Forged Double Flange Wheels

Forged Double Flange Wheels by WALKSON

Product Overview
WALKSON’s Forged Double Flange Wheels are precision-engineered components designed to deliver unparalleled strength, stability, and durability in heavy-duty industrial applications. These wheels feature dual flanges on both sides of the rim, ensuring secure tracking and enhanced lateral stability on rail systems, even under extreme loads and harsh conditions. Crafted from premium forged steel, our double flange wheels are the preferred choice for industries requiring robust, reliable rail solutions. At WALKSON, we combine advanced manufacturing, rigorous quality assurance, and customized solutions to meet the unique demands of our global clients. Contact us at info@walkson.com (mailto:info@walkson.com) or via WhatsApp/WeChat to discuss your project needs.

Function and Applications
Forged Double Flange Wheels are critical for maintaining alignment and stability in rail-guided systems. The dual flanges prevent derailment by guiding the wheel along tracks, making them ideal for applications where uneven or debris-laden rails are common. Commonly used in:

· Cargo Trains: Supporting heavy freight transport, such as coal, minerals, or containers, with load capacities exceeding 50 tons per wheel.

· Sugar Plants: Facilitating material transfer carts and kilns handling high-temperature, abrasive loads.

· Port Machinery: Powering rail-mounted gantry cranes and container handling equipment in ports and shipyards.

· Mining Operations: Enabling mine carts and transfer vehicles to navigate rugged rail systems.

· Heavy Industry: Used in steel mills, cement plants, and other facilities for bulk material transport.

Their robust design ensures reliability in high-load, high-wear environments, reducing maintenance costs and downtime. WALKSON’s wheels are tailored to withstand extreme conditions, from corrosive port environments to the abrasive settings of sugar processing.

Design and Customization

WALKSON’s Forged Double Flange Wheels are specifically designed to meet the rigorous demands of industrial rail systems. Key design features include:

· Dual Flange Configuration: Provides superior lateral stability, preventing derailment on uneven or worn tracks.

· Optimized Geometry: Customizable wheel diameters (from 200 mm to 1,500 mm) and flange heights to suit specific rail profiles and load requirements.

· High Load Capacity: Engineered to support dynamic loads up to 100 tons per wheel, depending on size and material.

· Custom Finishes: Options for heat treatment, surface hardening, or anti-corrosion coatings to enhance durability in harsh environments.

Our in-house engineering team collaborates with clients to deliver bespoke solutions, ensuring compatibility with existing rail systems and operational needs. Whether you need wheels for standard-gauge cargo trains or specialized sugar plant carts, WALKSON delivers precision and performance.

Material Grades (EN and ASTM Standards)

WALKSON uses premium forged steel grades to ensure strength, ductility, and wear resistance. Commonly used materials include:

· EN Standards:

· S355J2 (EN 10025): A high-strength, low-alloy steel for general heavy-duty applications.

· 42CrMo4 (EN 10083): A chromium-molybdenum alloy steel for high-load, wear-resistant wheels.

· C45E (EN 10083): A medium-carbon steel for balanced strength and machinability.

· ASTM Standards:

· AISI 1045 (ASTM A29): Equivalent to C45E, offering excellent toughness for rail wheels.

· AISI 4140 (ASTM A29): Equivalent to 42CrMo4, ideal for high-stress applications like port cranes.

· AISI 4340 (ASTM A29): A high-strength alloy for extreme load conditions in mining or freight trains.

Each material is selected based on the application’s load, environmental exposure, and wear requirements, ensuring optimal performance and longevity. WALKSON provides material certification to EN 10204 3.1 or 3.2 standards upon request.

Modern and Standardized Manufacturing Process

WALKSON employs a state-of-the-art manufacturing process to produce Forged Double Flange Wheels, adhering to international standards at every step:

· Material Selection: High-quality steel ingots are sourced from certified suppliers, verified for chemical composition and purity.

· Forging: Hot forging at 1,100–1,250°C using hydraulic presses (up to 10,000 tons) to achieve a dense, uniform grain structure, enhancing strength and fatigue resistance.

· Standard: ISO 6892-1 (tensile testing), ASTM E8/E8M.

· Heat Treatment: Normalizing, quenching, and tempering to optimize hardness (HB 229–269 for 42CrMo4) and toughness.

· Standard: EN 10083-3, ASTM A29.

· Machining: CNC lathes and milling machines ensure precise dimensions, flange profiles, and surface finishes (Ra 3.2 or better).

· Standard: ISO 2768 (tolerances), ASME Y14.5 (GD&T).

· Surface Treatment: Optional induction hardening (HRC 50–55) or anti-corrosion coatings (e.g., zinc-rich primer) for enhanced durability.

· Standard: ISO 12944 (corrosion protection).

· Inspection: Comprehensive quality checks using advanced equipment (see below).

Our facilities are ISO 9001:2015 certified, ensuring consistent quality and traceability. We also comply with EN 13262 (railway wheels) and ISO 6506 (hardness testing) for rail-specific applications.

Manufacturing and Inspection Equipment

WALKSON invests in cutting-edge equipment to ensure precision and quality:

· Forging: 10,000-ton hydraulic forging presses, induction furnaces.

· Machining: 5-axis CNC machining centers, high-precision lathes.

· Inspection:

· Ultrasonic Testing (UT): Krautkramer USM 36 for detecting internal defects (EN 10160, ASTM A388).

· Magnetic Particle Testing (MT): Magnaflux Y-7 for surface crack detection (EN 1369, ASTM E709).

· Coordinate Measuring Machines (CMM): Zeiss Contura for dimensional accuracy (ISO 10360).

· Hardness Testers: Mitutoyo HR-530 for Brinell and Rockwell testing (ISO 6506, ASTM E18).

· Spectrometers: Thermo Scientific ARL 3460 for material composition analysis (ASTM E415).

Testing Procedures and Protocols

WALKSON implements rigorous testing to ensure Forged Double Flange Wheels meet industry standards and client specifications:

· Non-Destructive Testing (NDT):

· Ultrasonic Testing: Per EN 10160 or ASTM A388 to detect internal flaws.

· Magnetic Particle Testing: Per EN 1369 or ASTM E709 for surface and near-surface defects.

· Dimensional Inspection: CMM and laser scanning to verify flange height, wheel diameter, and bore accuracy (ISO 2768).

· Mechanical Testing:

· Tensile Testing: Per ISO 6892-1 or ASTM E8/E8M to confirm yield strength (e.g., 600 MPa for 42CrMo4).

· Impact Testing: Per EN 10045-1 or ASTM E23 for toughness at low temperatures.

· Hardness Testing: Per ISO 6506 or ASTM E18 to ensure surface hardness (HB 229–269).

· Fatigue Testing: Cyclic load testing per ISO 1099 to simulate rail conditions (optional for cargo train wheels).

Pre-Production Quality Assurance:
WALKSON employs advanced quality planning to ensure reliability before batch production:

· PPAP (Production Part Approval Process): Submits detailed documentation, including control plans and process capability studies, for client approval.

· FAT (Factory Acceptance Testing): Conducts witnessed performance tests under simulated load conditions (e.g., 50-ton axial load for cargo train wheels).

· PFMEA (Process Failure Mode and Effects Analysis): Identifies and mitigates potential manufacturing risks.

· APQP (Advanced Product Quality Planning): Ensures alignment with client specifications from design to delivery.

Clients are invited to witness FAT and other tests at our facility. WALKSON welcomes third-party inspectors (e.g., SGS, TÜV) designated by clients, ensuring transparency and compliance with client standards.

International Standards Compliance

Our Forged Double Flange Wheels adhere to the following standards:

· EN 13262: Railway applications – Wheelsets and bogies.

· AAR M-107/M-208: Association of American Railroads standards for freight train wheels.

· ISO 9001:2015: Quality management systems.

· ISO 14001:2015: Environmental management for sustainable production.

· ASTM A504: Standard specification for wrought carbon steel wheels.

· EN 10083-3: Technical delivery conditions for alloy steels.

Advantages of Choosing WALKSON

· Unmatched Expertise: With decades of experience in forged steel components, WALKSON delivers wheels tailored to the toughest industrial challenges.

· Customization: From material selection to flange design, we offer bespoke solutions to match your rail system and operational needs.

· Global Reach: Serving clients in over 30 countries, with seamless logistics and after-sales support.

· Rigorous Quality: Our ISO-certified processes and advanced testing ensure zero-defect products.

· Client-Centric Approach: We welcome client oversight, third-party inspections, and collaborative design reviews to ensure satisfaction.

· Competitive Pricing: High-quality forged wheels at cost-effective rates, maximizing your ROI.

Contact WALKSON Today

Elevate your industrial operations with WALKSON’s Forged Double Flange Wheels. For inquiries, custom designs, or technical consultations, email us at info@walkson.com (mailto:info@walkson.com) or reach out via WhatsApp/WeChat. Our team is ready to provide detailed specifications, quotes, or arrange a facility visit. Partner with WALKSON for reliable, high-performance rail solutions that drive your success.