AUSHAPUR (V) GHATKESAR (M) 501301

DEPARTMENT OF MECHANICAL ENGINEERING

“STUDY ON CORROSION REPAIRS AND COACH

CONVERSIONS”

TEAM MEMBERS:

R.SHIVA : 15P61A0370
R.VIJAY KUMAR : 15P61A0384
D.SAI SHIVAJI : 16P65A0317
B.SHRAVAN KUMAR : 16P65A0322
 “STUDY ON CORROSION REPAIRS AND COACH CONVERSIONS”
ABSTRACT
Modern Railway systems are subjected to use with fast trains and large
loads. Corrosion of coaches has been recognized as one of the most
serious causes to damage of Railway coaches. The coach corrosion is so
complex involving physical, chemical and electrochemical process that it
is very difficult to assess the condition and causes of corrosion affected
coaches.
Corrosion when once started spreads rapidly and this would be dangerous
in so for as stress bearing members of the shell are concerned. It is,
therefore, essential to stop the initiation of corrosion and attempts made
to arrest the spread of corrosion particularly in places, which are not
easily accessible for inspection and attention. In this project we have
made an attempt to present the basic causes of rail coach corrosion, its
process and preventive measures to avoid the corrosion, influencing
factors, and necessary measures to control it and also the conversion of
railway coaches which are made unused.
 Contents
 INTRODUCTION.

 VARIOUS SUB-ASSEMBLIES AND THAT ARE PRONE FOR CORROSION.

 DIFFERENT TYPES OF CORROSIONS.

 CORROSION REPAIRS.

 PREVENTIVE AND PROTECTIVE COATING USED FOR CORROSION.

 COACH CONVERSIONS.
 INTRODUCTION
Indian railway coaches are made of corton steel and mild steel.

This coaches are welded with manual metal arc welding (MMW) and
metal inert gas welding (MIG).

It consists of buffers , destruction tube, Z-panel, sole bar, side pillars,
head stock, etc.

The coach is about approximately 22 meters long, 4mts height.

The coaches gets corroded mainly at the aqueous places .

This coaches are painted to prevent and protect from the corrosion.

The old coaches are auctioned for sale at a particular time for
making of coach conversions to convert them as restaurants, hotels,
library, home, etc.
Through floor Sole bar
Head stock

Pillars
Body side doors and Roof sheets around ventilators

End wall stanchions and end wall sheets

Battery box frames:

 The battery box gets start corroded due

to the position of its placement under the
coaches.

 The water from the toilets get

sprinkled around the battery boxes due
to movement of the train.

 When the corrosion gets started at

the battery box , the battery gets
damaged and corrosion also spread over to
the other elements.
DIFFERENT TYPES OF CORROSION:

UNIFORM CORROSION

PITTING CORROSION:
•Pitting is one of the most destructive types of corrosion, as it can be hard to
predict, detect and characterize.

•Pitting is a localized form of corrosion, in which either a local anodic point, or

more commonly a cathodic point, forms a small corrosion cell with the
surrounding normal surface.
 • Crevice corrosion occurs in shielded areas such as
those under washers, bolt heads, gaskets, etc. where
oxygen is restricted.

Crevice corrosion

Causes of Corrosion in Indian Railway Coaches:

1.Water seepage through the flooring to the top of trough floor.

2.Leakage of water through lavatory flooring.
3.Defective water pipe fittings.
4.Habits of flushing the flooring with the water jet for cleaning.
Procedure for corrosion repairs:

 Corrosion repairs are required to be

carried out to the best standard of
workmanship.

 Trained and experienced welders

should be deputed for carrying out
welding under careful supervision of
qualified welding supervisors.

 Approved class B-II electrodes suitable

for vertical and overhead welding should
only be used for corrosion repairs.
 PREVENTIVE AND PROTECTIVE COATING USED FOR CORROSION
• Corrosion of metals/alloys not desirable .

• It tarnishes the metals/alloys & reduces its strength, ductility, malleability,

electrical conductivity etc.

• Protection against corrosion means not allowing corrosion reaction to take

place

PROTECTIVE COATINGS:
• Protective coatings are means for separating the surface that are susceptible
to corrosion from the factors in the environment which cause corrosion to occur
• Most widely used corrosion control technique
• Coating of oil, grease can be used to give a temporary protective coating
• Organic polymers or rubber latex can be applied to give coatings which can be
stripped off when required
• Paint: The most common coating
• Any protective coatings can never provide 100% protection of 100% of the
surface
Coating for coaches
METHODS OF CORROSION PREVENTION:
1. Proper designing
2. Proper selection of materials for the environment concerned
3. Cathodic protection
4. Modification of the environment
5. Corrosion inhibitors
6. Protective coatings
Coach conversions:
We many had a dream of
having a train coaches at our
own and wanted to make them
as desirable to us because
every one likes the train
journey and enjoy the climate
at window seat.

To make that dreams come

true Indian railways auction at
a particular time for sale and
that coaches does come with
wheels and other parts.

We can make them as of our

desire like fancy restaurants,
hotels, library, homes, etc.
 Conclusion

Different elements subjected to corrosion and their repairs were

studied.
Sole bar , side pillars , Z-panel, trough floor replacement has been
observed.
Welding process made for ICF coaches to replace the corroded
areas noticed.
I got an idea that how coaches prone for corrosion and what
precautions , coating and material selection to be chosen has been
noticed.

Besides that, I got an opportunity to observe all the different

sections of coach repairs.