EN 13261-2009 Engleza

EUROPEAN STANDARD EN 13261
NORME EUROPENNE
EUROPISCHE NORM March 2009
ICS 45.040 Supersedes EN 13261:2003
English Version
Railway applications - Wheelsets and bogies - Axles - Product

requirements
Applications ferroviaires - Essieux monts et bogies - Bahnanwendungen - Radstze und Drehgestelle -

Essieux-axes - Prescriptions pour le produit Radsatzwellen - Produktanforderungen
This European Standard was approved by CEN on 29 November 2008.
CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European
Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national
standards may be obtained on application to the CEN Management Centre or to any CEN member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by translation
under the responsibility of a CEN member into its own language and notified to the CEN Management Centre has the same status as the
official versions.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland,
France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal,
Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION

COMIT EUROPEN DE NORMALISATION
EUROPISCHES KOMITEE FR NORMUNG
Management Centre: Avenue Marnix 17, B-1000 Brussels
2009 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 13261:2009: E
worldwide for CEN national Members.
EN 13261:2009 (E)
Contents Page
Foreword..............................................................................................................................................................5
Introduction .........................................................................................................................................................6
1 Scope ......................................................................................................................................................7
2 Normative references ............................................................................................................................7
3 Product definition ..................................................................................................................................8
3.1 Chemical composition ..........................................................................................................................8
3.1.1 Values to be achieved ...........................................................................................................................8
3.1.2 Location of sample ................................................................................................................................8
3.1.3 Chemical analysis..................................................................................................................................8
3.2 Mechanical characteristics ...................................................................................................................9
3.2.1 Characteristics from tensile test ..........................................................................................................9
3.2.2 Impact test characteristics .................................................................................................................10
3.2.3 Fatigue characteristics........................................................................................................................13
3.3 Microstructure characteristics ...........................................................................................................14
3.3.1 Values to be achieved .........................................................................................................................14
3.3.2 Location of the test piece ...................................................................................................................15
3.3.3 Test method..........................................................................................................................................15
3.4 Material cleanliness .............................................................................................................................15
3.4.1 Micrographic cleanliness....................................................................................................................15
3.4.2 Internal integrity...................................................................................................................................16
3.5 Permeability to ultrasound .................................................................................................................17
3.5.1 General..................................................................................................................................................17
3.5.2 Level to be achieved............................................................................................................................17
3.5.3 Test piece .............................................................................................................................................17
3.5.4 Test method..........................................................................................................................................17
3.6 Residual stresses ................................................................................................................................17
3.6.1 General..................................................................................................................................................17
3.6.2 Values to be achieved .........................................................................................................................18
3.6.3 Test piece and position of measurement points ..............................................................................18
3.6.4 Measurement method..........................................................................................................................18
3.7 Surface characteristics .......................................................................................................................18
3.7.1 Surface finish .......................................................................................................................................18
3.7.2 Surface integrity...................................................................................................................................21
3.8 Geometrical and dimensional tolerances .........................................................................................22
3.9 Protection against corrosion and against mechanical aggression................................................27
3.9.1 Final protection ....................................................................................................................................27
3.9.2 Temporary protection..........................................................................................................................31
3.10 Marking .................................................................................................................................................31
Annex A (normative) Particular characteristics for axles of steel grade EA1T and EA4T ........................33
A.1 Chemical composition ........................................................................................................................33
A.2 Mechanical characteristics .................................................................................................................33
A.2.1 Characteristics from tensile test ........................................................................................................33
A.2.2 Impact test characteristics .................................................................................................................33
A.2.3 Fatigue characteristics........................................................................................................................34
A.3 Metallographic characteristics ...........................................................................................................34
Annex B (normative) Standard wedge for measurement of permeability to ultrasound ...........................35
B.1 Test piece .............................................................................................................................................35
B.2 Tolerances of the wedge.....................................................................................................................35
B.3 Steel grade............................................................................................................................................35
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EN 13261:2009 (E)
Annex C (normative) Method to assess resistance to impact of the coating.............................................36

C.1 Principle................................................................................................................................................36
C.2 Test piece .............................................................................................................................................36
C.3 Apparatus .............................................................................................................................................36
C.4 Procedure .............................................................................................................................................36
C.5 Expression of results ..........................................................................................................................36
Annex D (normative) Method to assess resistance to gritting of the coating ............................................37
D.1 Principle................................................................................................................................................37
D.2 Test piece .............................................................................................................................................37
D.3 Apparatus .............................................................................................................................................37
D.4 Procedure .............................................................................................................................................37
D.5 Expression of results ..........................................................................................................................37
Annex E (normative) Method to assess the resistance of the coating to specific corrosive
products ...............................................................................................................................................38
E.1 Principle................................................................................................................................................38
E.2 Test piece .............................................................................................................................................38
E.3 Apparatus .............................................................................................................................................38
E.4 Corrosive products .............................................................................................................................38
E.5 Procedure .............................................................................................................................................38
E.6 Expression of results ..........................................................................................................................39
Annex F (normative) Method to assess the resistance of the coating to cyclic mechanical
stresses ................................................................................................................................................40
F.1 Purpose ................................................................................................................................................40
F.2 Principle................................................................................................................................................40
F.3 Test piece .............................................................................................................................................40
F.4 Apparatus .............................................................................................................................................40
F.5 Procedure .............................................................................................................................................40
F.6 Expression of results ..........................................................................................................................41
Annex G (normative) Measurement of the hydrogen content in the steel for axles at the melting
stage .....................................................................................................................................................42
G.1 Sampling...............................................................................................................................................42
G.2 Analysis methods................................................................................................................................42
G.3 Precautions ..........................................................................................................................................42
Annex H (informative) Drawings of test pieces..............................................................................................43
Annex I (informative) Product qualification....................................................................................................45
I.1 Introduction..........................................................................................................................................45
I.2 General .................................................................................................................................................45
I.3 Requirements.......................................................................................................................................45
I.3.1 Requirements to be met by the supplier...........................................................................................45
I.3.2 Requirements to be met by the product ...........................................................................................46
I.4 Qualification procedure ......................................................................................................................46
I.4.1 General .................................................................................................................................................46
I.4.2 Documentation required .....................................................................................................................46
I.4.3 Evaluation of the manufacturing plant and of the production processes.....................................47
I.4.4 Laboratory tests ..................................................................................................................................47
I.5 Qualification certificate.......................................................................................................................47
I.5.1 Condition of validity ............................................................................................................................47
I.5.2 Modification and extension ................................................................................................................48
I.5.3 Transference ........................................................................................................................................48
I.5.4 Lapsed certification.............................................................................................................................48
I.5.5 Cancellation .........................................................................................................................................48
I.6 Qualification file...................................................................................................................................48
Annex J (informative) Product delivery ..........................................................................................................49
J.1 Introduction..........................................................................................................................................49
J.2 General .................................................................................................................................................49
J.3 Delivery condition ...............................................................................................................................50
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J.4 Controls on each axle .........................................................................................................................50

J.5 Batch control........................................................................................................................................50
J.5.1 Controls ................................................................................................................................................50
J.5.2 Permeability to ultrasound .................................................................................................................51
J.5.3 Surface finish .......................................................................................................................................52
J.5.4 Visual examination ..............................................................................................................................52
J.6 Quality plan ..........................................................................................................................................52
J.6.1 General..................................................................................................................................................52
J.6.2 Purpose.................................................................................................................................................52
J.6.3 Application of the quality plan ...........................................................................................................52
J.7 Allowable rectification.........................................................................................................................53
Annex ZA (informative) Relationship between this European Standard and the Essential
Requirements of Council Directive 96/48/EC of 23 July 1996 on the interoperability of the
trans-European high-speed rail system amended by Directive 2004/50/EC of 29 April 2004......54
Annex ZB (informative) Relationship between this European Standard and the Essential
Requirements of Directive 2001/16/EC of the European Parliament and of the Council of
19 March 2001 on the interoperability of the trans-European conventional rail system
amended by Directive 2004/50/EC of 29 April 2004..........................................................................55
Bibliography ......................................................................................................................................................57
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EN 13261:2009 (E)
Foreword
This document (EN 13261:2009) has been prepared by Technical Committee CEN/TC 256 Railway
applications, the secretariat of which is held by DIN.
This European Standard shall be given the status of a national standard, either by publication of an identical
text or by endorsement, at the latest by September 2009, and conflicting national standards shall be
withdrawn at the latest by September 2009.
Attention is drawn to the possibility that some of the elements of this document may be the subject of patent
rights. CEN and/or CENELEC shall not be held responsible for identifying any or all such patent rights.
This document supersedes EN 13261:2003.
This document has been prepared under a mandate given to CEN/CENELEC/ETSI by the European
Commission and the European Free Trade Association, and supports essential requirements of EU Directives
96/48/EC and 2001/16/EC, amended by Directive 2004/50/EC.
For relationship with EU Directives 96/48/EC and 2001/16/EC, see informative Annex ZA and ZB, which are
integral parts of this document.
According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following
countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Cyprus, Czech
Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia,
Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain,
Sweden, Switzerland and the United Kingdom.
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EN 13261:2009 (E)
Introduction
Normative documents which have been used until now in Europe for axle delivery (UIC leaflets, national
standards) had, for the main purpose, a complete definition of delivery procedures and axle characteristics
that were to be measured.
Product qualification was sometimes mentioned, but the procedures and the characteristics that had to be
verified for the qualification were not given.
This standard addresses these issues by:
a) definition of all axle characteristics; these are verified either during qualification or delivery of the product
(see clause 3);
b) definition of qualification procedures (see Annex I);
c) definition of delivery conditions (see Annex J); here, a choice is given to the supplier of either:
1) a traditional delivery procedure with a control by batch sampling as in existing documents (see J.5),
or;
2) a delivery procedure using quality assurance concepts (see J.6).
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EN 13261:2009 (E)
1 Scope
This European Standard specifies the characteristics of axles for use on European networks.
It defines characteristics of forged or rolled solid and hollow axles, made from vacuum-degassed steel grade
EA1N1 that is the most commonly used grade on European networks. For hollow axles, this standard applies
only to those that are manufactured by machining of a hole in a forged or rolled solid axle
In addition, the particular characteristics for axles in grade EA1T1 and EA4T1 are given in Annex A.
Two categories of axle are defined, category 1 and category 2. Generally, category 1 is chosen when the
operational speed is higher than 200 km/h.
This standard is applicable to axles that are designed in accordance with the requirements of EN 13103 and
EN 13104.
NOTE Different values for some characteristics may be agreed if a particular process of fabrication (e.g. cold rolling,
shot peening) has an influence on them.
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.
EN 10002-1, Metallic materials Tensile testing Part 1: Method of test at ambient temperature
EN 10045-1, Metallic materials Charpy impact test Part 1: Test method
EN 13103, Railway applications Wheelsets and bogies Non-powered axles Design method
EN 13104, Railway applications Wheelsets and bogies Powered axles Design method
EN 13260, Railway applications Wheelsets and bogies Wheelsets Product requirements
EN 20898-2:1993, Mechanical properties of fasteners Part 2: Nuts with specified proof load values
Coarse thread (ISO 898-2:1992)
EN 22768-1, General tolerances Part 1: Tolerances for linear and angular dimensions without individual
tolerance indications (ISO 2768-1:1989)
EN 22768-2, General tolerances Part 2: Geometrical tolerances for features without individual tolerance
indications (ISO 2768-2:1989)
EN ISO 643:2003, Steels Micrographic determination of the apparent grain size (ISO 643:2003)
EN ISO 2409:2007, Paints and varnishes Cross-cut test (ISO 2409:2007)
1 N for a normalized metallurgical condition

T for a quenched and tempered metallurgical condition
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EN 13261:2009 (E)
EN ISO 2808:2007, Paints and varnishes Determination of film thickness (ISO 2808:2007)
EN ISO 9227:2006, Corrosion tests in artificial atmospheres Salt spray tests (ISO 9227:2006)
EN ISO 14284:2002, Steel and iron Sampling and preparation of samples for the determination of
chemical composition (ISO 14284:1996)
ISO 4967:1998, Steel Determination of content of non-metallic inclusions Micrographic method using
standard diagrams
ISO 5948:1994, Railway rolling stock material Ultrasonic acceptance testing
ISO 6933:1986, Railway rolling stock material Magnetic particle acceptance testing
.
ISO/TR 97692 Steel and iron Review of available methods of analysis.
3 Product definition
3.1 Chemical composition
3.1.1 Values to be achieved
The maximum percentage contents of the various elements are given in Table 1.
Table 1 Limit values by product analysis (%)
C Si Mn Pa S ab Cr Cu Mo Ni V
0,40 0,50 1,20 0,020 0,020 0,30 0,30 0,08 0,30 0,06
a A maximum content of 0,025 % may be agreed at the time of enquiry and the order.
b A minimum sulfur content may be agreed at the time of enquiry and the order according to the steelmaking process, in order to
safeguard against hydrogen embrittlement.
3.1.2 Location of sample
The test sample shall be taken at mid-radius of solid axles or at mid-distance between external and internal
surfaces of hollow axles.
3.1.3 Chemical analysis
The chemical composition analysis shall be performed according to the methods and definitions described in
ISO/TR 9769.
2 See also CEN/TR 10261.
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EN 13261:2009 (E)
3.2 Mechanical characteristics
3.2.1 Characteristics from tensile test
3.2.1.1 Values to be achieved
The values to be achieved at mid-radius of solid axles or at mid-distance between external and internal
surfaces of hollow axles are given in Table 2.
The values to be achieved near the external surface shall be greater than or equal to 0,95 times the values
measured at mid-radius of solid axles or at the mid-distance between external and internal surfaces of hollow
axles.
The values to be achieved in the centre of solid axles or near the internal surface of hollow axles shall be
greater than or equal to 0,8 times the values measured at mid-radius or at mid-distance between external and
internal surfaces.
Table 2 Values to be achieved at mid-radius of solid axles or at mid-distance between external and
internal surfaces of hollow axles
ReH(N/mm)a Rm (N/mm) A5%
320 550-650 22
a If no distinctive yield strength is present, the proof stress R
p0,2 shall be determined.
3.2.1.2 Location of test pieces
The test pieces shall be taken from three levels in the largest axle section:
1) as near as possible to the external surface for all the axles;
2) at mid-radius and in the centre of solid axles;
3) at mid-distance between external and internal surfaces, and near the internal surface of hollow axles
as shown in Figure 1 a) and b).
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EN 13261:2009 (E)
Dimensions in millimetres
1a) Solid axle
1b) Hollow axle
Figure 1 Location of test pieces
3.2.1.3 Test method
The test shall be carried out in accordance with EN 10002-1. The test piece diameter shall be at least 10 mm
in the machined-down portion. The gauge length shall be five times the diameter.
3.2.2 Impact test characteristics
Impact test characteristics shall be determined at 20 C in the longitudinal and the transverse directions.
Values to be achieved at mid-radius of solid axles, or at mid-distance between external and internal surfaces
of hollow axles, are given in Table 3.
Near the surface, they shall be greater than or equal to 0,95 times the values measured at mid-radius or at
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EN 13261:2009 (E)
mid-distance between external and internal surfaces of hollow axles.
In the centre of solid axles or near the internal surface of hollow axles, they shall be greater than 0,8 times
the values measured at mid-radius or at mid-distance between external and internal surfaces.
For each level (surface, mid-radius, centre), the average value of the 3 test pieces (see 3.2.2.2) is defined in
Table 3.
No individual value shall be less than 70 % of the values in Table 3.
Table 3 Values to be achieved at mid-radius or at mid-distance between external and internal

surfaces of hollow axles
KU longitudinal (J) KU transverse (J)
30 20
3.2.2.2 Location of test pieces
The test pieces shall be taken from three levels in the largest axle section:
1) as near as possible to the external surface for all the axles;
2) at mid-radius and in the centre of solid axles;
3) at mid-distance between external and internal surfaces, and near the internal surface of hollow axles
as shown in Figure 2a) and 2b).
3.2.2.3 Test method
The test shall be carried out in accordance with EN 10045-1.
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EN 13261:2009 (E)
2a) Solid axle
2b) Hollow axle
Key
1 longitudinal test piece
2 transverse test piece
Figure 2 Location of test pieces
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EN 13261:2009 (E)
3.2.3 Fatigue characteristics
3.2.3.1 General
3.2.3.1.1 Introduction
Verification of the fatigue characteristics is essential in order to have a correctly dimensioned axle. The
satisfactory performance of an axle in service depends upon these characteristics. The values defined in this
subclause are used for the calculation of the maximum permissible stresses that are referred to in the design
rules in EN 13103 and EN 13104.
It is necessary to estimate the fatigue limits in the following two areas, in order to predict the behaviour of the
axle under in-service stresses:
1) for the material, tests are made on reduced test pieces, for which the shapes do not depend upon the
product geometry;
2) for the product, tests are made on full size test pieces, for which the dimensions and manufacture are
similar to the final product and its associated permissible fabrication defects.
3.2.3.1.2 Fatigue limits on reduced test pieces
The fatigue limits defined with reduced test pieces are used to verify that the notch effect of the material used
for the fabrication of the axle is in accordance with the security coefficient "S" defined in design standards
EN 13103 and EN 13104. They are determined from:
unnotched surface test pieces (fatigue limit RfL );
notched test pieces (fatigue limit RfE).
3.2.3.1.3 Fatigue limits on full size test pieces
The limits determined on full size test pieces are used to verify that the axle fatigue characteristics are in
accordance with those that are used to calculate the maximum permissible stresses referred to in design
standards EN 13103 and EN 13104.
These fatigue limits apply to different axle areas. Only the fatigue limits applying to the axle body are taken
into account in this standard. The limits applying to the wheelset depend mostly on the assembly and are
referred to in EN 13260.
It is necessary to define two fatigue limits:
on the body surface, limit F1;
on the bore surface in the case of a hollow axle, limit F2.
The values to be achieved are given in Table 4.
Table 4 Fatigue limit values
Limit F1 F2 RfL RfE q=RfL/RfE
Value 200 N/mm 80 N/mm 250 N/mm 170 N/mm 1,47
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EN 13261:2009 (E)
3.2.3.3 Fatigue test pieces
For F1 and F2 determination, the test piece areas where the cracks initiate shall have a similar geometry and
surface roughness to those of the axle areas that have to be analysed. For F2 determination, the test piece
surface shall have a 1 mm deep notch as shown in Figure 3b. All of these test pieces shall come from the
same fabrication process as that for the axle.
For RfL and RfE determination, the test piece diameter is around 10 mm in the area where the crack initiates.
The roughness (Ra) of the test piece for RfL determination is less than or equal to 0,4 m. The notch for RfE
determination is shown in Figure 3a. These test pieces are located as near as possible to the surface of the
axle body.
3 a) Notch for determination of RfE 3 b) Notch for determination of F2
Figure 3 Fatigue test piece notches
Examples of drawings of full-size and reduced dimension test pieces are given in Annex H.
3.2.3.4 Test method
The tests shall be performed with machines that induce rotating bending stresses in the area where it is
required to initiate a fatigue crack.
7
For each limit, F1 and F2, it shall be verified that for three test pieces there is no crack after 10 cycles of load
that generates a surface stress level equal to F1 and F2. The values of the stresses are calculated by classical
beam theory where it may be applied. If not, the stresses shall be measured by strain gauges in the areas
where the fatigue cracks initiate.
RfL and RfE shall be determined for 107 cycles for a non-fracture probability of 50 %, which requires the use of
at least 15 test pieces for each limit and a statistical method for the interpretation of the results.
3.3 Microstructure characteristics
The microstructure shall be one of ferrite and pearlite. The grain size shall not be greater than that defined by
the reference diagram 5 in Annex B of EN ISO 643:2003.
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EN 13261:2009 (E)
3.3.2 Location of the test piece

2
The test pieces shall be taken from the largest axle section in a 200 mm plane, perpendicular to arrow F, at
mid-radius of solid axles, or at mid-distance between external and internal surface of hollow axles, as shown
in Figure 4.
3.3.3 Test method
Tests shall be performed in accordance with EN ISO 643.
3.4 Material cleanliness
3.4.1 Micrographic cleanliness
3.4.1.1 Cleanliness level to be achieved
The level of cleanliness shall be measured by micrographic examination as defined in 3.4.1.2 and 3.4.1.3. The
maximum values of inclusions to be obtained are given in Table 5.
Table 5 Maximum values of inclusions in thin and thick series
Type of inclusions Category 1 Category 2

Thick series Thin series Thick series Thin series
(maximum) (maximum) (maximum) (maximum)
A (Sulfur) 1,5 1,5 1,5 2

B (Aluminate) 1 1,5 1,5 2
C (Silicate) 1 1,5 1,5 2
D (Globular oxide) 1 1,5 1,5 2
B+C+D 2 3 3 4
3.4.1.2 Location of the micrographic sample
The examination field is given in Figure 4.
The examination shall be made in a 200 mm plane, perpendicular to arrow F, at mid-radius of the solid axles,
or at mid-distance between external and internal surface of hollow axles. The test pieces shall be taken from
the largest axle section.
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EN 13261:2009 (E)
Figure 4 Location of sample for micrographic examination
3.4.1.3 Test method
Cleanliness level determination shall be carried out in accordance with ISO 4967:1998, method A.
3.4.2 Internal integrity
3.4.2.1 General
Internal integrity shall be determined by ultrasonic examination. Standard defects shall be flat bottom holes at
different depths.
3.4.2.2 Level to be achieved
The axles shall have no internal defects that give echo magnitudes equal to or greater than those obtained for
a standard defect situated at the same depth. The diameter of this standard defect shall be 3 mm. No
attenuation of the back echo higher than 4 dB due to non-homogenates or internal defects shall be accepted.
3.4.2.3 Test piece
The examination shall be made on the axle itself after heat treatment and in the delivery condition before the
final protection is applied.
3.4.2.4 Method of examination
The axle internal integrity is verified by ultrasonic diametral examination according to method Da of
ISO 5948:1994. The whole axle shall be examined, except certain parts (fillets, grooves, etc.) after agreement
between the customer and the supplier.
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EN 13261:2009 (E)
3.5 Permeability to ultrasound
3.5.1 General
The permeability shall ensure the feasibility of ultrasonic testing during service and is verified by producing a
record for the axle after a preliminary calibration of the testing apparatus.
3.5.2 Level to be achieved
The echo obtained on the axles being checked shall have an amplitude equal to or greater than 50 % of full
screen height, after preliminary calibration of the apparatus on the standard wedge described in Annex B. The
height of the background noise shall be less than 10 % of the screen height.
3.5.3 Test piece
The test piece to be examined shall be the axle, after full heat treatment.
The condition of the journal ends, at the moment of inspection, shall be the same as that required for delivery,
without protection.
3.5.4 Test method
The ultrasonic permeability examination shall be performed by longitudinal checking of the axle according to
method T of ISO 5948:1994.
If the tests are not performed by an automated process, the measurement shall be performed at a minimum of
6 points, equally distributed around the axle journal section.
The probes used are the piezoelectric type, transmitter and receiver, in quartz or barium titrate BaTi with
2 2
round or rectangular sections (between 80 mm and 450 mm ). Their frequency and the height of the echo
obtained in front of the flat bottom of diameter 1 mm are described in Table 6 for each category of axle. The
noise during the calibration shall not exceed 5 % of the full screen height.
For this test, the instrument shall operate with narrow frequency bands centred on the nominal frequencies
"Fn" so that the band is between Fn - 20% and Fn + 20%, for an attenuation of 3 dB in relation to the frequency
signal Fn.
Table 6 Calibration for permeability examination
Category 1 Category 2
Frequency Fn 5 MHz 2 MHz to 3 MHz
Conditions for calibration 90 % 40 %
(% of full screen height)
For other types of probes, an agreement between the customer and the supplier is required in order to define
the calibration and results to be achieved.
3.6 Residual stresses
3.6.1 General
The different fabrication phases shall not create residual stresses that can cause in-service deformations of
axles or facilitate fatigue crack initiation.
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EN 13261:2009 (E)

2
On the axle surface, residual stresses shall be less than or equal to +100 N/mm .
The difference between residual stress values measured at two different points 2 mm under the surface shall
2
be 40 N/mm .
3.6.3 Test piece and position of measurement points
The test piece shall be the axle in the delivery condition. The position of measurement points is given in
Figure 5.
Sections 1 and 2 Section 3
Figure 5 Position of measurement points
3.6.4 Measurement method
The measurements shall be made either with strain gauges or by X-ray diffraction. The method shall be
agreed between the customer and the supplier.
3.7 Surface characteristics
3.7.1 Surface finish
3.7.1.1 Characteristics to be achieved
The axle surface shall not show any other marks than those stipulated in this standard.
The surface roughness (Ra) is given in Table 7. The symbols are those defined in Figure 6.
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EN 13261:2009 (E)
Table 7 Surface finish
Surface roughness a Ra (m)
Designation Symbol
(see Figure 6) Rough-machined Finished or ready for

assembly
End of the axle
- axle end and chamfer
a - 6,3
- axle centre face (solid and See details - 3,2
hollow axle)
R1 and R2
Journal
- journal diameter
b 12,5 0,8
- stress relieving grooves c (detail V) 0,8
Abutment
- abutment diameter
d 12,5 1,6
Wheelseat
- wheelseat diameter
e 12,5 Minimum 0,8
Maximum 1,6 c
- lead in taper f (detail U) 1,6
Body
- inner transitional radii to wheelseat
g (detail T) - 1,6
- axle body diameter l 3,2 b
- gearwheel, seat and brake disc seat h 12,5 Minimum 0,8

diameter
Maximum 1,6 c
- bearing seat and seal seat diameter j 12,5 0,8
- transitional radii between two seats k (detail S) 1,6
Bore
- bore diameter
m 3,2 c
(detail R1)
a For old axle types with plain bearing journals, the requirements are in the standards that deal with these products.
b 6,3 may be agreed if fatigue limits F and F defined in 3.2.3.2 and the sensitivity required for the in-service ultrasonic
1 2
control are achieved.
c In-service Non-Destructive Examination may require smaller values of surface finish, e.g. Ra 2 m for the bore.
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EN 13261:2009 (E)
Figure 6 Symbols for surface finish
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EN 13261:2009 (E)
3.7.1.2 Measurement method
The mean roughness of the axle surfaces (Ra) in their delivery condition, given in Table 7, shall be measured
with a roughness test apparatus. In fillet radii, the roughness may be evaluated by comparison with tactile and
visual specimens agreed between the customer and the supplier.
3.7.2 Surface integrity
3.7.2.1 General
Surface integrity of the axles shall be determined by a magnetic particle test for the external surfaces and by
an ultrasonic examination or an equivalent method, agreed between the customer and the supplier, for the
bore surface of hollow axles.
3.7.2.2 Level to be achieved
On the external surface of the axle:
transverse defects are not permissible;
longitudinal defects are acceptable outside z0 zones (see Figure 7), provided they are within the limits
given in Table 8 (see also J.7).
A defect shall be considered as a longitudinal defect if its inclination with the axle centreline is less than 10.
Figure 7 Zones
On the bore surface of the hollow axles, transverse defects are permitted if they are no more than 0,5 mm
deep and if there is not more than one per metre of axle length.
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EN 13261:2009 (E)
Table 8 Longitudinal defect limits
Category 1 Category 2
Maximum length Maximum Maximum length Maximum

Zones
of an isolated defecta cumulative of an isolated defecta cumulative
length of isolated length of isolated
defects defects
z0 0 0 0 0
z1 6 mm 6 mm 6 mm 6 mm
z2 6 mm 15 mm 6 mm 15 mm
z3
6 mm 15 mm 10 mm 30 mm
a Defects are to be considered as isolated when the space between two of them, located on the same circumferential
line, is more than 10 mm.
3.7.2.3 Test piece
The test piece shall be the axle itself, after heat treatment, in the finish-machined condition defined by the
purchase order and before the application of the protection.
3.7.2.4 Methods of examination
3.7.2.4.1 External surface of the axle
The general conditions of the magnetic particle test are given in ISO 6933, except for:
the surface magnetic flux, which shall be greater than 4 mT;
the lighting energy of ultra-violet light, which shall be greater than 15 W/m.
The magnetization methods are those described in ISO 6933:
circumferential magnetization for longitudinal defect investigation (see Figure "a" of ISO 6933:1986);
axial magnetization for transverse defect investigation (see Figure "b" of ISO 6933:1986).
3.7.2.4.2 Bore surface of the axle
The method shall be agreed between the customer and the supplier. Unless otherwise specified,
45-incidence ultrasonic examination from the external surface is to be undertaken.
3.8 Geometrical and dimensional tolerances
Geometrical tolerances are given in Table 9. The symbols used are defined in Figure 8.
Dimensional tolerances are given in Table 10. The symbols used are defined in Figure 9.
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EN 13261:2009 (E)
Table 9 Geometrical tolerances

ab
Designation Symbol Geometrical tolerances
(see Figure 8) (mm)
Rough- Ready for assembly
machined
Journal and abutment n

Cylindricity 0,015
Run out of the vertical face of the
abutment relative to the reference Y-Z 0,03
Run out of the abutment relative to the
reference Y-Z 0,03
Wheelseat p
c
Run out relative to the reference Y-Z 1,5 0,03
Cylindricity 0,1 0,015
Gearwheel seat q
c
Motor bearing seats r
c
Run out relative to the reference Y-Z
0,1 0,015
Disk brake seat s
c
Axle body t
c
Run out relative to the reference Y-Z 0,5
d
Bore u
Concentricity relative to the reference 0,5
c
Y-Z
Holes for fixing axle end caps v
Concentricity relative to the reference 0,5
c
Y-Z
Machining centre run out relative to the w1 0,02
c
reference Y-Z w2 0,03
(details R1/R2)
a
For parameters which do not have a tolerance in this table, the general tolerances of EN 22768-2 shall be
applied.
b
For old axle types with plain bearing journals, the requirements are in the standards that deal with these
products.
c
Reference axis: the reference axis is taken from the axle journals, identified as Y-Z in Figure 8.
d
0,3 mm for category 1 axles.
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EN 13261:2009 (E)
Figure 8 Geometrical tolerance symbols
24
EN 13261:2009 (E)
Table 10 Dimensional tolerances

a
Symbol Dimensional tolerances
(mm)
Designation (see Figure 9)
Rough- Ready for
machined assembly
Longitudinal sizes
b
- Length of axle A +2 / 0 1
- Length of wheelseat (including collar) B +2 / 0 0 /- 0,5

d
- Length over abutments (between C +2 / 0 0,5
reference planes)
- Journal bearing seat length D 0 / -2 +1 / 0
Diameters
c
- Diameter of journal H +2 / 0
c
- Wheelseat diameter K +2 / 0
c
- Diameter of seats of gear wheel, or brake J +2 / 0
disc, or plain seal spacer, or bearing seat
for motor suspension or motor drive roller
bearing seat
- Abutment diameter N +2 / 0 0,25
- Diameter of body P +4 / 0 +2/ 0
- Diameter of bore O - 1
a
For parameters that do not have a tolerance defined in this table, the general tolerances of EN 22768-1 shall be
applied.
b
Attention is drawn to the fact that compliance with tolerances over the total length "A" does not allow all the individual
tolerances to be cumulatively applied to the particular dimensions.
c
According to the requirements of the drawing or documents accompanying the order.
d
Other geometries may be proposed and defined in the order.
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EN 13261:2009 (E)
Key
1 reference surfaces
Figure 9 Dimensional tolerance symbols
26
EN 13261:2009 (E)
3.9 Protection against corrosion and against mechanical aggression
3.9.1 Final protection
3.9.1.1 General
All axles in service shall be protected against corrosion for the areas where there are no fitted components.
For some axles, it is necessary to have protection against mechanical aggression (impacts, gritting, etc.).
Four classes of protection are defined, according to the use of the axle and the maintenance policy that is
applied to the axle:
class 1: sections of axles that are subject to atmospheric corrosion and to mechanical impacts;
class 2: sections of axles that are subject to the action of specific corrosive products;
class 3: sections of axles that are subject to atmospheric corrosion;
class 4: axles that are subject to atmospheric corrosion when the stresses calculated according to
EN 13103 and EN 13104 in the sections that are subject to atmospheric corrosion are less than 60 % of
the permissible stresses;
different classes are permitted on the same axle.
The choice between these four classes shall be defined in the order unless other requirements are defined.
Some areas of an axle protected by a class 1 or class 3 coating can be requested with a class 2 coating.
The protective coatings for each class are, as a minimum, defined by the following characteristics given in
Table 11. Other characteristics may also be required in the order according to particular conditions of
utilization of the axles. The tests shall be carried out several days after the application of the coating,
depending on the paint system and the recommendations of the paint supplier. In the absence of any
information, a period of 14 days after the application of the coating may be adopted.
The bore surface of hollow axles shall be protected against corrosion using a product whose properties are
specified by the customer and the supplier.
Table 11 Protective coatings
Class 1 Class 2 Class 3 Class 4
Coating thickness X X X -
Coating adhesion X X X -
Resistance to impacts X - - -
Resistance to gritting X X X -
Resistance to salt spray X X X -
Resistance to specific corrosive X
- - -
products
Coating resistance to cyclic X X X -
mechanical stresses
NOTE Particular attention should be paid to the environmental impact of the paint system used. In order to avoid the
emission of volatile organic components (VOC), water-based paints are recommended. In this case, the surface
preparation and specific application requirements should be defined by the customer and supplier in order to meet the
requirements of this standard.
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EN 13261:2009 (E)
3.9.1.2 Coating thickness
3.9.1.2.1 Values to be achieved
Unless the order includes special requirements, the minimum coating thickness shall be that which was
recorded and found satisfactory during the "axle" product qualification.
3.9.1.2.2 Test piece
The test piece shall be the axle covered with its coating.
3.9.1.2.3 Method of measurement
The measurement shall be carried out by the 6 Ba method of EN ISO 2808:2007, provided that the thickness
of the coating permits this. If not, it is to be agreed between the customer and the supplier.
3.9.1.3 Coating adhesion
3.9.1.3.1 General
The adhesion is a characteristic of all adhesive forces applied between the coating and the axle surface.
3.9.1.3.2 Characteristics to be achieved
For a coating thickness of up to 250 m, the appearance shall comply with classification 1 of
EN ISO 2409:2007, after incisions and coating wrench tests.
For a coating thickness greater than 250 m, the adhesion characteristic shall be agreed between the
customer and the supplier.
The test piece shall be the axle or an axle section covered with the coating to be evaluated.
3.9.1.3.4 Test method
For a coating thickness of up to 250 m, the test method shall be that recommended by EN ISO 2409.
For a coating thickness greater than 250 m, EN ISO 2409 cannot be applied, therefore the test method shall
be agreed between the customer and the supplier.
3.9.1.4 Resistance to impacts
3.9.1.4.1 General
This characteristic defines the ability of the coating to protect the axle from damage due to impacts from
projectiles, e.g. ballast. This characteristic applies only to class 1.
After the test defined in 3.9.1.4.4, no hole shall be found in the coating, nor shall there be any alteration to the
test piece surface.
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EN 13261:2009 (E)
The test piece shall be tested by firing a projectile onto the protected surface in accordance with Annex C.
3.9.1.5 Resistance to gritting
3.9.1.5.1 General
This characteristic defines the ability of the coating to protect the axle from damage due to repeated sand or
grit blasting.
After the test defined in 3.9.1.5.4, the coating surface shall comply with:
coating loss level 3 for the protection of classes 1 and 2;
coating loss level 4 for the protection of class 3
as described in Annex D.
The method to assess the resistance to gritting is given in Annex D.
3.9.1.6 Resistance to salt spray
3.9.1.6.1 General
This characteristic defines the ability of the axle surface, when protected by its coating, to resist corrosion
accelerated by an artificial salt spray.
After the test defined in 3.9.1.6.4, no corrosion shall be found under the coating, nor shall there be any
corrosion present at a distance of more than 2 mm from the edges or from the incisions in the coating.
The length of the incision is divided into successive 10 mm sections. The maximum width of the corrosion is
noted for each of these sections. The average of these measurements constitutes the increase in corrosion.
The test piece shall consist of an axle section covered with the coating to be evaluated in which cross-shaped
incisions (for coating thickness 250 m) or an aperture (for coating thickness > 250 m) have been made
(see Figure 10).
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EN 13261:2009 (E)
Key
1 generating line
Figure 10 Salt spray test pieces
The assessment of resistance to salt spray is carried out in accordance with EN ISO 9227:2006; the solution
used is that of the NSS test of that standard.
3.9.1.7 Resistance to specific corrosive products
3.9.1.7.1 General
This characteristic, which only affects the class 2 coating, assesses its resistance to specific corrosive
products that might affect it (corrosive environments, products transported, etc.).
After the test defined in 3.9.1.7.4, no alteration of the coating shall be found, nor of the surface. Furthermore,
compliance with an adhesion test carried out according to EN ISO 2409 shall allow this coating to be classified
as class 1 also.
The test piece shall consist of an axle section covered with the coating to be evaluated.
The resistance to specific chemicals is determined by means of a test that includes repeated submergence
and emergence. This test is described in Annex E (normative). It shall be followed by the adhesion test
defined in EN ISO 2409, performed 24 h after the end of the corrosion test phase.
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EN 13261:2009 (E)
3.9.1.8 Coating resistance to cyclic mechanical stresses
3.9.1.8.1 General
This characteristic, which defines the ability of the coating to resist cyclic mechanical stresses, shall be
verified by means of test pieces. They shall be stressed in rotary bending by increasing the stress levels up to
the failure point of the coating. The level reached before this point defines the resistance of the coating.
3.9.1.8.2 Characteristic to be achieved
In the test conditions defined in 3.9.1.8.4,
level 5 shall be reached with class 1 and class 3 coatings,
level 10 shall be reached with class 2 coating.
The rotary bending test piece (with a diameter of 8,5 mm at its active part) shall be made of steel grade EA1N,
protected by the coating to be evaluated.
An example of a drawing of the test piece is given in Annex H.
The test method and conditions are defined in Annex F.
3.9.2 Temporary protection
Before assembly, the parts of the axle that have been prepared to receive the other components shall have
been given temporary protection against corrosion and impact, in accordance with the delivery condition.
The characteristics of the protection are to be agreed between the customer and the supplier according to the
transportation conditions and storage conditions (handling, environment, etc.).
This protection shall remain effective for at least 3 months in normal atmospheric conditions, unless otherwise
specified.
3.10 Marking
Each axle shall be identified, as a minimum, with the following stamped marks:
manufacturer's mark;
cast number;
steel grade;
month and two last figures of the year of production;
number of the axle in the batch, following heat treatment.
These marks shall be located on one journal end only and shall be limited to one half of the surface of this
journal end. The other half of the surface shall be dedicated to the wheelset manufacturers marking.
On the other journal end, half of the surface shall be free of any marks. This shall be dedicated to the
operators marks.
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EN 13261:2009 (E)
The configuration of this marking shall be defined in the order. Any burrs resulting from the stamping shall be
levelled in order to permit in-service ultrasonic examination.
32
EN 13261:2009 (E)
Annex A
(normative)
Particular characteristics for axles of steel grade EA1T and EA4T
A.1 Chemical composition

The chemical composition shall be as given in Table A.1.
Table A.1 Maximum limit by product analysis (%)

a
Grade C Si Mn P S Cr Cu Mo Ni V
ab
EA1T 0,40 0,50 1,20 0,020 0,020 0,30 0,30 0,08 0,30 0,06
0,22 0,15 0,50 0,90 0,15
EA4T
b
0,29 0,40 0,80 0,020 0,015 1,20 0,30 0,30 0,30 0,06
a
A maximum content of 0,025% may be agreed at the time of enquiry and the order.
b A minimum sulfur content may be agreed at the time of enquiry and the order according to the steelmaking process, in
order to safeguard against hydrogen embrittlement.
A.2 Mechanical characteristics
A.2.1 Characteristics from tensile test
The values of ReH, Rm and A5 shall be as defined in Table A.2.
Table A.2 Values to be achieved at mid-radius of solid axles or at mid-distance between external
and internal surfaces of hollow axles
a
Grade ReH (N/mm) Rm (N/mm) A5 %
EA1T 350 550 - 700 24
EA4T 420 650 - 800 18
a
If no distinctive yield strength is present, the proof stress Rp0,2 shall be determined .
A.2.2 Impact test characteristics
The values of absorbed energy with U-notch specimens (KU) shall be as defined in Table A.3.
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EN 13261:2009 (E)
Table A.3 Values to be achieved at mid-radius of solid axles or at mid-distance between external
and internal surfaces of hollow axles
Grade KU longitudinal (J) at 20 C KU transverse (J) at 20 C

EA1T 40 25
EA4T 40 25
A.2.3 Fatigue characteristics
The limiting stresses shall be as defined in Table A.4.

Table A.4 Fatigue limit values
Grade F1 F2 RfL RfE RfL/RfE

2 2 2 2
EA1T 200 N/mm 80 N/mm 250 N/mm 170 N/mm 1,47
2 2 2 2
EA4T 240 N/mm 96 N/mm 350 N/mm 215 N/mm 1,63
A.3 Metallographic characteristics

For EA1T, the micrographic structure shall be of ferrite and pearlite. The grain size shall not be greater or finer
than that defined by standard chart 5 in Annex B of EN ISO 643.
Steel grade EA4T consists of a micrographic structure of bainite/annealed martensite. The grain size shall not
be greater or finer than that defined by standard chart 5 in Annex B of EN ISO 643.
34
EN 13261:2009 (E)
Annex B
(normative)
Standard wedge for measurement of permeability to ultrasound
B.1 Test piece

The longitudinal test piece is taken from an axle that has been examined by ultrasound in order to ensure that
there are no defects.
B.2 Tolerances of the wedge
Length and diameter 0,1 if values are 100 mm
0,2 if values are > 100 mm
Perpendicularity between faces 5
Roughness 1,6 Ra 3,2
B.3 Steel grade

EA1N with double normalization and a chemical composition and mechanical characteristics conforming to
this standard. The grain size shall not exceed that defined by standard chart 8 in Annex B of EN ISO
643:2003.
35
EN 13261:2009 (E)
Annex C
(normative)
Method to assess resistance to impact of the coating
C.1 Principle
The test method is to fire a projectile perpendicular to the protected surface and then to study the change to
the coating and that of the test piece surface.
C.2 Test piece

The test piece shall be a coated axle or coated axle section representative of the finished product.
C.3 Apparatus
A machine that allows a treated steel projectile to be fired (diameter: 32 mm; top angle:105; mass: 60 g). Its
Vickers hardness shall be 400.
C.4 Procedure
It shall be fired by the expansion of a volume of air compressed at 8 bar in order to ensure an exit speed of
19,4 m/s.
The resistance to the impact is assessed at 25 C and at ambient temperature.
C.5 Expression of results

After the impact, the appearance of the coating surface shall be examined with the naked eye, as well as the
appearance of the test piece surface, once the coating has been removed. Changes shall be recorded and
compared to the criteria given by this standard.
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EN 13261:2009 (E)
Annex D
(normative)
Method to assess resistance to gritting of the coating
D.1 Principle
A known quantity of grit is dropped onto the protected surface and the coating is then examined for any
change.
D.2 Test piece

The test piece shall be a coated axle or coated axle section representative of the finished product.
D.3 Apparatus
Straight tube (inside diameter: 38 mm; height: 5 m) in the upright position, with a funnel at the top to receive
the grit and closed by a trapdoor at the bottom.
The grit is represented by a kilogram of HM6 steel nuts, of class 8.8, as defined by EN 20898-2:1993.
D.4 Procedure
Place the test piece with its coating 30 mm beneath the tube so that the falling direction of the grit makes an
average angle of 45 with the tangent to the test surface.
Open the trap door and drop the grit all at once.
Examine the impacted surface and record the results.
D.5 Expression of results
Use the following table to note the percentage P of surface3 where the coating has come off in flakes.
Table D.1 Results
Level P% Level P%
1 10 6 60
2 20 7 70
3 30 8 80
4 40 9 90
5 50 10 100
3 Inner surface of the closed convex polygonal line passing through the outside points of impact.
37
EN 13261:2009 (E)
Annex E
(normative)
Method to assess the resistance of the coating to specific corrosive

products
E.1 Principle
The test piece is repeatedly submerged in a test solution and the coating and the protected surface of the test
piece is examined for possible changes.
E.2 Test piece

The test piece shall be a coated axle or a coated axle section representative of the finished product.
E.3 Apparatus
A watertight enclosure, which is kept at constant temperature, and in which a system allows for a test piece to
be submitted to alternate submergence/emergence cycles.
E.4 Corrosive products

The corrosive products into which the specimen is dipped shall be selected according to the specific
aggressive elements that the axle shall be submitted to during its lifetime.
The three following solutions:
1) 3% water solution, by volume, with (95-97)% sulfuric acid, in demineralized water with a resistivity of
more than 10 M.m;
2) 10% water solution, by mass, with potassium chloride, in demineralized water with a resistivity of
more than 10 M.m;
3) 10% water solution, by mass, with sodium hydroxide, in demineralized water with a resistivity of more
than 10 M.m
are representative of the majority of the corrosive agents the axles are subjected to in service.
NOTE Other products, such as oils, fuels, etc. may be considered.
E.5 Procedure
The tests shall be performed on the test piece for each specific corrosive product and in the following
conditions:
temperature of the enclosure and solution: 23 2 C;
duration of a submergence period: 4 h;
duration of an emergence period: 4 h;
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EN 13261:2009 (E)
number of submergence/emergence cycles: 32
The customer and the supplier may agree on different test conditions, according to the specific corrosive
product under examination.
After testing, the test pieces shall be rinsed out with clear water and dried by ambient air for a period of 1 h.
E.6 Expression of results

After the test piece has been submitted to the tests, rinsed out and dried, possible changes shall be examined
with the naked eye; an adhesion test shall also be carried out, according to EN ISO 2409.
39
EN 13261:2009 (E)
Annex F
(normative)
Method to assess the resistance of the coating to cyclic mechanical

stresses
F.1 Purpose
The purpose of this test is to assess the resistance of the coating to cyclic mechanical stresses.
F.2 Principle
The test comprises the stressing of a steel test piece, covered with the coating to be evaluated, in rotary
bending, by increasing stress levels up to failure point of the coating.
A corrosive product is used to initiate a crack in the test piece when the coating is torn.
F.3 Test piece

The test pieces are those defined in Figure H.2. Their diameter is 8,5 mm over their active part.
The test pieces are made of steel grade EA1N as defined in this standard. They are covered over their active
parts with the coating to be evaluated.
F.4 Apparatus
The apparatus shall allow rotary bending tests to be carried out on the test pieces in which the stresses
applied to active parts vary according to the level.
The apparatus shall also allow for the application to the test pieces of a corrosive product during testing.
F.5 Procedure
The tests shall be performed on four test pieces, at successive level numbers, for which the maximum value
of the stresses applied to the test piece surfaces is given by the following relation:
2
n = 160 + n x 10 N/mm
where:
is the maximum stress on the test piece surface, over its active part
n is the level number (n > 0).
The test begins with n equal to 1

6
Each level comprises 13 x 10 cycles under the simultaneous action of the mechanical stress and the
specified corrosive product. A 96-h non-testing time shall be allowed after each level, with no stress and no
action from the corrosive product.
40
EN 13261:2009 (E)
Demineralized water shall be used as the corrosive product, with a resistivity of more than 100 M.m, which is
distributed "drop by drop", one drop every (15 2) s being applied to the active part of the test piece.
F.6 Expression of results

Three of the four test pieces shall reach the indicated level without failure.
41
EN 13261:2009 (E)
Annex G
(normative)
Measurement of the hydrogen content in the steel for axles at the

melting stage
G.1 Sampling
In order to meet the specified requirements, samples are taken from the molten bath using one of the
following 4 methods:
1) copper mould;
2) silica dip tubes;
3) quartz bubbling tube (translucent quartz is prohibited because of its hygroscopic ability);
4) immersion probe method (carrier gas method with thermal conductivity detector).
G.2 Analysis methods

Two methods only are accepted:
vacuum extraction in a temperature range of 650 C to 1050 C;
injecting a carrier gas into the liquid steel at (650 20) C. The resulting diffused gas containing hydrogen
is recovered for re-circulation and analysis.
G.3 Precautions
See 6.5 of EN ISO 14284:2002.
NOTE The operators should be specifically trained for performing this analysis.
42
EN 13261:2009 (E)
Annex H
(informative)
Drawings of test pieces
Figure H.1 Small-scale test piece for steel fatigue limit determination
Figure H.2 Small-scale test piece to assess coating resistance under cyclic mechanical stresses
43
EN 13261:2009 (E)
Key
1 centre to centre distance of journals 2000
Figure H.3 Full-size test piece for fatigue test
44
EN 13261:2009 (E)
Annex I
(informative)
Product qualification
I.1 Introduction
CEN/TC 256 considers that the following clauses represent the best means of assessing conformity of a
range of products to this standard. However, a quality system other than the one specified in EN ISO 9001
may be applied.
I.2 General
An axle shall be qualified before being used on a European network.
This clause specifies the requirements and procedures to be applied for product qualification.
Qualification of an axle is directly linked to the supplier and an axle can only be qualified if the supplier meets
the requirements specified in I.3.
These requirements and procedures apply only to axles for which the design has already been approved:
either by previous use on European networks;
or by application of EN 13103 and EN 13104.
The requirements are to be applied in the following cases:
any axle to be provided by a new supplier;
any non-qualified axle to be provided by a supplier, when its diameter is appreciably different to qualified
axles from this supplier;
any change in the manufacturing process of a qualified axle from a supplier.
I.3 Requirements
I.3.1 Requirements to be met by the supplier
I.3.1.1 General
Where manufacture of an axle involves more than one supplier, the following requirements shall be met by all
concerned.
I.3.1.2 Quality organization
The supplier should operate a quality assurance system conforming to EN ISO 9001.
45
EN 13261:2009 (E)
I.3.1.3 Staff qualification
Staff trained in non-destructive testing shall be qualified in accordance with EN 473.
I.3.1.4 Equipment
The equipment used by the supplier for manufacture, control and monitoring shall allow the requirements of
this standard to be met.
For ultrasonic testing, an automatic method should be used. For non-automatic methods, the reproducibility
shall be demonstrated.
I.3.2 Requirements to be met by the product
The product shall meet the product requirements specified in clause 3.
The traceability of each axle shall be established after its heat treatment.
I.4 Qualification procedure
I.4.1 General
The qualification procedure for the product comprises three successive stages:
provision of documents by the supplier;
evaluation of the manufacturing equipment and production processes;
laboratory tests.
I.4.2 Documentation required
When a request for qualification is submitted, the supplier shall provide a file comprising:
a) a description of the products that are the subject of the request;
b) a description of the company stating:
c) company size (number of employees, defining the proportion between production, control and quality
assurance),
1) annual production of all the products;
2) a list of all the means of production and control;
d) data about the company organization, with the relevant organization charts;
e) a description of the manufacturing processes with explanations of the different stages of manufacture,
including the reduction ratio of the rolling or forging process;
f) data about raw materials with the list of suppliers;
g) results of tests on the products that are the subject of the request;
h) qualification certificates if the product has been previously qualified.
46
EN 13261:2009 (E)
If a file has already been provided by a supplier for the qualification of a different axle, the file to be provided
by this supplier for the qualification of a new axle shall include only data specific to this new axle or new to the
company
I.4.3 Evaluation of the manufacturing plant and of the production processes
This evaluation comprises:
an inspection of the manufacturing plant and examination of the production processes;
an inspection of the raw material manufacturing plant and examination of its production processes;
auditing of the data provided by the supplier to confirm whether the requirements of I.3.1 have been fully
met;
auditing of the information provided in the documents referred to in I.4.2.
At the end of this stage, a report shall be produced. It shall identify all the production processes including
those of the raw material which are essential for product quality for which qualification is requested. It shall
give an assurance that the evaluation satisfies the requirements of I.3.1 for the qualification procedure to
continue.
I.4.4 Laboratory tests
All characteristics defined in clause 3, except fatigue characteristics, shall be proven for two axles taken from
one production process.
For the fatigue characteristics defined in 3.2.3, the verifications shall be carried out on axles to be qualified or
on test pieces taken from products from the same fabrication process.
The method for verifying the level of residual stresses shall be defined following agreement between the
customer and the supplier (see 3.6.4).
.
For better identification of the product to be qualified, there may be a need for further tests (metallographic,
etc.) to be conducted at this stage, in addition to those mentioned in clause 3. The results of these tests have
no influence on the final decision on qualification.
A report shall be produced. It shall describe the test pieces and the different tests. It shall also indicate the
thickness of the final protective coating measured of the test pieces tested. It shall give the results and specify
whether the product satisfies the requirements.
I.5 Qualification certificate
I.5.1 Condition of validity
The certificate of qualification shall specify the limits of validity at least for:
the steel grades;
the axle diameters;
the availability of fatigue data;
the class and thickness of the final protection.
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EN 13261:2009 (E)
I.5.2 Modification and extension
At the request of the supplier, the scope of the certification validity may be modified or extended if:
other products are to be considered;
the main parameters have been modified (manufacturing processes, quality organization, etc.).
I.5.3 Transference
In the case of a change in ownership, an existing qualification may, if requested, be transferred to another
company if the relevant content and conditions prior to the qualification have not been modified.
I.5.4 Lapsed certification
The manufacturing equipment and processes described in I.4.3 shall be re-assessed if, in a period of 2 years,
no products have been supplied within the scope of the product that was the subject of the qualification.
I.5.5 Cancellation
If the customer registers significant defects in the product, the parts of the qualification procedure concerned
shall be repeated.
If the supplier has not ensured that important conditions of the qualification were met, it may be cancelled.
I.6 Qualification file

A qualification file shall be prepared for each qualified product. It shall contain the following documents:
the application request from the supplier;
the documents provided by the supplier (see I.4.2);
the assessment reports (see I.4.3);
the laboratory test reports (see I.4.4);
the qualification certificate (see I.5).
48
EN 13261:2009 (E)
Annex J
(informative)
Product delivery
J.1 Introduction
CEN/TC 256 considers that the following clauses represent the best means of assessing conformity of the
products delivered to this standard.
J.2 General
The customer shall define the following in the order:
1) the geometry and the dimensions of the axle (drawings);
2) the steel grade if it is not grade EA1N;
3) the category of the axle according to its utilization;;
4) the delivery condition (see J.3);
5) the class of the final protection against corrosion and mechanical aggression and if it has to be on
the axle before the assembly of the wheelset (see 3.9.1);
6) the nature and characteristics of the temporary protection for finished parts (see 3.9.2);
7) the configuration of the marking on the axle ends (see 3.10).
In the offer, the supplier shall make a proposal for the fabrication quality supervision of the products:
8) either by batch control as described in J.5.1,
9) or by a quality plan approved by the customer, as indicated in J.6.
The customer and the supplier shall agree on the following points:
10) internal integrity: parts which it is not possible to examine (see 3.4.2.4);
11) permeability to ultrasound: type of probes (see 3.5.4);
12) residual stresses: measurement method (see 3.6.4);
13) surface integrity: examination method of the bore surface (see 3.7.2.4);
14) protection against corrosion of the bore (see 3.9.1.1);
15) coating thickness: method of measurement (see 3.9.1.3);
16) coating adhesion: test method (see 3.9.1.3.4);
17) choice of controls (Table J.1).
The customer and the supplier shall agree on the following point:
49
EN 13261:2009 (E)
18) roughness condition of the fillet radii: measurement method by comparison with tactile and visual
specimens (see 3.7.1.2).
J.3 Delivery condition

The degree of finish of the different parts of an axle on delivery shall be any one of the following:
unmachined (as-forged or as-rolled condition) where the specific area has not been machined except for
what the manufacturer has to do to make the axle compatible with the requirements of this standard;
rough-machined, where the specific part has been machined and requires subsequent machining;
finished, where the specific part has undergone final machining (not applicable to seats);
ready to assemble, where a seat has received final machining for assembly.
J.4 Controls on each axle

Whether the fabrication quality supervision is made with controls by batch sampling (see J.5), or with a quality
plan (see J.6), controls are required to ensure that the special characteristics, which are defined in clause 3,
are achieved. These controls shall be made on each delivered axle and are:
internal integrity (see 3.4.2);
permeability to ultrasound (see 3.5 or J.5.2);
surface integrity (see 3.7.2).
J.5 Batch control
J.5.1 Controls
The nature and number of controls are defined in Table J.1. A batch comprises axles from the same cast and
heat treated under the same conditions.
50
EN 13261:2009 (E)
Table J.1 Nature and number of controls to be carried out
Characteristics to be verified Number of axles per batch to References

control
Maximum size of the batch 100 > 100
e
- Chemical composition 1 1 3.1
a a b
- Hydrogen content
e
- Tensile characteristics (mid-radius) 1 2 3.2.1
ce
- Impact test 3) 3.2.2
1 2
- longitudinal (mid-radius) 1 2
- transverse (mid-radius)
e
- Micrographic cleanliness 1 2 3.4.1
- Permeability to ultrasound 100 % 100 % 3.5 or J.5.2

f
- Internal integrity 100 % 100 % 3.4.2
dg
- Surface integrity 100 % 100 % 3.7.2
- Surface appearance 100 % 100 % 3.7.1 or J.5.3

- Geometry and dimensions 100 % 100 % 3.8
- Final protection:
- film thickness 10 % 10 % 3.9.1.1
a
One analysis per cast. Care should be taken to ensure that the reported maximum hydrogen content value is
representative of the whole cast.
b
The hydrogen content is determined according to the methods described in Annex G (normative). It shall be < 2 ppm
for category 1 axles and < 2,5 ppm for category 2 axles.
c
Three test pieces are used for each test.
d
By agreement between the customer and the supplier, the magnetic particle test for determining longitudinal defects
may be replaced by a visual examination as defined in J.5.4.
e
By agreement between the customer and the supplier, the test pieces may be taken from a journal extension. In this
case, the values to be achieved shall be agreed between the customer and the supplier.
f
By agreement between the customer and the supplier, the AVG method may be used.
g
Depending on the magnetization process, demagnetization may be necessary. The method shall be agreed between
the customer and the supplier.
J.5.2 Permeability to ultrasound
J.5.2.1 General
Comparison shall be made with the permeability of a reference axle that is agreed between the customer and
the supplier.
J.5.2.2 Level to be obtained
The back echo obtained on inspected axles shall have an amplitude greater than or equal to the back echo
amplitude recorded on the reference axle.
51
EN 13261:2009 (E)
J.5.2.3 Test piece
Every axle shall be examined after heat treatment and in the finish-machined condition, before the application
of the final protection.
J.5.2.4 Test method
Ultrasonic permeability shall be verified by examination in a direction parallel to the axle, according to
method T of ISO 5948:1994. The probe frequency shall be 5 MHz for category 1 axles and equal to or higher
than 2,5 MHz for category 2 axles.
J.5.3 Surface finish
The surface finish characteristics shall be in accordance with 3.7.1.1.
They may be estimated by comparison with the roughness specimens that are the subject of an agreement
J.5.4 Visual examination
The visual examination shall be made under normal conditions of vision.
The acceptability criteria shall be established on the basis of the reference images used by agreement
J.6 Quality plan
J.6.1 General
In the case of quality control by a quality plan (according to the definition in EN ISO 9000) of the products to
be delivered, it shall be established by the supplier and shall be agreed with customer.
This quality plan shall refer to the quality manual of the supplier; it shall contain specific elements for the
product.
J.6.2 Purpose
This plan shall be drawn up with the offer with the objective of:
describing the processes and quality control of the producer in order to achieve the required quality of the
product to be delivered; the reasons for their selection shall be given;
the quality plan shall provide at least the same confidence as that from batch control.
This quality plan shall define the controls that are made during the manufacturing process and those for
product delivery. These controls may be collated in the control plan of the fabrication process.
J.6.3 Application of the quality plan
Any modification to the quality plan shall only be made with the agreement of the customer.
If a non-conformity is discovered by the customer in the products to be delivered, the applicable clauses of the
quality plan shall be discussed and if the result is unsatisfactory the quality plan can be cancelled.
52
EN 13261:2009 (E)
In this case, the controls and tests defined by the "control by sampling of batches" mode shall be applied in
their entirety until a new agreement is reached between the customer and the supplier.
J.7 Allowable rectification

With the exception of wheelseats, journals ready for assembly, stress relieving grooves and fillets, on which
retouching work is not authorized, surface defects may be eliminated by metal removal. This may be achieved
by machining or fine grinding, on the condition that these processes do not result in excessive heating or the
formation of cracks and do maintain dimensional tolerances. The resultant surface shall be carefully blended
into the adjacent material.
In z0 zones (see Figure 7) of powered axles, such rectification is allowed if the depth of the defect to be
repaired is less than 0,25 mm.
Each rectification is followed by inspection to determine that the requirements given in 3.7.2 have been met.
53
EN 13261:2009 (E)
Annex ZA
(informative)
Relationship between this European Standard and the Essential

Requirements of Council Directive 96/48/EC of 23 July 1996 on the
interoperability of the trans-European high-speed rail system amended
by Directive 2004/50/EC of 29 April 2004
This European Standard has been prepared under a mandate given to CEN/CENELEC/ETSI by the European
Commission and the European Free Trade Association to provide one means of conforming to Essential
Requirements of the New Approach Directive 96/48/EC, amended by Directive 2004/50/EC.
Once this standard is cited in the Official Journal of the European Communities under that
Directive and has been implemented as a national standard in at least one Member State, compliance with the
normative clauses of this standard indicated in Table ZA.1 confers, within the limits of the scope of this
standard, a presumption of conformity with the relevant Essential Requirements of that Directive and
associated EFTA regulations.
.
Table ZA.1 Correspondence between this European Standard and Directive 96/48/EC
Clause(s)/sub-clause(s) of this Clauses/subclauses/points and Corresponding text,
EN annexes of the June 2006 TSI clauses/subclauses/annexes of
adopted by the Council on 21 Directive 96/48/EC
February 2008
The whole standard is applicable 4.2.3.4.1 Dynamic rolling stock Annex III, Essential
behaviour. General requirements, General
requirements 1.1.1, 1.1.3
Safety
Annex III, Essential
requirements, General
requirements 1.5 Technical
compatibility
requirements, Requirements
specific to each subsystem
"Control and Command and
Signalling" 2.3.2 Technical
compatibility
requirements, Requirements
specific to each subsystem
"Rolling stock" 2.4.2 Reliability
and availability
WARNING Other requirements and other EU Directives may be applicable to the product(s) falling within
the scope of this standard.
54
EN 13261:2009 (E)
Annex ZB
(informative)
Relationship between this European Standard and the Essential

Requirements of Directive 2001/16/EC of the European Parliament and of
the Council of 19 March 2001 on the interoperability of the trans-
European conventional rail system amended by Directive 2004/50/EC of
29 April 2004
This European Standard has been prepared under a mandate given to CEN/CENELEC/ETSI by the European
Commission and the European Free Trade Association to provide one means of conforming to Essential
Requirements of the New Approach Directive 2001/16/EC, amended by Directive 2004/50/EC.
Once this standard is cited in the Official Journal of the European Communities under that Directive and has
been implemented as a national standard in at least one Member State, compliance with the normative
clauses of this standard indicated in Table ZB.1 confers, within the limits of the scope of this standard, a
presumption of conformity with the relevant Essential Requirements of that Directive and associated EFTA
regulations.
.
Table ZB.1 Correspondence between this European Standard and Directive 2001/16/EC
Clause(s)/sub-clause(s) of Clauses/subclauses/points and Corresponding text,
this EN annexes of the January 2005 rolling clauses/subclauses/annexes of
stock freight wagon TSI and Directive 2001/16/EC
approved by the committee on the
interoperability and safety of the
European rail system
The whole standard is 4.2.3.4.1 Vehicle dynamic behaviour. Annex III, Essential
applicable General requirements, General
requirements 1.1.1, 1.1.3
5.3.2.4 Vehicle track interaction and
Safety
gauging. Axle
5.4.2.4 Vehicle track interaction and
requirements, General
gauging. Axle
requirements 1.5 Technical
6.1.3.2.4 Vehicle track interaction compatibility
and gauging. Axle
Annex E: Vehicle track interaction requirements, Requirements
and gauging, Wheelset dimensions specific to each subsystem
and tolerances for standard gauge "Control and Command and
Signalling" 2.3.2 Technical
Annex M: Vehicle track interaction compatibility
and gauging, Axle
Annex Q: Assessment procedures, requirements, Requirements
interoperability constituents specific to each subsystem
"Rolling stock" 2.4.2 Reliability
Annex Y: Constituents, bogies and and availability
running gear
55
EN 13261:2009 (E)
Clauses/subclauses/points and
annexes of the Conventional Rail
Rolling Stock TSI for Locomotives
and Traction Units (draft submitted to
the committee on the interoperability
and safety of the European rail
system in September 2008)
3.10.1.1.1 4.2.3.5.2 Wheelsets
WARNING Other requirements and other EU Directives may be applicable to the product(s) falling within
the scope of this standard.
56
EN 13261:2009 (E)
Bibliography
[1] EN 473, Non-destructive testing Qualification and certification of NDT personnel General principles
[2] EN ISO 9000, Quality management systems Fundamentals and vocabulary (ISO 9000:2005)
[3] EN ISO 9001, Quality management systems Requirements (ISO 9001:2008)
[4] CEN/TR 10261, Iron and steel Review of available methods of chemical analysis.
57

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EUROPEAN STANDARD EN 13261

ICS 45.040 Supersedes EN 13261:2003

Railway applications - Wheelsets and bogies - Axles - Product

Applications ferroviaires - Essieux monts et bogies - Bahnanwendungen - Radstze und Drehgestelle -

This European Standard was approved by CEN on 29 November 2008.

EUROPEAN COMMITTEE FOR STANDARDIZATION

Management Centre: Avenue Marnix 17, B-1000 Brussels

Annex C (normative) Method to assess resistance to impact of the coating.............................................36

J.4 Controls on each axle .........................................................................................................................50

This document supersedes EN 13261:2003.

This standard addresses these issues by:

b) definition of qualification procedures (see Annex I);

2) a delivery procedure using quality assurance concepts (see J.6).

EN 10045-1, Metallic materials Charpy impact test Part 1: Test method

EN 13260, Railway applications Wheelsets and bogies Wheelsets Product requirements

EN ISO 2409:2007, Paints and varnishes Cross-cut test (ISO 2409:2007)

1 N for a normalized metallurgical condition

ISO 5948:1994, Railway rolling stock material Ultrasonic acceptance testing

3.1 Chemical composition

3.1.1 Values to be achieved

3.1.2 Location of sample

3.1.3 Chemical analysis

2 See also CEN/TR 10261.

3.2 Mechanical characteristics

3.2.1 Characteristics from tensile test

3.2.1.1 Values to be achieved

ReH(N/mm)a Rm (N/mm) A5%

3.2.1.2 Location of test pieces

1) as near as possible to the external surface for all the axles;

2) at mid-radius and in the centre of solid axles;

as shown in Figure 1 a) and b).

1a) Solid axle

1b) Hollow axle

Figure 1 Location of test pieces

3.2.1.3 Test method

3.2.2 Impact test characteristics

3.2.2.1 Values to be achieved

mid-distance between external and internal surfaces of hollow axles.

No individual value shall be less than 70 % of the values in Table 3.

Table 3 Values to be achieved at mid-radius or at mid-distance between external and internal

KU longitudinal (J) KU transverse (J)

3.2.2.2 Location of test pieces

1) as near as possible to the external surface for all the axles;

2) at mid-radius and in the centre of solid axles;

as shown in Figure 2a) and 2b).

3.2.2.3 Test method

The test shall be carried out in accordance with EN 10045-1.

2a) Solid axle

2b) Hollow axle

1 longitudinal test piece

2 transverse test piece

Figure 2 Location of test pieces

3.2.3 Fatigue characteristics

3.2.3.1.2 Fatigue limits on reduced test pieces

unnotched surface test pieces (fatigue limit RfL );

notched test pieces (fatigue limit RfE).

3.2.3.1.3 Fatigue limits on full size test pieces

It is necessary to define two fatigue limits:

on the body surface, limit F1;