WHEELS AND TYRES FOR RAILWAYS

COMMITTED TO WHEELS

Railway wheels and tyres

KLW is the wheels brand of global steel company Interpipe. Interpipe has more than seventy years of experience in manufacturing railway wheels at the companys renowned Interpipe NTRP mill in Dnepropetrovsk, Ukraine. These wheels are supplied to the customers worldwide through sales company KLW Wheelco SA (Switzerland). With annual production of over 600,000 pieces, Interpipe NTRP has a huge portfolio of over 200 products. All the products have distinctive KLW stamp insignia. KLW global network is strong with clients in 60 countries on ve continents. Years of manufacturing and supply experience enable KLW to compete successfully everywhere where there is a major railway operation. As our company has evolved we have gained over forty years of experience in partnership with railway operators in countries as far aeld as India and Australia as well as in traditionally large markets like Germany and Russia. KLW is committed to providing the highest quality railway wheels according to the specications and requirements of the customer, corresponding to strict international standards. Our products are guaranteed by the quality control and management system certied by TUV (Germany) corresponding to the norms of DIN EN ISO 9002. Quality control is enforced at all stages of product manufacturing from steel melting to the acceptance test of wheels and tyres. Our focus on reliability includes a wide range of measures including reducing residual stress and increasing durability as well as using mechanical, chemical and metallographic control measures in the Interpipe NTRP Central Laboratory. High levels of investment and R&D continue to bring signicant benets across the design, development and production of our wheels. This allows us to achieve the best results for our customers across all of the key mechanical and operational properties as well as life cycle costs. Our product portfolio has developed rapidly over the years as our business has expanded globally. Now we provide an extremely wide range of railway wheels and products to the highest international requirements, including tyres.

Range of railway wheels and tyres

Wheels
Outside diam- Inside diameter Width eter d1, d2 mm of rim H, mm D, mm 650-1269 600-1100 95-160 Diameter Height of hub d, mm of hub L, mm 185-500 90-405 Diameter of hole in hub d0, mm 60-200 Thickness of disk t1, t2, mm 15-80 Mass, kg

165-1050

Tyres
Outside diameter D, mm 690-1300 Inside diameter d, mm 550-1100 Width of rim d, mm 80-150 Width of ange h, mm 15-50 Mass, kg 100-600

List of standards
The railway wheels and tyres are exported according to the specications and requirements of the Customer, the norms of international standards, including: AAR M 107/208 ASTM A504 ASTM A551 ASTM A551-81 BN 918277 BS 5892 part 4 BS 5892, part 3: 92 BS24 IRS R 15-95 IRS R 3403 IRS R 19-93, parts 1-5 ISO 1005 JIS E 5402 KRS 2242-2107 M4T 2000 MOR-M-2001-2 NF EN 10228-3 NF F 01-111 NF F 01-115 NF F 01-131 NF F 01-33 PN-84 PN-84 H84027/06 PN91/K91032 PN-92 PN-92/K91018 pr EN 13262 RSP #SM-55/2543 SNCB A-12 TJZL 01-98 TJZL 02-99 TTS 094 TTS 248 UIC 810-1 UIC 812-1 UIC 812-3 UNI 6102

Quality Management System

ISO 9001-2000 AAR M-1003

Our approvals
AAR Freight & Locomotive Wheels DB Locomotive Wheels Railtrack Freight Car Wheels BB - Freight Car Wheels DB Freight Car Wheels PKP Freight Car Wheels SZ - Freight & Locomotive Wheels BZ - Freight & Locomotive Wheels

Production facility Interpipe NTRP

Railway wheels shop includes: z Forging-rolling line for production of wheels from 650 to 1269 mm z Forging-rolling for production of tyres z Mechanical nishing oor z Heat treatment lines z Shot blasting line z Non-destructive testing (ultrasonic, magnetic and hardness testing) z Finishing line In 2002 -2007 Interpipe invested in increase of production capacities by building new nishing and testing lines, mechanical hardening (ultrasonic, magnetic hardness testing, geometry control, mechanical operation). As a part of its strategic investment program, Interpipe has purchased equipment for the installation of a new full prole line for railway wheels machining. The automated line will include four RQQ machines, the complex of inter-machine equipment (systems for loading and unloading of wheels). The expected capacity of the automated line, which has selfoperated control for full prole railway wheel machining, is 100,000 nally machined wheels per year.

Key facts:
1935 - the rst railway wheel rolled off the production line in starting one of the most absorbing stories of modern industrial times 1970 - Interpipe NTRP wheel shop produced its 10 millionth railway wheel just 35 years after the rst one had rolled off the production line 1979 - the company started to supply wheels across Eastern Europe 1987 - new purpose-built railway wheels and tyres shop, which started to produce railway tyres 1991 - the KLW brand entered the Indian market 1996 - the rst wheels were supplied in China

Steel Making Process

Steel for the production of railway wheels and tyres is melted in the open-hearth furnaces with the charge of 250 tons and tapping in two ladles. High quality characteristics of steel are provided by the subsequent processing at the out-of-furnace complex of steel treatment. The ladles with metal are delivered in turn to the unit furnace-ladle, where the metal nishing and rening takes place. Steel blowing in the ladle by argon along with the rening process provide for the sulphur content in the nished metal equal to 0.010% phosphorus 0.015% and less, and uniform distribution of another elements. Degassing process is effected by means of removing the hydrogen, nitrogen, oxygen dissolved in metal at the vacuum degassing set simultaneously with argon blowing. Hydrogen content in steel is within the limits up to 2 ppm.

The Technology of the Production of Railway Wheels

1 2 3 4

Open-hearth furnace 5

Ladle 6

Ladle-furnace 7

Vacuum degassing set 8

Bottom pouring 9

Notching and breaking of ingot into initial billets 10

Billets inspection and repairing 11

Billets heating in the rotary furnace 12

Hydroscaling of cinder 13

Open forging on the press 20MN 14

Closed forging on the press 50MN 15

Punching on the press 100MN 16

Wheel rolling on the rolling mill 17

Wheel calibration on the press 35/8 MN and piercing of central hole 18

Intermediate cooling and anti-oking isometric holding 19

Cooling of the wheel in open air 20

Machining
8

Wheels heating 22

Rim quenching 23

Tempering in pit in the furnaces 24

21

Adjustable cooling

CNC machining, imbalance checking

Automated non-destructive control (ultrasonic test, magnetic particle inspection etc)

Wheels inspection and measuring, hardness determination

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26

Testing of mechanical and other properties on the samples

Storage

The Technology of the Production of Railway Tyres

1 2 3 4

Open-hearth furnace 5

Ladle 6

Ladle-furnace 7

Vacuum degassing set 8

Bottom pouring 9

Notching and breaking of ingot into initial billets 10

Billets inspection and repairing 11

Billets heating in the rotary furnace 12

Hydroscaling of cinder 13

Open forging on the press 20MN 14

Weighing 15

Punching and closed piercing 16

Piercing 17

Rolling on one or two mills 18

Marking 19

Hot dressing 20

Thermal treatment (anti-ocking, hardening with tempering or normalizing) 21

Non-destructive control (hardness, ultrasonic test)

Selection of the samples and holding of all testing on the samples

Inspection and measuring

9

Storage

Products Quality Control

High quality characteristics of the products corresponding to the requirements of international standards, are guaranteed by the system of quality control and management certied by the rm TV (Germany) for correspondence to the norms of DIN EN ISO 9002. Quality control is effected at all the stages of product manufacturing from steel melting to the acceptance test of the wheels and tyres: z Control of the chemical composition of rawmaterials, steel during melting process, ready rolled-stock is effected on the spectrometers Polyvac 2000 type z Control of hydrogen content in liquid steel is effected before and after vacuum degassing using sound determination by HYDRIS device of company Heraeus Elecro-Nite z Control of nitrogen, oxygen, hydrogen content is performed at the devices PH-402 and TS-236 of the rm Leco z 100% automated Ultrasonic test as well as magnetic particle of ready products, is effected to determine the presence of internal defects inspection z Control of the hardness on the rim surface of the wheels and tyres is realized during the production using durometer of EMCO company z Metal testing for elongation is realized at the machine UTS-600-1 with microcomputer control and automatic registration of parameters and printing-out of the results z Pendulum testing impact machine Psd 50/15 of Wpm Werkstoffprufmaschinen GmbH company is used to determine the impact strength of steel z The determination of steel toughness K1C according to the ASTM-E 300 is effected on the universal computerized testing machine Hydropuls Sinus 250 by company Carl Schenk z By the request of the customers the testing of wheels and tyres by the falling weight or static compression, as well as the control of micro and macro structure and nature of stresses are made by the up-to-date methods

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Countries supplied to:

Argentina Armenia Australia Austria Azerbaijan Bangladesh Belgium Brazil Bulgaria Byelorussia Canada Chile China Croatia Egypt Finland France Georgia Germany Greece Hungary India Indonesia Iran Italy Kazakhstan Kenya Kirghizstan Korea, North Korea, South Latvia Lithuania Macedonia Malaysia Mauritania Moldova Poland Netherlands Norway Romania Russia South Africa Slovakia Slovenia Spain Sri-Lanka Sweden Switzerland Tajikistan Tanzania Thailand Tunisia Turkey Turkmenistan Ukraine United Kingdom Uruguay USA Uzbekistan Vietnam Yugoslavia Zambia

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