REQUIREMENTS FOR WHEELS AND AXLES MANUFACTURED TO AAR

THIS PAGE LEFT BLANK INTENTIONALLY

AXLES, CARBON STEEL, HEAT-TREATED

Adopted: 1914; Last Revised: 20

7.0 CHEMICAL COMPOSITION

8.0 LADLE ANALYSIS

10.0 TENSION TESTS

12.0 PROLONGATION FOR TEST

16.0 ULTRASONIC TESTING (NEW AXLES ONLYRADIAL AND AXIAL)

16.3.1 Axial Transducers

16.3.2 Radial Transducers

17.0 DIMENSIONS AND TOLERANCES

7.2 All Other Axles

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

STAMP HERE NOTE 4 NOTE 6 NOTE 5

11-66 66 A001 F R NOTE 7

ROLLER BRG. L 00000 USS-H

NOTES: GENERAL NOTES:

Manufacturers Name or Brand

Fig. C.2 AAR standard marking requirements

NOTE: V DIMENSION DESIGNATES MINIMUM LENGTH OF FULL THREAD. DEPTH OF DRILLED

Freight Car Axles

AXLE SIZES G 7" 12"

WHEELS, CARBON STEEL

Adopted: 1962; Last Revised: 2011

7.2.6 Portable Peeners

8.0 LADLE ANALYSIS

8.3.2 Test Method II

9.3 Sample Preparation and Evaluation

11.0 NUMBER OF TESTS

Fig. 11.1 Hardness mapping locations

18.4.3.9 System Verification and Test Results Validation

Fig. B.1.1 Axial rim test

Fig. B.3 Axial rim test

Fig. B.3.1 Tread rim test

Fig. B.3.2 Axial rim test

Fig. B.4 Marking of locomotive wheels rim stamping

160 TAPE SIZE

SERIAL NUMBER DESIGN

Fig. B.5 Marking of carbon steel wheels hub stamping

Manufacturers Cast or No Longer

Fig. B.7 Raised markings on cast carbon steel wheels

Fig. B.8 Standard dimensions and tolerances and permissible variations

9.0 PERMISSIBLE VARIATIONS IN DIMENSIONS NOT SHOWN BY TOLERANCES ON

DIMENSION AND TOLERANCESALL ENTRIES IN INCHES, EXCEPT TAPES

STANDARD AAR WHEEL TYPESNARROW-FLANGE CONTOURFOR DIESEL LOCOMOTIVE

DIMENSION AND TOLERANCESALL ENTRIES IN INCHES, EXCEPT TAPES,

Fig. B.10 Standard wheel types for locomotive service

AAR-1B WIDE PROFILE CENTERS OF

AAR-1B WIDE PROFILE INTERSECTION OF POINTS

AAR-1B NARROW PROFILE CENTERS

Adopted: 1914; Last Revised: 20