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N10153
Rev. 01 - en
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In-house standard
8/12/2024, confidential / vertraulich
Printed copies are uncontrolled.

Grey cast iron castings – cylinders for

air supply equipment for rail vehicles,
grey cast iron castings with lamellar
graphite

Technical conditions of d elivery

Created: 05.07.2021 Checked: 05.07.2021

Date Date

M. Hartl / S. Khambekar J. Löw

Name Name

MUC - R/ASD03 MUC - R/BET6

Department Department

Approved: 05.07.2021 Translated: 11/2022

Date Date

Kraus Acolad Germany

Name Name

MUC - R/RST03 R/RST2

Department Department

pereirlu, Brazil - Itupeva, e-NORM Knorr-Bremse

 Grey cast iron castings – cylinders for air supply
equipment for rail vehicles, grey cast iron castings
with lamellar graphite
In-house standard Doc. No.: N10153
Revision: 01 - en

Contact address
Knorr-Bremse Systeme für Schienenfahrzeuge GmbH
Moosacher Str. 80
80809 Munich, Germany
Telephone: +49 (89) 3547-0
www.knorr-bremse.com
Ausdrucke unterliegen nicht dem Aenderungsdienst.

Preface
8/12/2024, confidential / vertraulich

This in-house standard was drawn up by:

Printed copies are uncontrolled.

MUC – R/ASD03 - Mr M. Hartl / S. Khambekar

MUC – R/ASD - Dr T. Kipp

The content of this in-house standard was approved by:

MUC – R/ASD - Dr T. Kipp

Previous editions
N10153: 1989-09

Change history
The following changes have been made to revision 00:

Section Description of the change

Rev. 00 Rev. 01
Adjustment of the value range: Updating the
a)
values for the chemical composition
b) 3.3 C´ not permissible C´ acceptable up to 5%

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pereirlu, Brazil - Itupeva, e-NORM Knorr-Bremse

 Grey cast iron castings – cylinders for air supply
equipment for rail vehicles, grey cast iron castings
with lamellar graphite
In-house standard Doc. No.: N10153
Revision: 01 - en

Referenced / additional standards and other documents

Doc. no. Title

DIN 1690-2 Technical delivery conditions for castings of metallic materials

DIN EN 1561 Foundry work: Grey cast iron
DIN EN 1370 Foundry work: Examination of the surface condition
DIN EN ISO 945-1 Microstructure of cast irons – Part 1: Graphite classification by visual analysis
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DIN EN ISO 6506-1 Metallic materials – Brinell hardness testing – Part 1 – Test procedure
DIN EN 10204 Metallic products – Types of inspection documents
8/12/2024, confidential / vertraulich

DIN EN ISO 5579 General principles for radiographic examination of metallic materials using
Printed copies are uncontrolled.

X-rays and gamma rays

DIN EN 12681 Foundry work: Radiographic examination
VDG leaflet no.1 Avoidance and elimination of residual stresses in grey cast iron castings
with lamellar graphite
ASTM E446 Standard reference radiographs for steel castings up to 2 inches (51 mm)
in thickness, American Society for Testing and Materials
BNIF 359 Technical recommendation of the Bureau de Normalisation des Industries
de la Fonderie. Caractérisation d’états de surface des pièces moulées –
Utilisation des échantillons types de 110 x 160 mm, Editions Techniques
des Industries de la Fonderie, 44 avenue de la Division Leclerc,
92310 Sèvres, France

The documents referenced are required for the application of this document. In the case of dated references, only the referenced
edition is valid. For undated references, the latest edition (including all changes) of the document referred to is applicable.

The document was originally written in German.

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pereirlu, Brazil - Itupeva, e-NORM Knorr-Bremse

 Grey cast iron castings – cylinders for air supply
equipment for rail vehicles, grey cast iron castings
with lamellar graphite
In-house standard Doc. No.: N10153
Revision: 01 - en

Contents

1 Scope of application 5

2 Material 5

3 Characteristics and test method 6

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3.1 Chemical composition 6

3.2 Hardness test 6
3.3 Metallographic characteristics 7
8/12/2024, confidential / vertraulich
Printed copies are uncontrolled.

3.4 Internal casting faults (inhomogeneities, blowholes and microporosities) 7

3.5 Visual inspection of the raw part 7
3.6 Surface defects 8
3.7 Dimension testing for raw part 8
3.8 Heat treatment 8
3.9 Sketch for taking samples 9

4 Test requirements 9

5 Welding / reworking 10

6 Marking 10

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pereirlu, Brazil - Itupeva, e-NORM Knorr-Bremse

 Grey cast iron castings – cylinders for air supply
equipment for rail vehicles, grey cast iron castings
with lamellar graphite
In-house standard Doc. No.: N10153
Revision: 01 - en

1 Scope of application

This standard specifies the characteristics, tests and test conditions for air supply system cylinders for
rail vehicles, made of grey cast iron with lamellar graphite to DIN EN 1561.

2 Material

Type of material: Cast iron with lamellar graphite (DIN EN 1561)

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Grade of material: EN-GJL-KB

Casting method: Sand casting
8/12/2024, confidential / vertraulich

Melting technique: Cupola or electric oven

Printed copies are uncontrolled.

Heat treatment: Stress-relief annealing

Cleaned, deburred and bead-blasted

General
characteristics free from visible cracks, sand inclusions, slag inclusions,
2.1 of the parts and pinholes
(visual inspection) Free of cooling fin fractures and sprues

2.2 Type of material Grey cast iron with lamellar graphite to DIN EN 1561

2.3 Kind of material EN-GJL-KB

2.4 Casting method, Sand casting

2.5 Melting technique Cupola or electric oven

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pereirlu, Brazil - Itupeva, e-NORM Knorr-Bremse

 Grey cast iron castings – cylinders for air supply
equipment for rail vehicles, grey cast iron castings
with lamellar graphite
In-house standard Doc. No.: N10153
Revision: 01 - en

3 Characteristics and test method

3.1 Chemical composition

The chemical composition of white cast samples shall be determined by spectral analysis.
Element Set-point in %
of mass
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C* 3.25 to 3.65
Si 1.50 to 1.85
Mn* 0.50 to 0.80
8/12/2024, confidential / vertraulich

Cu 0.10 to 0.30
Printed copies are uncontrolled.

Sn Max. 0.15
P < = 0.10
S* < = 0.10
Cr
Ni
Sum total < = 0.40
Mo
Ti

The determination of the carbon content of castings is by thermal analysis. All other elements are
determined by spectral analysis.
* Note: During the spectroscopic analysis of the component, indications of deviations in the carbon,
manganese and sulphur content are to be expected due to the graphite formation.

3.2 Hardness test

The hardness test to DIN EN ISO 6506-1 for initial sample and series delivery shall be documented
with individual and average values in the 3.1 Certificate.

Characteristic value Set-point Unit Remark

HBW5/750
Hardness 200 to 240 HBW Casting skin removed
2.5/187.5

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pereirlu, Brazil - Itupeva, e-NORM Knorr-Bremse

 Grey cast iron castings – cylinders for air supply
equipment for rail vehicles, grey cast iron castings
with lamellar graphite
In-house standard Doc. No.: N10153
Revision: 01 - en

3.3 Metallographic characteristics

Desired cast structure
Graphite formation V = 100:1, form I,
(DIN EN ISO 945) Arrangement A, size 4 to 5, C´ up to 5% permissible,
Arrangements D and E acceptable up to 20%
Matrix V = 200:1 (500:1)
Fine lamellar perlite. Ferrite not exceeding 5% acceptable
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No secondary cementite
No ledeburite
8/12/2024, confidential / vertraulich
Printed copies are uncontrolled.

Note: The microstructure is assessed on the piston ring running surface. The ferrite content is assessed
microscopically at 200x magnification on five adjacent images in format (8 x 10) cm.

3.4 Internal casting faults (inhomogeneities, blowholes

and microporosities)
During first article inspection, the entire component shall be examined using suitable methods
(radiographic testing or cross-section sampling). The internal defects are acceptable up to an upper
limit of V2 to DIN 1690-2 as shown in the reference pictures in ASTM E446. However, the leakage
testing of the part is conclusive. The finished cylinder must be airtight, test pressure: 12 bar gauge
pressure.

3.5 Visual inspection of the raw part

Visual inspection is performed to DIN EN 1370 (surface roughness) with the aid of the reference pattern
set BNIF 359. Visual inspection should be performed by the unaided naked eye.

The minimum requirements are defined as follows:

Category satisfies BNIF Remark

reference pattern
Surface roughness 3 S1
Mechanical cleaning 3 S2 A rougher grinding down is
acceptable in exceptional cases;
the overall impression is decisive.

Identification of raw parts:

The identification of all raw parts should be checked for whether it is legible and has been applied as
specified in the drawing. If the identification has been applied in such a way that it will be removed either
partially or completely during machining, appropriate measures should be taken in advance so as to
recondition the unmachined casting identification without loss of traceability.

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pereirlu, Brazil - Itupeva, e-NORM Knorr-Bremse

 Grey cast iron castings – cylinders for air supply
equipment for rail vehicles, grey cast iron castings
with lamellar graphite
In-house standard Doc. No.: N10153
Revision: 01 - en

3.6 Surface defects

Surface defects (discontinuities in the surface) are determined by means of visual inspection and
evaluated and classified by their size and number.

Requirements:
• Quality level VD3: general areas to DIN EN 1370
• Surface defects are not permissible in the piston surface running area
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3.7 Dimension testing for raw part

8/12/2024, confidential / vertraulich
Printed copies are uncontrolled.

The dimensions of the unprocessed part should be checked for adherence to the drawing specifications
for the finished parts (as minimum values).

3.8 Heat treatment

Stress-relief annealing
Annealing temperature: 500 to 550 °C
Holding time: 90 min
Cooling: T ≤ 300 °C in the oven
Cooling rate: ≤ 40 °C/h

Stress relief annealing can be omitted if residual stresses are largely avoided by slow cooling in the
mould (cooling rate ≤ 40° /h) and removing the cylinders from the mould at temperatures T ≤ 300 °C.
See VDG leaflet N 1.
If stress-relief annealing is carried out, a factory test with acceptance test certificate must be sent.

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pereirlu, Brazil - Itupeva, e-NORM Knorr-Bremse

 Grey cast iron castings – cylinders for air supply
equipment for rail vehicles, grey cast iron castings
with lamellar graphite
In-house standard Doc. No.: N10153
Revision: 01 - en

3.9 Sketch for taking samples

For chemical composition, hardness test area and ground sample.

Sketch
Hardness test area I
(1 mm removed from the casting
Hardness test area II surface by turning)
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Area for ground sample

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Centre of
the cylinder Area for C-determination

4 Test requirements

The table below describes the test scope for first articles and series production parts.

Item Feature Characteristics Test scope Object Documentation

and test First Series * **
method articles
1 piece Unprocessed
1 Chemical composition 3.1 1 pc 3.1
per batch part
1 piece Unprocessed
2 Hardness test 3.2 1 pc 3.1
per batch part
Metallographic 1 piece Unprocessed
3 3.3 1 pc 3.1
characteristics per batch part
Radiographic Unprocessed
4 3.4 3 pc - FAIR
examination part

5 Surface test 3.5 3 pc - Finished part SPC

Unprocessed
6 Visual inspection 3.6 3 pc - FAIR
part
* Definition of batch: foundry batch.
** 3.1: Acceptance test certificate to DIN EN 10204
FAIR: First article inspection report
SPC: Statistical process control
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pereirlu, Brazil - Itupeva, e-NORM Knorr-Bremse

 Grey cast iron castings – cylinders for air supply
equipment for rail vehicles, grey cast iron castings
with lamellar graphite
In-house standard Doc. No.: N10153
Revision: 01 - en

5 Welding / reworking

As a matter of principle, production and repair welding is not acceptable. As a matter of principle, other
reworking methods (such as the use of filling materials) are not acceptable.

6 Marking
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The identification of the castings must allow full traceability of the entire production process.
8/12/2024, confidential / vertraulich

If the identification of the raw part is removed during machining, it must be re-applied at some other
Printed copies are uncontrolled.

appropriate position after the machining process. In particular, ensure that traceability is maintained
(see Sec. 3.5 − Visual inspection of the unmachined casting identification).

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