标准编号:	TB/T 3012-2016
中文名称:	铁道货车铸钢摇枕、侧架
英文名称:	Cast steel bolster and side frame for railway freight car
行业分类:	TB    铁路运输行业标准
发布机构:	国家铁路局
发布日期:	2016-12-15
实施日期:	2017-7-1
标准状态:	现行
替代旧标准:	TB/T 3012-2006
翻译语言:	英文
文件格式:	PDF
中文字符数:	20000 字
翻译价格(元):	4740.00 元
交付时间:	付款后 1 个工作日

Codeofchina.com is in charge of this English translation. In case of any doubt about the English translation, the Chinese original shall be considered authoritative.



This standard is developed in accordance with the rules given in GB/T 1.1-2009.



This standard replaces TB/T 3012-2006 Specification of Cast Steel Bolster and Side Frame for Railway Freight Car. The following main technical changes have been made with respect to TB/T 3012-2006:



——The chemical composition and mechanical properties requirements of Grade B+ steel are added (see 3.2 and 3.3);



——The requirements for mechanical property of physical product are added (see 3.3.2);



——The requirements for the smelting process of electric arc furnace and refining furnace are added (see 3.5.1);



——The process requirements for residual aluminum and steel reducing slag (FeO) of steel are added (see 3.5.2);



——The process requirements for the killing of molten steel after tapping are added (see 3.5.3):



——The requirements for the automatic integral core setting process for bogie bolster and side frame with axle weight of 25t and above as well as the continuous heat treatment process of bogie bolster and side frame with axle weight of more than 25t are added (see 3.5.4):



——The requirements for heat treatment process of Grades B and B+ steels are modified (see 3.5.5; 3.5.3 of Edition 2006);



——The process requirement for shake-out and cleaning of castings are added (see 3.5.6);



——The process requirements for cleaning of castings after heat treatment are modified (see 3.5.7; 3.5.5, Edition 2006):



——The requirements for visual inspection are modified (see 3.6.1; 3.6.2, Edition 2006);



——The requirements for magnetic particle testing are modified (see 3.6.9; 3.10.1, Edition 2006);



——The requirements for compactness inspection are modified (see 3.7.1; 3.11, Edition 2006);



——The requirements for radiographic testing are modified (see 3.7.2; 3.10.2, Edition 2006);



——The requirements as to the preparation of the groove for repair welding after heat treatment are modified (see 3.8.3; 3.7.4, Edition 2006);



——The requirements for the welding environment are added (see 3.8.5);



——The processing method in case of casting temperature lower than 4°C and the requirements for repair welding of Grade C steel are added (see 3.8.6);



——The requirements for the quality of repair welding are modified (see 3.8.10; 3.7.8, Edition 2006);



——The requirements for the recommended temperature for repair welding and tempering of bolsters and side frames after heat treatment are added (see 3.9.1);



——The requirements for the repair welding of Parts A and B of bolster after heat treatment are modified (see 3.9.1.1; 3.8.1.1, Edition 2006):



——The requirements for the post heating repair welding treatment of the area 50mm around the bolster lever hole are modified (see 3.9.2.2; 3.8.1.2, Edition 2006);



——The requirements for repair welding of Part A of side frame after heat treatment are modified (see 3.9.3.1; 3.8.2.1, Edition 2006);



——The requirements for post-heating repair welding treatment of Part B on side frame are modified (see 3.9.3.2; 3.8.2.2, Edition 2006):



——The requirements for the post-heating repair welding treatment are added for the connection corner between the post of side frame central frame and the spring cushion cap as well as the area (R+45)mm around the corner (see 3.9.3.2; 3.8.2.3, Edition 2006);



——The requirements for static load and fatigue tests are modified (see 3.11; 3.12, Edition 2006);



——The requirements for specimen preparation are added (see 4.1);



——The methods for surface roughness inspection are added (see 4.5.1);



——The methods for internal quality inspection are added (see 4.6);



——The inspection method for geometric dimension of castings are added (see 4.7);



——The rules for type inspection, periodic inspection and end-of-manufacturing inspection are added (see 5.1, 5.2 and 5.3);



——The rules for mechanical property inspection of bolster and side frame in case of insufficient test rods are deleted (see 4.2.8, Edition 2006);



——The requirements for marking are modified (see 6.1; 5.1, Edition 2006);



——The requirements for quality certificate are modified (see 6.2; 5.2, Edition 2006);



——The division methods for Parts A and B of ZK7 bolster and side frame are added (see Annex A);



——The metallographic atlas for metallographic microstructure examination of Grade B cast steel (ZG25MnNi) and Grade C cast steel (ZG25MnCrNiMo) are deleted (see Annexes A and B, Edition 2006);



——The requirements for qualified level of Parts A and B of bolster and side frame upon radiographic testing are added (See Annex C);



——The schematic diagrams are added as to dissected part for compactness inspection of ZK7 bolster and side frame (see Annex E);



——The position requirements are added as to the thickness measurement points for important parts of the bolster and side frame are added (see Annex F).



This standard was proposed by and is under the jurisdiction of CRRC Qishuyan Locomotive & Rolling Stock Technology Research Institute Co., Ltd.



Previous editions of this standard are as follow: TB/T 3012-2001 and TB/T 3012-2006.







Cast Steel Bolster and Side Frame for Railway Freight Car



1 Scope



This standard specifies technical requirements, inspection methods, inspection rules, marking and quality certificate and records for Grade B steel (ZG25MnNi), Grade B+ steel (ZG25MnCrNi) and Grade C steel (ZG25MnCrNiMo) bolsters and side frames for railway freight car.



This standard is applicable to the manufacture and inspection of Grades B, B+ and C steel bolster and side frame for railway freight car.



2 Normative References



The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.



GB/T 222 Permissible Tolerances for Chemical Composition of Steel Products

GB/T 223 Methods for Chemical Analysis of Iron, Steel and Alloy

GB/T 228.1 Metallic Materials - Tensile Testing - Part 1: Method of Test at Room Temperature (GB/T 228.1-2010, ISO 6892-1: 2009 MOD)

GB/T 229 Metallic Materials - Charpy Pendulum Impact Test Method (GB/T 229-2007, ISO 148-1: 2006, MOD)

GB/T 6394 Metal-methods for Estimating the Average Grain Size

GB/T 6414-1999 Castings - System of Dimensional Tolerances and Machining Allowances (eqv ISO 8062: 1994)

GB/T 15056 Evaluation Method on Cast Surface Roughness

JB/T 5105 Casting Form Pattern Draft

TB/T 1959 Static Load and Fatigue Test of Bolster and Side Frame for Railway Freight Car

TB/T 2451 Metallographic Inspection for Non-metallic Inclusion in Cast Steel

TB/T 2942 General Technical Specifications of Steel Castings for Rolling Stock

TB/T 3105.1 Nondestructive Testing of Cast Steel Bolster and Side Frame for Railway Freight Car - Part 1: Radiographic Testing

TB/T 3105.3 Nondestructive Testing of Cast Steel Bolsters and Side Frames for Railway Freight Car - Part 3: Magnetic Particle Testing

TB/T 3105.4-2014 Nondestructive Testing of Cast Steel Bolsters and Side Frames for Railway Freight Car - Part 4: Digital Radiography and Industrial Computed Tomography Testing

TB/T 3211 Imperfections of Radiographic Testing for Steel Castings for Rolling Stock

TB/T 3212.1 Metallographic Atlas for Metallographic Microstructure Examination of Low Alloy Cast Steel for Rolling Stock - Part 1: Grades B and B+ Cast Steel

TB/T 3212.2 Metallographic Atlas for Metallographic Microstructure Examination of Low Alloy Cast Steel for Rolling Stock - Part 2: Grades C Cast Steel



3 Technical Requirements



3.1 General requirements



3.1.1 The bolster and side frame shall be in accordance with this standard as well as those specified in the technical documents and product drawings approved via established procedures.



3.1.2 The two important parts, i.e., A and B, shall be determined according to the stress state of the bolster and side frame and then specified in the product drawing. See Annex A for the division of Parts A and B of bolster and side frame.



3.2 Chemical composition



The chemical composition of the steel shall be in accordance with those specified in Table 1.



Table 1 Chemical Composition

Grade Chemical composition (mass fraction)

%

C≤ Si≤ Mn≤ P≤ S≤ Cu≤ Ni≥ Cr≤ Mo≤

Grade B 0.28 0.40 1.00 0.030 0.030 0.30 0.30 — —

Grade B+ 0.29 0.50 1.00 0.030 0.030 0.30 0.20 0.50 —

Grade C 0.28 0.40 1.50 0.030 0.030 0.30 0.35 0.60 0.30



For Grades B and B+ steels, if the carbon content is lower than the maximum value specified, the manganese content is allowed to be 0.04% higher than the specified maximum value each time the carbon content is reduced by 0.01%, but the maximum manganese content shall not be greater than 1.20%.



3.3 Mechanical property



3.3.1 The mechanical property of steel test rod shall be in accordance with the relevant requirements of TB/T 2942.



3.3.2 Where the products are randomly inspected or it is required by the customer, the mechanical property of cast steel may be evaluated with a physical specimen of which the mechanical properties shall be in accordance with the relevant requirements of TB/T 2942.



3.4 Metallographic phase



The metallographic analysis of cast steel covers the evaluation of nonmetallic inclusion, grain size and metallographic structure. Non-metallic inclusions shall be evaluated according to TB/T 2451 and shall be in accordance with those specified in Table 2; the grain size of the product shall be evaluated according to GB/T 6394, and the conformity level shall be stricter than or equal to Grade 6; the metallographic structure of Grade B and B+ steels shall be evaluated in accordance with TB/T 3212.1, and that of Grade C steel shall be evaluated in accordance with TB/T 3212.2.



Table 2 Rating of Non-metallic Inclusions in Cast Steel

Inclusion classification Conformity level Rating chart

Type I (globular) inclusion Thin: Grades 1~3; thick: Grade 1 Third rating chart

Type II (point-net) inclusion Grade 1~Grade 2 Second rating chart

Type III (dotted) inclusion Thin: Grades 1~3; thick: Grades 1 Third rating chart

Type IV (aluminum oxide cluster) inclusion Grade 1 Fourth rating chart



3.5 Process requirements



3.5.1 The cast steel shall be smelted with electric arc furnace and refining furnace.



3.5.2 The residual aluminum in the steel shall be controlled within 0.020%~0.080%. The reducing slag (FeO) in at least one melting furnace shall be taken every week to measure the reducing slag (FeO) content which shall not be greater than 1.0%; the keel block of the steel in at least one furnace No. shall be taken to inspect the oxygen content of the steel, which shall not be greater than 0.0060%.The residual aluminum, reducing slag (FeO) and oxygen content in steel will not be used as the basis for product delivery.



3.5.3 After tapping (in the pouring pot), the molten steel shall be killed for at least 5min and the pouring temperature shall not exceed 1,585°C.



3.5.4 Automatic integral core setting process shall be adopted for bogie bolsters and side frames with axle weights of 25t and above. Continuous heat treating furnace process shall be adopted for bogie bolsters and side frames with axle weights of 25t and above.



3.5.5 The bolster and side frame shall be subjected to heat treatment. Bolster and side frame made of Grades B and B+ steels shall be subjected to normalizing or normalizing & tempering heat treatment, and those made of Grade C steel shall be subjected to normalizing and tempering heat treatment. Where re-heat treatment is necessary, the frequency of re-heat treatment shall not exceed two times (the frequency of tempering is unlimited).The heat treatment of bolster and side frame shall be in accordance with the relevant requirements of TB/T 2942.



3.5.6 Dry knockout shall be adopted for bolster and side frame. During shake-out, the temperature of the casting shall not be higher than 540°C, the method of sand removal and its cooling rate shall not impair the quality of the casting.



3.5.7 After final heat treatment, the bolster and side frame shall not be cleaned via thermal method.



3.5.8 The temperature for correcting the distorted bolster and side frame shall not exceed 850°C; the castings corrected after heat treatment shall be heat treated and inspected again.



3.6 Surface quality



3.6.1 The surface of bolster and side frame shall be free of cracks via visual inspection; and the sand burning that impedes use and inspection shall be removed.



3.6.2 Unless it is otherwise specified in the product drawing and technical documents, the surface roughness of castings shall be NMR Ra100.



3.6.3 As for the castings, the flying edge and burrs presenting on the outer edge and the edges of the holes shall be totally removed and the edges shall be rounded; the conspicuous raised surface on the casting shall be polished flat and smooth.



3.6.4 The residual casting head on non-machined surface shall not exceed 3mm and it shall be smoothly transitioned to the surrounding casting surface.



3.6.5 Parts A and B of the bolster and side frame shall be free from visible chipping marks or nicks; the depth of those chipping marks and nicks on other parts shall not be greater than 2mm;chipping marks and nicks produced during manufacturing are allowed to be removed by grinding and shall be smoothly transitioned to the surround part, but the wall thickness at the ground part shall not be less than the minimum allowable size.



3.6.6 The non-machined casting surface within a radius of 25mm around the center of bolt (rivet) hole shall be flat and smooth.



3.6.7 The following defects are allowed to be left on the bolster without repair:



a) Local dent with a casting wall thickness no less than the minimum allowable value specified in the drawing and a depth less than or equal to 2mm after cleaning, which shall be so finished as to transition smoothly to the surrounding casting surface;



b) Local protrusions which are less than or equal to 2mm in height and have no influence on processing and assembly;



c) Gas holes scattered on the bolster surface (excluding Part A), which are less than or equal to 2mm, 5mm and 3pcs/cm2 in diameter, depth and density.



3.6.8 The following defects are allowed to be left on the side frames without repair:



a) Local dents spaced less than 100mm on Part A, of which the casting wall thickness is no less than the minimum allowable value specified in the drawing, the depth is less than or equal to 2mm, and the maximum dimension is less than or equal to 10mm after cleaning; such dents shall be so finished as to transition smoothly to the surrounding casting surface;



b) Local dent presenting on other parts with a casting wall thickness no less than the minimum allowable value specified in the drawing and a depth less than or equal to 3mm after cleaning, which shall be so finished as to transition smoothly to the surrounding casting surface;



c) Local protrusions which are less than or equal to 2mm in height and have no influence on processing and assembly;



d) Gas holes scattered on the side frame surface (excluding Part A), which are less than or equal to 2mm, 5mm and 3pcs/cm2 in diameter, depth and density respectively.



3.6.9 The magnetic particle testing of the surface shall be in accordance with the following requirements:



a) magnetic particle testing shall be performed on Parts A and B of the bolsters and side frames as well as other parts required to be tested in the drawing. The parts to be tested shall be free of cracks or transverse linear magnetic trace of defects;



b) for the bolster, the length of magnetic particle indication for a single longitudinal linear defect is allowed to be no larger than 5mm; the accumulative length of magnetic particle indication for dispersed defects with length greater than or equal to 3mm and less than 5mm is allowed to be no larger than 30mm within a rectangular area (with the long side no larger than 150mm) of 2,500mm2;



c) for the side frame, the length of magnetic particle indication for a single longitudinal linear defect is allowed to be no larger than 5mm; the accumulative length of magnetic particle indication for dispersed defects with length greater than or equal to 3mm and less than 5mm is allowed to be no larger than 24mm within a rectangular area (with the long side no larger than 150mm) of 2,500mm2;



3.6.10 In case of any of the following defects, the bolster shall be discarded:



a) transverse penetrating cracks on Parts A and B;



b) other penetrating casting defects presenting on Parts A and B with a single area exceeding 30 cm2 or a total area exceeding 60 cm2.



3.6.11 In case of any of the following defects, the side frame shall be discarded:



a) transverse penetrating cracks on Parts A and B;



b) the following defects presenting on Part A: other penetrating cracks with a length exceeding 50mm; or a single penetrating defect of other type with the area exceeding 20cm2, or more than one penetrating defects of other type with the area exceeding 20cm2;



c) the following defects presenting on Part B: other penetrating cracks with a length exceeding 50mm; or a single penetrating defect of other type with the area exceeding 25cm2, or more than one penetrating defects of other type with the area exceeding 50cm2;

Foreword i
1 Scope
2 Normative References
3 Technical Requirements
4 Inspection Method
5 Inspection Rules
6 Marking and Quality Certificate
7 Record
Annex A (Normative) Partitioning Methods for Part A and Part B of Bolsters and Side Frames
Annex B (Normative) Bolster and Side Frame Compactness Standard Picture
Annex C (Normative) Radiography Qualification Grades for Part A and Part B of Bolster and Side Frame
Annex D (Normative) Measuring Basis of Bolster and Side Frame
Annex E (Normative) Bolster and Side Frame Compactness Inspection and Dissection Positions
Annex F (Normative) Location of Thickness Measuring Points for Important Parts of Bolster and Side Frame

铁道货车铸钢摇枕、侧架
1 范围
本标准规定了铁道货车用B级钢(ZG25MnNi)、B+级钢(ZG25MnCrNi)、C级钢(ZG25MnCrNiMo)摇枕、侧架的技术要求、检验方法、检验规则、标志及质量证明书、记录。
本标准适用于铁道货车用B级钢、B+级钢、C级钢摇枕、侧架的制造与检验。
2规范性引用文件
下列文件对于本文件的应用是必不可少的。凡是注日期的引用文件，仅注日期的版本适用于本文件。凡是不注日期的引用文件，其最新版本(包括所有的修改单)适用于本文件。
GB/T 222钢的成品化学成分允许偏差
GB/T 223 钢铁及合金化学分析方法
GB/T 228.1 金属材料 拉伸试验 第1部分：室温试验方法(GB/T 228.1—2010，ISO 6892-1：2009 MOD)
GB/T 229金属材料夏比摆锤冲击试验方法(GB/T 229—2007，ISO 148-1：2006，MOD)
GB/T 6394 金属平均晶粒度测定法
GB/T 6414—1999铸件尺寸公差与机械加工余量(eqv ISO 8062：1994)
GB/T 15056铸造表面粗糙度 评定方法
JB/T 5105 铸件模样起模斜度
TB/T 1959 铁道货车摇枕、侧架静载荷及疲劳试验
TB/T 2451 铸钢中非金属夹杂物金相检验
TB/T 2942机车车辆用铸钢件通用技术条件
TB/T 3105.1 铁道货车铸钢摇枕、侧架无损检测 第1部分：射线照相检验
TB/T 3105.3 铁道货车铸钢摇枕、侧架无损检测 第3部分：磁粉检验
TB/T 3105.4—2014 铁道货车铸钢摇枕、侧架无损检测 第4部分：数字化射线成像及工业计算机层析成像检测
TB/T 3211 机车车辆用铸钢件射线照相检验参考图谱
TB/T 3212.1 机车车辆用低合金铸钢金相组织检验图谱 第1部分：B级铸钢、B+级铸钢
TB/T 3212.2 机车车辆用低合金铸钢金相组织检验图谱 第2部分：C级铸钢
3 技术要求
3.1 一般要求
3.1.1 摇枕、侧架应符合本标准和经规定程序批准的技术文件及产品图样的规定。
3.1.2 根据摇枕、侧架的受力状态应划分出A、B两个重要部位并在产品图样中规定。摇枕、侧架的A部位、B部位划分见附录A。
3.2 化学成分
钢的化学成分应符合表1的规定。
表1 化学成分
级 别 化学成分(质量分数)
％
C≤ Si≤ Mn≤ P≤ S≤ Cu≤ Ni≥ Cr≤ Mo≤
B级 0.28 0.40 1.00 0.030 0.030 0.30 0.30 — —
B+级 0.29 0.50 1.00 0.030 0.030 0.30 0.20 0.50 —
C级 0.28 0.40 1.50 0.030 0.030 0.30 0.35 0.60 0.30

B级钢、B+级钢在低于规定的最大含碳量时，每降低0.01％的碳，允许锰含量比规定的最大值增0.04％，但锰的最高含量不应大于1.20％。
3.3 力学性能
3.3.1 钢的试棒力学性能应符合TB/T 2942的相关规定。
3.3.2产品抽检或客户有需求时，可以采用实物试样来评定铸钢的力学性能，实物试样力学性能应符合TB/T 2942的相关规定。
3.4 金 相
铸钢的金相分析包括非金属夹杂物、晶粒度和金相组织的评定。非金属夹杂物按TB/T 2451评定，应符合表2的规定；品粒度按GB/T 6394进行评定，合格级别应细于或等于6级；B级钢、B+级钢金相组织的评定应符合TB/T 3212.1的规定，C级钢金相组织的评定应符合TB/T 3212.2的规定。
表2铸钢中非金属夹杂物评定等级
夹杂物类别 合格级别 评 级 图
I型(球状)夹杂物 细系1级～3级，粗系1级 第三评级图
Ⅱ型(点网状)夹杂物 1级～2级 第二评级图
Ⅲ型(点状)夹杂物 细系1级～3级，粗系1级 第三评级图
Ⅳ型(群状三氧化二铝)夹杂物 1级 第四评级图

3.5 工艺要求
3.5.1 铸钢应采用电弧炉或电弧炉加精炼炉冶炼。
3.5.2 钢中残铝应控制在0.020％～0.080％范围内；每周至少应抽取一熔炼炉的还原渣(FeO)，进行还原渣(FeO)含量的检测，其含量不应大于1.0％；每月至少应抽取一个熔炼炉号钢的基尔试块，进行钢的氧含量检测，其含量不应大于0.006 0％。钢中残铝、还原渣(FeO)以及钢中氧含量不作为产品交货依据。
3.5.3 出钢后(在浇注包内)，钢水至少应有5 min的镇静时间，浇注温度不应高于1 585℃。
3.5.4 轴重25 t及以上的转向架摇枕、侧架应采用整体芯、自动下芯工艺。轴重25 t以上的转向架摇枕、侧架应采用连续式热处理工艺。
3.5.5摇枕、侧架应进行热处理。B级钢、B+级钢摇枕、侧架应经正火或正火加回火热处理；C级钢摇枕、侧架应经正火加回火热处理。当需要重新热处理，重新热处理的次数不应超过2次(回火次数不限)。摇枕、侧架的热处理应符合TB/T 2942中相关的要求。
3.5.6摇枕、侧架应采用干法落砂，开箱时铸件温度不应高于540℃，清砂方式及其冷却速率不应损害铸件质量。
3.5.7 摇枕、侧架最终热处理后的清理不应采用热法清理。
3.5.8 扭曲变形的摇枕、侧架校正温度不应高于850℃，热处理后校正的铸件应重新进行热处理和检验。
3.6 表面质量
3.6.1 目视检查时，摇枕、侧架的表面不应存在裂纹，摇枕、侧架上妨碍使用和检查的粘砂应予清除。
3.6.2产品图样和技术文件中无明确规定时，铸件的表面粗糙度应为NMR Ra100。
3.6.3铸件的外棱和孔的边缘出现的飞边、毛刺应清除干净，棱边应倒圆角；铸件表面明显凸起应打磨平整。
3.6.4非加工面上的浇冒口残留部分不应超过3 mm，与周围铸件表面圆滑过渡。
3.6.5摇枕、侧架A部位、B部位，不应有明显的铲痕和刻痕；其他部位的铲痕和刻痕深度不应大于2 mm；制造过程中产生的铲痕和刻痕允许采用磨修的方法去除，并与铸件周边平滑过渡，但磨修部位的壁厚不应小于最小的允许尺寸。
3.6.6螺栓(铆钉)孔中心半径25 mm范围内非加工的铸造表面应平整。
3.6.7 摇枕上允许存在下列不需要修复的缺陷：
a)清理后的铸件壁厚不小于图样规定的最小允许值，且深度小于或等于2 mm的局部凹陷，但应修整使之与周围的铸件表面圆滑过渡；
b)不影响加工与组装，且高度小于或等于2 mm的局部凸起；
c)除A部位外，弥散于摇枕表面的直径小于或等于2 mm、深度小于或等于5 mm，密度小于或等于每平方厘米3个气孔。
3.6.8 侧架上允许存在下列不需要修复的缺陷：
a)A部位清理后的铸件壁厚不小于图样规定的最小允许值，且深度小于或等于2 mm，最大尺寸小于或等于10 mm，相距不小于100 mm的局部凹陷，应修整使之与周围的铸件表面圆滑过渡；
b)其他部位清理后铸件壁厚不小于图样规定的最小允许值，深度小于或等于3 mm的缺陷应修整使之与周围的铸件表面圆滑过渡；
c)不影响加工与组装，且高度小于或等于2 mm的局部凸起：
d)除A部位外，弥散于侧架表面的直径小于或等于2 mm、深度小于或等于5 mm，密度小于或等于每平方厘米3个气孔。
3.6.9 表面磁粉探伤应符合以下规定：
a)应对摇枕、侧架A部位、B部位以及图样规定探伤的其他部位进行磁粉探伤。探伤部位不应存在裂纹及横向线状缺陷磁痕；
b)摇枕允许单个纵向线状缺陷磁痕长度不大于5 mm；允许长度大于或等于3 mm且小于5 mm的分散性缺陷磁痕，在2 500 mm2矩形面积内，累计长度不大于30 mm，其面积的长边不大于150 mm；
c)侧架允许单个纵向线状缺陷磁痕长度不大于5 mm；允许长度大于等于3 mm且小于5 mm的分散性缺陷磁痕，在2 500 mm2矩形面积内，累计长度不大于24 mm，其面积的长边不大于150 mm。
3.6.10 摇枕上如有下列缺陷之一时，应予报废：
a)A部位、B部位的横向贯通裂纹；
b)A部位、B部位上缺陷清除后单个面积超过30 cm2，或总面积超过60 cm2的其他贯通铸造缺陷。
3.6.11 侧架上如有下列缺陷之一时，应予报废：
a)A部位、B部位上的横向贯通裂纹：
b)A部位长度超过50 mm的其他贯通裂纹，或面积超过20 cm2的其他贯通缺陷一处，或面积虽未超过20 cm2但数量多于一处的其他贯通缺陷；
c)B部位上长度超过50 mm的其他贯通裂纹；或单个面积超过25 cm2，或总面积超过50 cm2的其他贯通缺陷。
3.7 内部质量
3.7.1 密实度
摇枕、侧架铸件的密实度解剖检查结果应符合附录B的要求，且评定区域内所在截面的集中缩孔的面积不应超过该部位截面内切圆的30％。
3.7.2 射线照相或数字化射线成像检验
3.7.2.1 摇枕、侧架A部位、B部位应进行射线照相或数字化射线成像检验。
3.7.2.2摇枕、侧架射线照相检验结果按照TB/T 3211进行评级，评定结果应符合附录C的规定；摇枕、侧架A部位数字化射线成像检验结果应符合TB/T 3105.4—2014中规定的不超过4级的要求，B部位数字化射线成像检验结果应符合TB/T 3105.4—2014中规定的不超过5级的要求。
3.7.2.3超过规定的A类、C类缺陷，按密实度进行评定。
3.8 焊修要求
3.8.1 铸件缺陷的焊修宜在热处理前进行。热处理后不超过3.6.10、3.6.11规定的缺陷允许焊修。
3.8.2 应采用直流电弧焊机对摇枕、侧架的缺陷进行焊修。焊工应经过培训并取得相应的职业资格证书及上岗证书。
3.8.3 全部缺陷应在焊修前除去。要焊修的部位应开出坡口，坡口的制备应采用机械方法或气割及碳弧气刨等热加工方法，但热处理后的焊修，坡口应采用机械方法制备。
3.8.4不应电弧击伤铸件表面，不应在铸件的非焊修表面上引弧。
3.8.5不应在雨、雪和穿堂风等不利的环境下施焊。
3.8.6 当铸件温度低于4℃时，允许局部预热或整体预热后施焊，焊修预热温度不应高于320℃。采用焊条电弧焊时，C级钢摇枕、侧架应预热，预热温度应高于200℃，宜采用整体预热的方式预热铸件；如不能整体预热时，则可采用局部预热，局部预热的范围为在焊缝两侧各取3倍的焊缝处截面厚度。
3.8.7 采用焊条电弧焊时，焊条应符合TB/T 2942的规定。
3.8.8焊修宜采用平焊位置进行焊修。在不能从铸件壁厚两侧施焊的地方，焊修部位的最大深度应在焊缝底部与铸件壁背面留有至少3 mm的金属。当缺陷贯穿壁厚，且可从铸壁两侧施焊时，则应使用双“V”或双“U”形坡口从铸壁的两侧进行焊修，双面焊时焊缝根部间隙不应小于3 mm，焊修时应反面清根，完全焊透；如果只能单面施焊，则应使用铜板、化学成分相近的钢板或陶瓷作焊接垫板，保证根部完全焊透，焊后应去除焊接垫板，背面应与母材平滑过渡。
3.8.9 多层焊时，每焊完一层应清除熔渣、缺陷。
3.8.10 焊修质量应符合下列要求：
a)不应有裂纹、未熔合、未焊满、弧坑等缺陷；
b)非加工部位上的焊修表面应平整，焊修区域与母材应平缓过渡；
c)非加工部位上的焊缝咬边深度，A部位、B部位上不应超过0.5 mm，其他部位上不应超过1 mm；
d)A部位、B部位焊修表面不应存在气孔和夹渣。其他部位焊修表面每50 cm2范围内，允许存在直径不大于2 mm的气孔或夹渣，且数量不应超过2个。
3.8.11 应对焊修区域进行磁粉探伤检查。
3.9 热处理后焊修的处理
3.9.1 一般要求
当铸件在热处理后焊修时，应根据缺陷情况进行焊后处理。当采用局部消除应力处理时，可采用机械方法或加热方法消除应力，加热及保温范围为距焊修区周围至少100 mm范围以内的区域，加热温度不应超过最终热处理回火温度。当采用整体回火热处理时，回火温度宜控制在500℃～550℃，最高不应超过最终热处理回火温度。
3.9.2摇 枕
3.9.2.1 A部位、B部位清除缺陷后单个面积不超过4 cm2、深度小于该处壁厚的1/4，整个A部位、B部位数量各不超过2处且相距不小于150 mm时，应进行局部消除应力处理；A部位缺陷清除后单个面积在4 cm2～25 cm2之间，B部位缺陷清除后单个面积在4 cm2～30 cm2之间，且最大深度小于或等于该处壁厚的1/2时，应进行整体回火热处理；A部位缺陷清除后单个面积超过25 cm2，B部位缺陷清除后单个面积超过30 cm2，且最大深度大于该处壁厚的1/2时，应重新进行正火处理。
3.9.2.2 摇枕拉杆孔周围50 mm范围内焊修后，应进行整体回火处理。
3.9.2.3 其他部位消除缺陷后，单个面积大于或等于20 cm2，深度大于或等于该处壁厚的1/2的焊修区域应进行整体回火热处理。
3.9.2.4 其他部位消除缺陷后单个面积小于20 cm2，深度小于该处壁厚的1/2且总面积不大于30 em2的焊修区域不需要回火处理或局部消除应力处理。
3.9.3 侧 架
3.9.3.1 A部位焊修后应进行整体回火热处理，缺陷清除后单个面积超过20 cm2，且最大深度大于该处壁厚的1/2时，应重新进行正火处理。
3.9.3.2 B部位及中央方框立柱与弹簧承台面的连接弯角区及其(R+45)mm范围内，包括该区域延伸至侧架横向边缘，立柱与上弦杆连接弯角区及其(R+45)mm范围内，清除缺陷后单个面积不超过4 cm2、深度小于该处壁厚1/4、数量不超过2处且相距不小于100 mm时，应进行局部消除应力处理：B部位缺陷清除后单个面积在4 cm2～25 cm2之间，且最大深度小于或等于该处壁厚的1/2时，应进行整体回火热处理；B部位缺陷消除后单个面积大于25 cm2，且最大深度大于该处壁厚的1/2时，应重新进行正火处理。
3.9.3.3其他部位消除缺陷后单个面积大于或等于20 cm2，深度大于或等于该处壁厚的1/2的焊修区域应进行整体回火热处理。
3.9.3.4其他部位消除缺陷后单个面积小于20 cm2，深度小于该处壁厚的1/2且总面积不大于30 cm2的焊修区域可不需要回火处理或局部消除应力处理。
3.10几何尺寸
3.10.1 摇枕弹簧承台面、侧架弹簧承台面的平面度公差为3.5 mm，如图1所示。摇枕斜楔槽磨耗板安装面应平整，不应有凸起，不应存在深度大于1.6 mm的凹陷。
单位为毫米

a)摇枕

b)侧架
图1 摇枕、侧架的平面度要求
3.10.2铸件拔模斜度按JB/T 5105执行，摇枕、侧架未注明尺寸公差按GB/T 6414—1999的CT12级，壁厚允许偏差应符合表3的规定。特殊情况应在产品图样中规定。
表3 摇枕、侧架壁厚允许偏差 单位为毫米
铸件壁厚基本尺寸 允许偏 差
上偏差 下偏差
>10～16 +3 -1.4
>16～25 +3 -1.6
>25～40 +3 -2
>40 +4 -2
注：制造方为了保证铸件的密实度，可以在局部区域增加补贴，补贴金属厚度不应计算在金属断面厚度的上偏差内。

3.10.3 经机械加工后，摇枕、侧架的形状和位置公差应符合下列要求：
a)摇枕、侧架的测量基准的确定按附录D的规定。
b)摇枕两端弹簧承台面对心盘安装面的平行度公差均为3 mm，摇枕两端的弹簧承台面的平行度公差为4 mm，如图2所示。
单位为毫米

图2 摇枕的平行度要求
c)对有轴箱挡的侧架，轴箱挡两内侧面对承载鞍(或轴箱)承台面的垂直度公差均为0.5 mm，如图3所示。
单位为毫米

图3侧架轴箱挡两内侧面对承载鞍(或轴箱)承台面的垂直度要求
d)侧架弹簧承台面对侧架纵向中心线(中心平面)的垂直度公差为每100 mm长度上为1 mm，如图4所示。
单位为毫米

纵向中心平面
图4侧架弹簧承台面的垂直度要求
e)侧架弹簧承台面对承载鞍(或轴箱)支承面的平行度公差为每100 mm×100 mm范围内为1 mm，如图5所示。
单位为毫米

图5 侧架弹簧承台面的平行度要求
f)对有轴箱挡的侧架，任一轴箱挡对侧架纵向中心线(中心平面)的对称度公差为4 mm，且一端的轴箱挡对另一端的轴箱挡的对称度公差为2 mm，如图6所示。
单位为毫米

侧架纵向中心线
图6侧架轴箱挡的对称度要求
g)轴箱挡两内侧而对侧架纵向中心线(中心平面)的垂直度公差为0.5 mm，如图7所示。
单位为毫米

侧架纵向中心线
图7 侧架轴箱挡两内侧面对纵向中心线的垂直度要求
3.11静载荷、疲劳试验
摇枕、侧架静载荷、疲劳试验结果应符合TB/T 1959的要求，其中转K5、转K6、转K7型摇枕、侧架疲劳试验按照TB/T 1959规定的载荷和循环次数进行试验，试验通过后，摇枕应增加载荷20％，循环次数增加2×105次进行试验，侧架应增加载荷40％，循环次数增加5×104次进行试验，摇枕、侧架试验结果应不发生TB/T 1959规定的危险裂纹。
3.12 涂 装
经制造方检查部门或采购方验收合格的摇枕、侧架，应按图样或相关技术要求涂上保护油漆。
4 检验方法
4.1 试样的制备
4.1.1 化学成分分析试样、力学性能试样的制备按TB/T 2942的规定执行。
4.1.2金相分析用试样从力学性能试验用试棒上制取，金相分析用试棒应与同一熔炼炉号浇注的摇枕、侧架同一炉次热处理。
4.2 化学成分
4.2.1 化学成分分析以熔炼分析试样的分析结果代表该熔炼炉号摇枕、侧架的化学成分。
4.2.2 化学成分分析按照TB/T 2942的规定进行。
4.2.3 若用户复验摇枕、侧架的化学成分的结果与制造方提供的分析报告不符合时，按GB/T 223和GB/T 222仲裁。
4.3 力学性能
4.3.1 拉伸试验按GB/T 228.1进行。拉伸试样的尺寸及加工质量应符合TB/T 2942的规定。
4.3.2 冲击试验按GB/T 229进行。冲击试样的尺寸和加T质量应符合TB/T 2942的规定。其中V形缺口每周应至少抽检6个试样在投影仪上放大50倍检查。
4.4 金相分析
4.4.1 非金属夹杂物检验按TB/T 2451的规定进行。
4.4.2 晶粒度检验按GB/T 6394的规定进行。
4.4.3 金相组织检验按TB/T 3212.1、TB/T 3212.2的规定进行。
4.5表面质量
4.5.1 铸造表面粗糙度的检验按GB/T 15056的规定进行。
4.5.2 表面缺陷采用目视检查。
4.5.3表面磁粉探伤检验按FB/T 3105.3的规定进行。
4.6 内部质量
4.6.1 密实度
密实度检查采用实物锯切解剖检查的方法进行，摇枕和侧架的解剖部位及评定区域按附录E的规定，但工艺补贴和冒口不计入在评定区域的尺寸范围内。
4.6.2 射线照相或数字化射线成像
射线照相检验按TB/T 3105.1的规定进行，数字化射线成像检验按TB/T 3105.4—2014的规定进行。
4.7几何尺寸
4.7.1 铸件的几何尺寸可采用满足测量精度要求的通用或专用量具进行检查。铸件壁厚的测量可以采用超声波测厚技术、解剖检查或其他方法进行测量。
4.7.2 铸件工艺补贴及拔模斜度不计算在几何尺寸范围内。
4.8静载荷、疲劳试验
静载荷、疲劳试验按TB/T 1959的规定进行。
5 检验规则
5.1 型式检验
5.1.1 有下列情形之一者，应做型式检验：
a)首次投产或试制完成时；
b)铸造生产场地转移时；
c)当产品结构或制造工艺有重大改变时，如重制模样、改变浇注系统、型砂、热处理方法和规范改变；
d)产品停产两年及以上恢复生产时；
e)连续生产三年时。
5.1.2 型式检验项目按表4的规定，无特殊规定的各抽取1件进行检验。
5.1.3应至少抽取两件不同熔炼炉号的样品进行密实度解剖检查。
5.1.4应至少抽取所生产每种摇枕和侧架进行一次静载荷、疲劳试验。当产品结构或制造工艺有重大改变时，应选择有代表性的摇枕、侧架进行至少一次静载荷试验。
5.1.5应至少抽取3件不同熔炼炉号的铸件进行全部尺寸公差及形状、位置公差检查。
表4检验项目