Fabricated Bogie

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GOVERNMENT OF INDIAMINISTRY OF RAILWAYS

TECHNICAL SPECIFICATION FOR FABRICATED

BOGIE FRAME & BOLSTER ASSEMBLY

FOR LOCOMOTIVES

SPECIFICATION No. VL.SPEC-6

(REVISION-01)

JANUARY, 2001

RESEARCH DESIGNS & STANDARDS ORGANISATIONMANAK NAGAR, LUCKNOW - 226 011

Priced Document


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C O N T E N T S

Para Description Page

1. Scope 1

2. Definition 1

3. Instructions for Purchaser 1

4. Specifications & Standards Referred 2

5. Deviation (s) 2

6. Quality Assurance Plan 3

7. Manufacturing Procedure 3

8. Stages of Inspection 8

9. Quality Control Process 9

10. Proof Load test 10

11. Identification Marks 10

12. Packing 11

13. Warranty 11

ANNEXURES

I List of Drawings of Various Types of Bogie Frame and BolsterAssemblies for Diesel & Electric Locomotives.

II List of Drawings for Proof Load Test and Weld Quality Checks forDifferent Zones of Various Types of Bogie Frames and BolsterAssemblies for Diesel and Electric Locomotives.

II Recommended Stress Relieving Procedure.


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TECHNICAL SPECIFICATION FOR

FABRICATED BOGIE FRAME & BOLSTER ASSEMBLY

FOR LOCOMOTIVES

1. SCOPE

1.1 This specification covers the technical requirements of fabricated bogie frameand bolster assemblies for diesel and electric locomotives.

1.2 The fabricated bogie frame and bolster assemblies shall be supplied

conforming in all respects to the relevant drawings as indicated in thepurchase order and this specification.

1.3 A list of drawings for various types of fabricated bogie frame & bolsterassemblies for diesel and electric locomotives is given at Annexure-I forreference of purchaser. List of drawings for Proof load test and weld qualitycheck for different zones of various types of bogie frames and bolsterassemblies which are required to be carried out during manufacturing is givenat Annexure-II.

For bogies not listed therein, the purchaser shall separately specify the

drawings.

2. DEFINITION

Wherever Inspecting Agency has been mentioned in this document, it shallbe taken as Authorised Inspecting Agency mentioned in the purchase orderof the Purchaser.

3. INSTRUCTIONS FOR PURCHASER

3.1 The tenderer shall be an RDSO Approved Vendor and the firms name shallbe on the current list of RDSO vendor directory MPM.0015, for fabricatedbogie frame and bolster assembly for locomotives.

3.2 Inspection of prototypes shall be carried out by RDSO (VDG / MP Dte.).Purchaser shall clearly indicate this in the Purchase Order.

3.3 Inspection of bogie frames and bolster assemblies other than prototypes shallbe carried out by the Inspecting Agency specified in the purchase order.

3.4 The purchase order shall clearly indicate reference of this specification.

SPECIFICATION No. VL-SPEC.6 (Rev.01) 1


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3.5 Purchaser is required to obtain clearance from RDSO for any deviations fromoriginal design, material specifications, dimensions etc. desired by themanufacturer.

4. SPECIFICATIONS & STANDARDS REFERRED

The firm shall have a copy of latest versions of following specifications &standards/codes:

Sl. Spec. No. Description

1. VL.Spec.-6(Rev.01)

Technical Specification for Fabricated Bogie Frame & BolsterAssemblies for Locomotives.

2. IS : 813 Scheme of Symbols for Welding.

3. IS : 817 Code of Practice for Training and Testing of Metal Arc

Welders.4. IS : 2062 Steel for General Structural Purposes.

5. IS : 2074 Ready Mixed Paint, air drying, red oxide - zinc chrome,Priming.

6. IS : 2102 General Tolerances (for Un-toleranced Linear and AngularDimensions).

7. IS : 3658 Code of practice for liquid penetrant flaw detection.

8. IS : 4225 Recommended Practice for Straight Beam Ultrasonic Testingof Steel Plates.

9. IS : 5334 Code of Practice for Magnetic Particle Flaw Detection ofWelds.

10. IS : 7310(Part 1)

Approval Tests for Welders working to Approved WeldingProcedures.

11. IS : 8662 Enamel, Synthetic, Exterior (a) Under Coating (b) Finishingfor Railway Coaches.

12. IS : 9595 Metal-Arc Welding of Carbon and Carbon Manganese Steels-Recommendations.

13. ASME-Sec IX Welding Procedure Specification.

14. ASTM E-164 Practice for Ultrasonic Contact Examination of Weldment

15. ASTM A: 435 Straight Beam Ultrasonic Examination of Steel Plates forPressure Vessels.

16. AWS - D.1.1 Structural Welding Code.17. IRS: M28 Classification, Testing and Approval of Metal-Arc Welding

Electrodes used and Gas Welding Rods.

18. Blue Std. ofRadiography

International Institution of Welding (IIW)

5. DEVIATION (S)

If deviations from original design, material specifications, dimensions etc. aredesired by the tenderer, specific proposals with reasons shall be submitted tothe purchaser. Commencement of manufacture shall not be done till thepurchase grants clear authorization for acceptance of the deviation.



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6. QUALITY ASSURANCE PLAN

6.1 The firm shall submit two copies of Quality Assurance Plan (QAP) outlining allaspects of quality control required to obtain a quality product for approval toRDSO.

6.2 QAP shall be prepared on the lines as indicated in RDSOs Report No. V-3titled Sample Quality Assurance Plan for Fabricated Locomotive BogieFrames and Bolsters.

6.3 The manufacturer shall proceed for manufacturing of bogie frame and bolsterassembly only after approval of QAP. The firm shall follow the stipulations ofQAP strictly.

7. MANUFACTURING PROCEDURE7.1 During manufacture of prototype bogie frame and bolster assemblies, the

vendor is required to co-ordinate and maintain liaison with VDG (MP Dte.),RDSO, Lucknow and with the Purchaser for any clarifications required inregard to drawings, specifications, manufacturing and testing etc.

7.2 During manufacture and assembly of prototype fabricated bogie frame andbolster assemblies, and changes in the design considered necessary shall beidentified by the Purchaser / RDSO, these changes shall be incorporated onall the bogie frame and bolster assemblies manufactured by the firm.

7.3 Raw Material

.1 The chemical composition & mechanical properties of steel shall conformto IS: 2062 Grade C, killed & normalised quality, Fe-410 WC unlesssome other material is specified in the drawings.

.2 Steel plates shall be procured along with their test certificates from SAIL /TISCO or other reputed manufacturers. These test certificates shall becorrelated with the stamping on plates to be taken up for manufactureprior to commencement of fabrication.

.3 All test certificates shall be submitted to Inspecting Agency for scrutiny.

.4 Any deviation in material specification would lead to rejection of material.

7.4 Inspection of Steel Plates

.1 All plates to be taken up for manufacture shall be cleaned for freedomfrom rust and scales and shall then be examined visually for surfacedefects such as cracks, dents, pitting, bends etc. Only those plates freefrom any surface defect as stated shall be used for manufacture.



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.2 The firm shall check chemical composition and mechanical properties ofall plates to be taken up for manufacture to ensure conformity ofproperties with the test certificates.

.3 Inspecting Agency shall draw one or two samples from these plates for

verifying chemical composition and mechanical properties. Themanufacturer shall provide facilities at his premises to Inspecting Agencyfor evaluation of chemical composition and mechanical properties.

.4 All plates of thickness 12 mm and above shall be subjected to ultrasonictest on the entire surface for detection of defects like lamination seamsand internal flaws. The ultrasonic testing shall be carried out as per ASTMA: 435 / IS: 4225 using angular / normal probes.

.5 Only those plates shall be used for fabrication which have been testedand found acceptable.

7.5 Welding Procedure

.1 Filler Metal

.1 Metal Inert Gas (MIG) welding process using CO2/Argon gas asshielding media and RDSO approved brand of filler wire shallonly be adopted for welding of bogie frame and bolsterassemblies including brackets.

Manual Metal Arc (MMA) welding may be permitted for weldingof some brackets only after obtaining express approval from thepurchaser for each order.

.2 In brackets where MIG welding is not adopted, RDSO approvedbrand of electrodes Type C2 & D1 to IRS: M28 having hydrogencontent less than 5 ml/100 gm preferably with IS code no. EB5426 H3JX or EB 5424 H3JX shall be used for MMA weldingprocess.

.3 In reference to Para 7.5.1.1. & 7.5.1.2, latest RDSO approvedbrands of welding consumables shall only be used. The firmneeds to take approval from the inspecting agency for use ofwelding consumables prior to commencement of manufacture ofbogie frame and bolster assembly.

.2 Run on and Run off tabs

Run- on and Run-off tabs (a bevelled fillet joint of about 150 to 200 mmlong and made out of the same plate and thickness) shall be attached withside beams at all corners by tack welding. During welding of the side

beams these tabs are also to be welded as a continuous welding of theside beams. These tabs are to be inspected as per Para 7.8.4.



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7.6 Welders Qualification

Welder employed for welding of bogie frame and bolster assemblies shall

have a high standard of workmanship and shall be qualified to AWS weldingcode D.1.1 or IS 817/ IS: 7310. Approval of Inspecting Agency to specificwelder(s) to be engaged for this fabrication job is / are needed prior tocommencement of welding work. Approval may be given by the InspectingAgency to individual welders based on valid certificate from reputedorganisation and / or trial welding done by welder in their presence.

7.7 Quality of Weld Joints

.1 Weld joints shall have uniform beading and smooth change over from

weld deposit to parent metal and thorough fusion between adjacent layersof weld metal and between weld metal and parent metal.

.2 Weld joints shall be free from cracks, craters, undercuts, overlaps,porosity, inclusions, blowholes etc.

.3 In butt welded area, one extra run of welding shall be applied; excessmetal shall then be ground off to eliminate stress raisers and normalisethe welded metal.

.4 The fillet weld profile shall be made concave by grinding so that smoothtransition occurs at the toe of weld maintaining correct size of the welds.Welds shall be ground to eliminate stress raisers and to improve fatiguelife.

.5 Adequate measures shall be taken by the manufacturer to avoid distortionduring welding. Minor distortion, if any, shall be corrected preferably in thecold (by mechanical method). Any correction to be done by flame heatingof members must be carried out only in presence of Inspecting Agency orhis representative; temperature of heated part shall not exceed 500 C.

.6 All linear discontinuities are unacceptable and shall be repaired bychipping or grinding and subsequent welding. After rectification of defectsin welding, the area shall be re-examined by the same method to ensuredefect free weld joint.

7.8 Inspection of Weld Quality

The quality of entire weld length shall be checked by Dye Penetrant test.However, weld quality of critical areas as shown in list of diagram given inAnnexure II for various bogie frames / bolster assemblies shall be checked

by magnetic particle test and quality of welding of butt joints shall be checked



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by radiographic / ultrasonic test as indicated in the diagram. Details of testsand their acceptance standards are given below:

.1 Dye Penetrant Test

Dye penetrant test shall be conducted to ensure absence of cracks, undercuts, blow holes, porosity etc. The procedure and acceptance standardshall be as per IS: 3658.

.2 Radiographic / Ultrasonic Testing

Butt weld joints shall be subjected to Radiographic tests. Butt weld jointsnot accessible to radiography shall be checked by Ultrasonic testing. Themanufacturer shall submit method of test of all butt joints to InspectingAgency indicating acceptance test for each joint. Proper record ofRadiographic / Ultrasonic testing shall be maintained. Acceptance

standard shall be as per Blue Standard of IIW for Radiography and ASTMA435 / IS: 4225 for Ultrasonic test.

.3 Magnetic Particle Test (MPT)

.1 All weld joints on critical areas as indicated in relevant drawinggiven in list at AnnexureII for various bogie frames / bolsterassemblies shall be checked by Magnetic Particle Test. Theseareas shall be cleaned and made smooth by grinding beforechecking of weld quality by magnetic particle test. The areas thenshall be checked by loop / yoke method for weld flaws. Theprocedure and acceptance standard shall be as per IS: 5334.

.2 Evaluation for MPT

Each discontinuity and defect indicated by retention of magneticparticles shall be explored to determine if linear discontinuities arepresent or defect is due to excessive surface roughness, heataffected zones etc. If the indication is suspected due to excessivesurface roughness, heat affected zones etc., it should be confirmedby re-checking the area by MPT after making the area smooth by

grinding.

.3 Rectification of Weld Defects

.1 All linear discontinuities are un-acceptable and shall beremoved and repaired by chipping / grinding and subsequentwelding and the area re-examined by the same method toverify complete rectification of observed defect.

.2 Further rectification shall not be allowed if linear discontinuityis observed again during checking after rectification.



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.3 All test reports of Magnetic particle inspection shall be

submitted to Inspecting Agency for review.

.4 Inspection of Run-on and Run-off tabs

Any two randomly selected run-on and run-off tabs welded with sidebeams are to be detached after welding in presence of InspectingAuthority and subjected to magnetic particle test to assess the quality ofwelding of side beams. These tabs should be free from any weld defectlike lack of root fusion, slag inclusion, porosity etc.

.1 Evaluation for Run-on and Run-off tabs

In case any one of the welds fails to meet the requirement of a goodfillet joint, the whole fillet welding of the BOX section of RH and LH

beams shall be subjected to ultrasonic test as per ASTM E-164.

7.9 Stress Relieving

.1 All rework including rectification welding and straightening operations shall becompleted before stress relieving.

.2 After completion of welding, the bogie frame & bolster assembly shall besubjected to stress relieving as per procedure given in AnnexureIII. Thestress relieving shall be carried out in oil fired / electric furnace equipped withthermocouples and graphical recorders. Adequate measures shall be taken toavoid distortion of bogie frame & bolster assembly during stress relieving.

.3 Record of stress relieving cycle shall be submitted to the Inspecting Agency.

7.10 Sand / Shot Blasting

After stress relieving, the bogie frame and bolster assembly shall be cleanedby sand / shot blasting.

7.11 Check for Distortion and Cracks in Welding

.1 After cleaning of bogie frame and bolster assembly by sand / shot blasting,the critical areas of bogie frames and bolster assembly shall be checked forpresence of cracks in welding.

.2 The bogie frame shall also be checked for distortion, if any.



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7.12 Anti Corrosive Paint

After sand / shot blasting and crack detection & acceptance of the bogieframe and bolster assembly, the same shall be painted with one coat of 25micron DFT red oxide zinc chromate primer conforming to IS: 2074. The paint

shall be of ICF approved brands procured from ICF approved firms.

7.13 Marking of Bogie Frame and Bolster Assembly

The bogie frame and bolster assembly shall be placed on marking table inorder to check:

.1 Profile and Geometry.

.2 Absence of distortion

.3 Machining allowances

Record of above checks shall be made in the Dimension Control Chartsapproved by the Inspecting Agency.

7.14 Machining of Bogie Frame and Bolster Assembly

The bogie frame and bolster assemblies shall be machined at all requiredlocations preferably in one setting.

7.15 Painting

Bogie frame and bolster assemblies shall be given a finish coat of 25-micronDFT synthetic enamel to IS: 8662. The paint shall be of ICF approved brandsprocured from ICF approved firms.

8. STAGES OF INSPECTION

8.1 Inspection shall be carried out by the Inspecting Agency at the end of thefollowing stages of manufacture:

.1 Inspection for raw material, approval of welders, welding consumables,gauges and fixtures.

.2 Inspection of plates in cut and machined conditions to check edgepreparation.

.3 Inspection of bogie frame and bolster sub-assemblies like side frames,transoms, end beams, horns (wherever provided) and brackets in tack-welded condition to check dimensional accuracy.



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.4 Inspection of bogie frame / bolster sub-assemblies like side frames,transoms, end beams, horns and brackets after full welding.

.5 Inspection after assembly of side frames, transoms and end beams ofbogie frame / bolster assembly in tack welded condition.

.6 Inspection after assembly of side frames, transoms and end beams aftercompletion of welding and assembly of brackets in tack welded condition.

.7 Inspection of complete bogie frame / bolster assembly after completion ofwelding and before stress relieving.

.8 Inspection of bogie frame / bolster assemblies after stress relieving andsand / shot blasting but before applying anti corrosive paint.

.9 Inspection after machining.

.10 Inspection during proof load test.

8.2 The manufacturer shall fabricate the bogie frame and bolster assembly instages as detailed in Para 8.1. The manufacturer shall start each stage ofmanufacturing of bogie frame and bolster assembly only after receipt ofclearance of previous stage by the Inspecting Agency.

9. QUALITY CONTROL PROCESS

9.1 Dimensions and tolerances

.1 All dimensions / tolerances shall be as per details given in the drawings.

.2 Detailed dimension control charts shall be prepared for stage inspectionduring manufacturing of bogie frame and bolster assembly in whichmeasurements of critical dimensions shall be recorded and kept forevaluation and verification by the Inspecting Agency.

.3 All non-toleranced dimensions shall be maintained in accordance withIS: 2102 (Medium) or as indicated in the drawing.

.4 Gauges, fixtures, templates and accurate measuring instruments shallbe used to ensure the correctness of the dimensions.

9.2 Periodic Calibration of Gauges and Fixtures

Gauges, fixtures, and templates shall be calibrated / checked for correctnessand accuracy periodically.



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10. PROOF LOAD TEST

10.1 Two bogie frames and bolster assemblies out of a lot of 25 bogie frames andbolster assemblies or two bogie frames and bolster assemblies per order if

the order is for less than 25 bogie frames and bolster assemblies shall besubjected to proof load test as shown in relevant drawing given in Annexure-II or as specified by the purchaser to check manufacturing quality. Thefollowing procedure shall be adopted for proof load test of bogie frame /bolster assemblies:

- The bogie frame / bolster assembly shall be kept on tables as per thearrangement shown in relevant drawing.

- Dial gauges shall be mounted at the locations on the transoms and sideframes as shown in the specified drawing and shall be set at zero beforeproof load test.

- The bogie frame / bolster assembly shall be loaded as per the loads givenin the specified drawings and the load shall be sustained for a minimumperiod of 10 minutes.

- Deflection of transoms and side frames shall be recorded under loadedcondition.

- Load shall be removed gradually and reading of the dial gauge shall be

recorded.

10.2 There should not be any sign of deformation, permanent set and any cracks.The detection of cracks shall be checked by Ultrasonic and Magnetic Particle /Dye-Penetrant test on critical areas as shown in the drawing.

11. IDENTIFICATION MARKS

Each bogie frame/bolster shall be provided with an identification plate at an

easily visible location. The identification plate shall contain:

a) Manufacturers Monogram.

b) Contract No./P.O. No.

c) Bogie Serial No. / Bolster Serial No.

d) Month & Year of Manufacture.



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12. PACKING

12.1 Rust preventive coatings shall be applied on all machined surfaces beforepacking.

12.2 While packing due care shall be taken to protect all machined surfacesagainst any damage during transit.

12.3 Bogie frames / bolster assemblies shall be packed in pairs, keeping horn legsin opposite directions (where applicable) with wooden planks using suitablefasteners.

12.4 All data packages including Dimensional Control charts, Test certificate forchemical and mechanical properties, radiography / UST, MPT, DPT and heattreatment records etc. shall be supplied along-with bogie frames / bolsterassembly and the same shall be the property of Purchaser.

13. WARRANTY

Themanufacturer shall undertake warranty for trouble free and satisfactoryservice performance on bogie frame and bolster assemblies supplied by themfor a period to be fixed by the purchaser from the date of commissioning intoservice. A recommended period is 5 years from the date of commissioninginto service. Any repairs / rectification required due to defects observed during

service on these bogie frames / bolster assemblies on account ofmetallurgical and / or manufacturing deficiency of raw material, manufactureand workmanship shall be carried out by the supplier at his own cost. The firmshall arrange replacement of bogie frame / bolster assemblies if the bogieframe / bolster assembly is considered unserviceable due to defects observedduring warrantee period on account of metallurgical and / or manufacturingdeficiency of raw material, manufacture and workmanship. The decision ofpurchaser in this regard shall be final.

..



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ANNEXURE I

LIST OF DRAWINGS OF VARIOUS TYPES OFBOGIE FRAMES AND BOLSTER ASSEMBLIES FOR DIESEL

AND ELECTRIC LOCOMOTIVES

Sl. Type of BogieDrawing no. for

Bogie frame Arrgt.

Drawing no. for

Bolster Arrgt.

1 Flexi-coil Mk IV bogie 16.04.102 16.04.63

2High Adhesion bogie forWAG7 locomotives

SK.DL-4181 N.A

3Co-Co Trimount fabricatedbogie Mk-1

SK.DL-3981&

SK.DL-3982N.A

4 Co-Co Trimount fabricatedbogie Mk-II SK.DL-4017 N.A

5 Bo-Bo Bogie for WDP1 loco SK.VL-152 N.A

6 Flexi-coil Mk-5 bogie VL.FM5-b.01 VL.FM5.b.21

7 Bogie for Srilanka loco 49.04.01 N.A

8Bogie for Cape/Meter gaugeloco

50.04.02 N.A

N.A : Not applicable as bogies are bolsterless.

Note: Lower level drawings are specified in respective arrangement drawingsmentioned above. Please ensure that drawings referred are with latestalterations.



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ANNEXUREII

LIST OF DRAWINGS FOR PROOF LOAD TESTAND WELD QUALITY CHECKS FOR DIFFERENT ZONES OF

VARIOUS TYPES OF BOGIE FRAMES AND BOLSTER ASSEMBLIESFOR DIESEL AND ELECTRIC LOCOMOTIVES

Sl. Type of BogieDiagram for Proof Load Test and

Zones for Radiographic / Ultrasonic,

Magnetic Particle Checks

1 Flexi-coil Mk IV bogie SK.DL-4304

2 High Adhesion bogie for WAG7 locomotives SK.DL-4305

3 Co-Co Trimount fabricated bogie Mk-1 SK.DL-4306

4 Co-Co Trimount fabricated bogie Mk-II SK.DL-4307

5 Bo-Bo Bogie for WDP1 locoVL-0.46VL-0.86

6 Flexi-coil Mk-5 bogie VL.FM5.b.13

7 Bogie for Srilanka loco -

8 Bogie for Cape/Meter gauge loco -



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ANNEXUREIII

RECOMMENDED STRESS RELIEVING PROCEDURE

1. To monitor the temperature effectively, four thermocouples shall be at the fourcorners of bogie frame / bolster assembly and two thermocouples at thecentre of the long beams shall be provided on the furnace. The thermocouplesshall be connected with associated recording equipment.

2. To avoid distortion during stress relieving operation, suitable tie-bars shall beprovided.

3. The bogie assembly shall be kept in the furnace, bottom side up (invertedposition).

4. The assembly shall be suitably supported while loading in furnace to avoidany permanent deformation.

5. The temperature of the furnace shall not exceed 315 C at the initial stagewhen the bogie frame / bolster assembly is kept in furnace.

6. Above 315 C, the rate of heating shall not exceed 160C/hour. During theheating period, variation in temperature throughout the portion of the part

being heated shall not be greater than 50 C.

7. Soaking temperature shall be between 600 C and 650C. On reachingsoaking temperature, the assembly shall be held within specified limits for atime not less than onehour per 25 mm thickness of plates.

For determining soaking time, the thickness of thickest part of assembly shallalso be considered. During the soaking period, difference between highestand lowest temperature at different points of the assembly shall not be greaterthan 50C.

8. The job shall then be allowed to cool down to 315C in closed furnace at arate not exceeding 100 C/hour. Below 315C,the assembly may be cooledin still air.

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