Railway wheels, tyres and axles

KLW: ART OF MOTION

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ContentsCoMMItteD to WHeeLs 4

Range of RaILWay pRoDuCts 6

InteRnatIonaL CeRtIfICatIon 9

InteRpIpe ntRp — a Long tRaDItIon of pRoDuCtIon 10

pRoDuCts QuaLIty ContRoL 11

InteRpIpe steeL: a neW eRa In KLW HIstoRy 12

KLW — a Key paRtneR of natIonaL RaILWay opeRatoRs 14

KLW — a pRoDuCeR of WHeeL CenteRs foR LeaDIng Wagon BuILDIng CoMpanIes 16

KLW — a stRategIC paRtneR foR LeaDIng euRopean ManufaCtuReRs 17

teCHnoLogy of foRgeD RaILWay WHeeLs pRoDuCtIon 18

tyRes pRoDuCtIon teCHnoLogy 20

KLW — a paRtneR of LeasIng CoMpanIes 22

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KLW is the wheel brand of Interpipe, the global steel company. Interpipe is one of the largest producers of railway wheels in the world.

Interpipe has more than 75 years’- experience in manufacturing of railway wheels. production takes place at one of the company’s mills - In-terpipe ntRp (Dnepropetrovsk, ukraine).

Railway wheels, under the KLW brand, are sup-plied to customers in more than 60 countries worldwide including global railway operators and wagon builders – in europe, north america, asia and the CIs countries.

KLW’s product portfolio includes more than 250 types of railway wheels and 80 types of rail-

COMMITTED to wheels

way tyres for locomotives, freight and passen-ger cars, metro and city rail transport.

KLW products satisfy the demands of the in-ternational standards and are certified by the leading railway operators. Quality manage-ment system is certified to the demands of Iso 9001, aaR M-1003, RIsas and tsI standards.

Quality is the starting point of our business de-velopment. our capability to integrate into the production process of our customers sets us apart from other producers of railway wheels.

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KEy facts:

1935 the 1st wheel was rolled (before 1950 the mill was the only producer of railway wheels in the ussR)

1970 the 10-millionth wheel was produced ( just 35 years after the production of wheels begun)

1979 the company started to supply wheels to eastern europe

1987 the complex modernization of railway wheels was completed. the production of tyres begun

1991 KLW entered the Indian market

1996 KLW entered the Chinese market

2000 Interpipe was recognized as the largest exporter of railway wheels in the world

2012 Interpipe ntRp started to roll wheels from continuous casted billet produced by Interpipe’s new eaf mill, Interpipe steel

2013 KLW became co-organizer of 17th International wheelsets congress and hosted it in ukraine

2014 Interpipe ntRp has begun producing of axles

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about 20 new types of railway wheels are an-nually developed under the KLW brand. these products are applied for different spheres of use starting from underground railway carriag-es to large-capacity freight transportations.In tandem with clients, Interpipe ntRp special-

RangE Of RaIlway productsists develop new types of railway wheels with different diameters and chemical structures of steel. to expand KLW product potfolio and satisfy the needs of our clients in 2014 Interpipe ntRp has begun producing of axles.

outsideDiameter ⌀ D, mm

700– 1269

Insidediameter⌀ d1,⌀ d2, mm 600–1100

Widthof rimH, mm

95–160

Diameterof hub⌀ d, mm

185–350

Heightof hubL, mm

150–250

Diameterof holein hub⌀ d0, mm

110–120

thicknessof diskt1, t2, mm

15–80

Mass,kg

165–1050

WHeeLs

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outsidediameter⌀ D, mm

570–1300

tyRes

Insidediameter⌀ d, mm

375–1100

Width ofrim H, mm

80–150

Width offlangeh, mm

15–45

Mass, kg

90–550

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In 2014 Interpipe has mastered the production of a new product – railway axles. Interpipe has already obtained necessary european certifi-cates for forged, rough machined and finished

axles for the most common types of freight ap-plications and is pursuing its efforts in widening its new product range to other segment.

Rough axle drawing No

Drawing of ВА002 type rough axle

Steel grade

Shaft diameter,⌀ d0, mm

Length of wheel seat (incl. flanges), l, mm

Wheel seat diameter, ⌀ D, mm

Diameter of axle body,⌀ d, mm

Length of the axle,L , mm

Axle load, t

Maximum speed

Weight of the axle, kg

ОC-0009-14 (rough axle)

oC-0007-14 (fwg 665.0.02.001.302)

oC-0006-14 (3fwg 665.0.02.001.001)

ea1n 163 ±0,5 242+2-1 211 +2 176 +2 2186+2 ― ― 419

oC-0006-14 oC-0006-14 (3fwg 665.0.02.001.001) ea1n 160+0,134

+0,174 238-0,5 200±0,023 173 +2 2180±1 23,5 up to 200 km/h 396*

oC-0007-14 oC-0007-14 (fwg 665.0.02.001.302) ea1n 160+0,134

+0,174 238-1 205±0,036 173 +2 2180±1 25 up to 200 km/h 398*

aXLes

*theoretical weight is calculated for 2/3 margin tolerance

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InTERnaTIOnalcertificationtHe RaILWay WHeeLs anD tyRes aRe eXpoRteD aCCoRDIng to tHe speCIfICatIons anD Re-QuIReMents of tHe CustoMeR anD tHe noRMs of InteRnatIonaL stanDaRDs, InCLuDIng:

aaR M107/M208astM a504Bn 918277Bn 918048Bn 918 049Bs 5892-2Bs 5892-3Bs 5892-4IRs R15-95IRs R 34IRs R 19 – 93 part IIIRs R 19 – 93 part V

Iso 1005JIs e 5402KRs 9221M4t 2000MoR-M-2001-2M. 9W-1999pn-84pn91en 13262Rsp #sM-55/2543snCB a-12tJZL 01

tJZL 02tts 094tts 248tŞ 02-024 tuLoMsas 010.025uIC 810-1uIC 812-1unI61023eeC200004-2148gM/Rt 2466gost 10791Dstu gost 10791

QuALITy MANAgeMeNT SySTeMIRIsaaR M-1003Iso 9001-2008

gost 9036gost 398gost 20179Dstu 3678VR y s 8264/460/12trenItalia 308185

OuR AppROvALStsI aaR – freight & Locomotive WheelsDB finish Machined WheelspKp – freight Car WheelsRailtrack – freight Car WheelsНŽ – Wheels and tyresСZ - freight & Locomotive Wheels sK - freight & Locomotive Wheels BZ - freight & Locomotive Wheels

KLW RAILWAy WheeL pRODucTS ARe ceRTIFIeD AccORDINg TO The INDIvIDuAL DeMANDS OF The RAIL OpeRATORS OF pOLAND, czech RepubLIc, SLOvAKIA, beLgIuM, gReAT bRITAIN, SLOveNIA AND huNgARy.

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InTERPIPE nTRP —a long tradition of productionRaILWay WHeeLs unDeR tHe KLW BRanD aRe pRoDuCeD at InteRpIpe ntRp MILL In DnepRo-petRoVsK, uKRaIne. tHe MILL Has MoRe tHan 75 yeaRs of eXpeRIenCe In tHe pRoDuCtIon of RaILWay WHeeL pRoDuCts. tHe annuaL pRoDuCtIon of RaILWay WHeeLs Is 600,000 pIeCes

RAILWAy WheeLS ShOp:• Forging-rollinglinefortheproductionofwheelsfrom650to1269mm• Forging-rollinglineforproductionoftyres• Mechanicalfinishingfloor• Heattreatmentlines• Shotblastingline• Non-destructivetesting(ultrasonic,magneticandhardnesstesting)• Finishingline

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PRODuCTs Quality Control

• Controlofthechemicalcompositionofrawmaterials,steelduringmeltingprocess,readyrolled-stock is implemented on the spectrometers polyvac 2000 type

• Controlofhydrogencontentinliquidsteelisinitiatedbeforeandaftervacuumdegassingusing sound determination by HyDRIs device of company Heraeus elecro-nite

• Controlofnitrogen,oxygen,hydrogencontentisperformedatdevicesPH-402andTS-236 by Leco

• 100%automatedUltrasonictestaswellasmagneticparticleofreadyproducts,isachieved to determine the presence of internal defects inspection

• Controlofthehardnessontherimsurfaceofthewheelsandtyresisrealizedduringtheproduction using durometers produced by eMCo company

• MetaltestingforelongationisrealizedatthemachineUTS-600-1withmicrocomputercontrol and automatic registration of parameters and printing-out of the results

• PendulumtestingimpactmachinePsd50/15ofWpmWerkstoffprufmaschinenGmbHcompany is used to determine the impact strength of steel

• ThedeterminationofsteeltoughnessK1CaccordingtotheASTM-E300isproducedus-ing the universal computerized testing machine Hydropuls sinus 250 by Carl schenk

• Followingrequestsfromcustomers,thetestingofwheelsandtyresbythefallingweightor static compression, as well as the control of micro and macro structure and nature of stresses, are processed through up-to-date methods

QuaLIty ContRoL Is IMpLeMenteD at aLL tHe stages of pRoDuCt ManufaCtuRIng – fRoM steeL MeLtIng to tHe aCCeptanCe test of tHe WHeeLs anD tyRes.

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InTERPIPE sTEEl:a new era in KLW historyIn 2012 InteRpIpe LaunCHeD a neW state-of-tHe-aRt eLeCtRIC steeL MeLtIng faCILIty. In-teRpIpe’s neW MILL Is tHe BIggest faCILIty foR HIgH QuaLIty RounD BILLets pRoDuCtIon In tHe easteRn euRope. WItH a pRoDuCtIon CapaCIty of 1.32 MILLIon tons of RounD BILLets peR yeaR, tHe MILL pRoVIDes KLW WHeeL pRoDuCtIon WItH HIgH QuaLIty steeL BILLets.

the turn-key construction of the mill has been carried out by Danieli Company – global leader inmetallurgicalequipmentmanufacturing.Danieli ensures the design, manufacturing, delivery, and assembly of the principal techno-logicalandancillaryequipment,buildingsandcommunications of the new mill.

The state-of-the-art high-tech equipment is installed and used along the entire techno-logical process at the electric steel-melting complex facilities:

• Electric-arcsteel-meltingfurnacewiththe heat size of 160 tons. Duration of melting is 53 minutes

• Twinpositionladlefurnacewithladlecapacity of 160 tons

• Vacuumdegassingunit• Continuouscastingmachines№1

(5-strands)and№2(4-strands).

Interpipe steel produces continuous casting billets out of the carbon and alloyed steel with diameters from 150 to 470 mm.

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sTEEl making process

steeL gRaDes aCCoRDIng CustoMeR speCIfICatIons

Interpipe steel mill technical expertise and capabilities allows to offer tailor made solutions to solve problems of our customers. It includes new steel grades with order chemical com-position and technical properties for different applications including steel grades for Heavy Haul wheels.

steel for the production of railway wheels is produced by Interpipe steel , Interpipe’s new EAFmill.Highqualitycharacteristicsofsteelareprovidedbythesubsequentprocessingat the out-of-furnace complex of steel treat-ment. the ladles with metal are delivered in turn to the unit furnace-ladle, where the metal finishing and refining takes place. steel blowing in the ladle by argon, along with the refining process provide the sulphur content in thefinishedmetalequalto0.010%,phospho-rus–0.015%aswellasuniformdistributionofanother elements. the degassing process is affected by means of removing the hydrogen, nitrogen, oxygen dissolved in metal at the

vacuum degassing set, while also argon blow-ing. Hydrogen content in steel is within the limits - up to 2 ppm.

Melted steel is then casted at continuous cast-ing machines. DanIeLI’s technology know-how is realized at both continuous casting machines toachievehighqualitybilletsurfaces,homoge-neity of the internal structure, and to exclude non-metallic elements. these technologies in-clude: full steel security, electromagnetic rab-bling, hydraulic system of mould oscillation (which decreases the depth of oscillation trace and provides high quality of the continuouscasted billet surface).

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Klw — a KEy PaRTnERof national railway operators

the Company supplies railway wheels under the KLW brand for different types of railway transport — from passenger to freight cars and underground railway carriages. KLW wheels are used for the new-built as well as for the repair of existing ukrainian rolling stock.

one of the latest mutual projects was the preparation of the ukrainian transport system for the european football championships euro 2012.

In collaboration with the leading ukrainian car building company – Kryukovsky Railway Car Building Works, KLW took part in the creation

of high-speed trans-regional trains, developed to ensure the movement of football fans all over ukraine.

for daily trans-regional trains a new type of KLW railway wheels with diameter of 968 mm was developed in collaboration with the Kryukovsky Railway Car Building Works. the technical characteristics and properties of the wheels provide reliability and guarantee the safe transportation of passengers during their journeys.

the KLW brand has worked for more than 18 years with the Indian Railroads. Railway

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wheels under the KLW brand are used on local trains and subway cars.

the collaboration between the two companies is not limited to the railway wheels supply. one of the latest projects was the hand over of 955 mm railway wheels manufacturing technology to the Durgapur steel plant. In-terpipe ntRp experts developed and handed over the rights on production technology related with design, including production of deformation tools for forging rolling line and

FOR MANy yeARS ALReADy KLW hAS beeN A ReLIAbLe pARTNeR OF The NATIONAL uKRAI-NIAN RAILWAy OpeRATOR – uKRzALySNyTSyA

KLW — A pARTNeR OF The INDIAN RAIL-WAyS

technical documentation for the mechanical fi nishing.

the whole project was carried out under the supervision of the Research Designs & stan-dards organization (RDso) of the Indian state Railways.

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Klw — a PRODuCER Of wHEEl CEnTERs fOR lEaDIngwagon building companies

The KLW pRODucT pORTFOLIO IS NOT LIMITeD TO RAILWAy WheeLS AND TyReS. 10 TypeS OF WheeL ceNTeRS WeRe DeveL-OpeD uNDeR The KLW bRAND

Responding to the demands of our clients we have developed, launched and certified rolled wheel centers.

from 2003 to 2010 we have developed and launched 10 types of wheel centers for the leading wagon building companies of Russia and ukraine. the diameters of wheel centers range from 726 mm to 1073 mm.among the users of wheel centers are wagon-building companies of the CIs, Russia, ukraine, europe and asia.the main advantages of KLW wheel centers are increased durabillity, reliability, economy in operation and higher exploitation characteris-tics in comparison with cast wheel centers.

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Klw — a sTRaTEgIC PaRTnERfor leading european manufacturers

pRODucTS uNDeR The KLW bRAND hAve beeN uSeD FOR MORe ThAN 50 yeARS by euROpeAN pRODuceRS OF WheeLSeTS FOR ALL TypeS OF ROLLINg STOcK FOR geRMAN AND FOReIgN MARKeTS

Quality wheel products, flexible system of work orders and continuous cooperation with clients allow KLW to receive the highest marks in terms of “Quality” from european railway experts.

at the beginning of the 21st century the first order for the supply of railway wheel products

for the switzerland Railways was realized. the complexity of this order lay in the characteris-tics of the wheels that had to take into ac-count the complex mountanious terrain of the country, the greater curvature of the railways, frequentbraking,significantdifferencesinelevation, climbs and descends and relatively high speeds on local railways.

In 2007 KLW signed a long-term contract with the world’s leading transport engineer-ing company, to supply railway wheels for passenger cars with operating speeds of up to 200 km per hour. KLW currently continues supplies of railway wheels to the great Britain

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TECHnOlOgy Of fORgEDRaILWay WHeeLs pRoDuCtIon

steel melting

Continuous casting

Billet inspectingand repairing

Hydrobreaking of the scale

processing in the ladle furnace

Billet cutting at thesawing complex

selective weighing

open forging on2 000 ton press

Degassing process

Billet notching and break-ing

Billet heating in therotary furnace

Closed forging on5 000 ton press

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10

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6

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open air wheel cooling

Heat treatment

samples testing for me-chanical and other charac-teristics

punching on the10 000 ton press

automated ultrasonic andmagnetic powder control

Machining

Drawing in thepit furnace

Machining

Wheel rolling on the rolling mill

Balancing, drillingand marking

Wheel heating

Cooling

automated geometryand hardness control

Wheel calibration on the 3500 ton press and piercing the hub

storage

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TyREs PRODuCTIOnteCHnoLogy

steel melting

Continuous casting

Billet inspectingand repairing

open forging on2 000 ton press

processing in theladle furnace

Billet cutting at thesawing complex

Billet heating in therotary furnace

Weighing

Degassing process

Billet notching and break-ing

Hydrobreaking of the scale

punching and flow formingon 4000 / 2000 ton press

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5

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piercing on 800 ton press

Hot pressing on1250 ton press

non-destructive control (hardness and ultrasonic testing)

Rolling on oneor two presses

thermal treatment

Inspecting andmeasurements

Marking on stamper press

samples selection andall kinds of testing

storage

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Klw — a PaRTnERof LeasIng CoMpanIesfRoM 2008 KLW togetHeR WItH paRtneR CoMpanIes HaVe staRteD to suppLy WHeeLsets to tHe LaRgest LeasIng CoMpanIes In easteRn anD CentRaL euRope

the KLW brand has supplied railway wheels for more than fi ve years to the largest eu-ropean leasing companies Vtg – germany and gatX Rail europe. Railway wheels under

the KLW brand are used for repairing and re-equipmentoffreightcarsownedbyVTG–germany and gatX Rail europe.

Interpipe central trade gmbhCornelliusstrasse 34 60325 – frankfurt am Main, germanyphone +49 1731575805

KLW Wheelco SAVia san salvatore 13 – p. o. Boz 745CH-6902 paradiso – Lugano, switzerlandphone +41 91 261 39 10, fax +41 91 261 39 19e-mail: info@klw-wheelco.chwww.klw.biz