WEBVTT

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The

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unit coal train, assigned service intermodal cars, visible signs of the railroads move toward

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higher utilization of equipment. Not so visible, but still very important to accomplishing more

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economical railroad operations is the freight car truck and its suspension system. This is the

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Barber friction casting, the car's vertical shock absorber and the key component of the

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S2 freight car truck. It is positioned in the pockets at the bolster ends. Its function is

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to generate friction when moved against the side frames. This model shows what occurs to a truck

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without friction castings. The springs bounce wildly. With the friction castings damping the

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load springs, the truck rides more smoothly. The wedge constantly moves under pressure and

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must handle the heat generated by the wearing action. As it does its job, it will eventually

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wear. So the casting must be designed with a very special material to provide the desired

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coefficient of friction to deliver thousands of trouble-free miles. To ensure a source for this

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material, standard car truck built their own foundry. The castings might appear to be relatively

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simple to make, but if the casting does not have exactly the correct shape and microstructure to

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control friction and wear, it will not do its job. To manufacture quality castings, we begin by

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measuring carefully all the elements that will be placed in the furnace to ensure a known mix.

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Once the individual ingredients are precisely weighed, then they can be transferred to the

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furnace.

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These are the cores that will form the internal shape of the friction casting.

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The friction casting is shaped in a green sand mold. Here the cores are set into the mold. Each

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The green sand is a mixture of many compacting materials and must be constantly monitored for

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moldability in our sandblast. The molds are now ready. The metal has been melted and is up to

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temperature. Before we pour, we always test the molten material for the iron's composition.

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An emission spectrometer analyzes the chemical relationships of 16 elements. Exact control of

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carbon and sulfur are very important. We make an additional analysis with a LECO tester. These

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The rate of cooling is critically important. It must be exactly controlled. The mold travels

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down a conveyor belt, slowly cooling at a predetermined rate. The cooling time and rates are

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very important to establish the correct microstructure. When the castings reach a

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specified temperature, they are removed from the sand molds. Cooling then continues at an

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accelerated rate.

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The job doesn't end here with a clean casting. Each piece is visually inspected and separated

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from returns. Each casting is precision ground to our specifications. After grinding, every casting

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is once again inspected. We use a Burnell hardness tester to check for the casting's consistency.

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If any piece does not fall within the limits, that lot can be investigated completely since

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every casting has an identification number showing the time, day, month, year that part

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was cast. Every casting also bears a part number. At the end of each furnace heat, we scrap one

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casting to examine it closely under a microscope. We mount a section to inspect the microstructure.

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Every casting should look like this. We photograph the results and permanently file the sample. We

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also manage a long-term evaluative program for improving our products. A drop test determines

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the casting's design strength. This wear test machine confirms the friction and wear characteristics

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of our material. When a product leaves our facilities, we know it is produced and engineered

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to perform. The friction casting is the heartbeat of the Barber Stabilized Truck. Easily assembled,

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the S2 truck will provide load-sensitive damping with lower maintenance than ever before.

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The S2 truck is ready to roll under your car. Barber, a symbol of quality.