AAR-M 216: Knuckles, Types E and F—Fatigue Test

(AAR Manual of Standards and Recommended Practices, Casting Details, M-216, Revised 2016)

1. Scope

 Specifies fatigue test requirements for knuckles used in North American interchange
freight equipment.

 Includes test procedures, test machine requirements, load spectrum, and reporting
criteria.

 Requires four fatigue test samples, in addition to static tests defined in AAR M-211.

2. Approval and Retesting

 Every knuckle design (existing or new) must be approved by the Coupling Systems
and Truck Castings Committee (CSTCC) before use in interchange service.

 Retesting Intervals:

o E-Type Knuckles: Every 3 years.

o F-Type Knuckles: Every 6 years.

 If a test fails, the design is not approved for the specific manufacturer or facility.

 Manufacturers must apply for approval via the Transportation Technology Center,
Inc. (TTCI), with technical drawings.

 Existing knuckles must comply within 1 year of implementation.

o Failure to meet requirements after 1 year results in conditional approval for 1

o If still non-compliant, approval is revoked.

 Structural design changes require retesting.

3. Test Facility and Observers

 Testing must be performed at an AAR-approved facility.

 AAR representatives must witness tests and certify compliance with AAR
requirements.

 The applicant is responsible for test arrangements.

4. Dynamic Fatigue Test Requirements

4.1 Test Machine

 Must apply draft (tensile) loads to a knuckle through an AAR-approved production

 Test knuckle must mate with an approved standard knuckle.

 Loads must be applied sinusoidally at frequencies that meet Table 4.1 requirements.

 C-10 pins must be used for all o icial tests.

4.2 Test Specimen Selection

 Lot of 25 knuckles required for selection of 4 test samples.

 Knuckles must be from recent production (cast date within 6 months).

4.3 Test Instrumentation

 Calibration of load measurement and control systems must be traceable to a known

 Annual calibration required.

 Records must be available for review during testing.

4.4 Standard Input Load Spectra (Fatigue Test Cycles)

 Load cycles simulate real-world stress on knuckles.

 The test runs sequentially through 13 load segments until failure.

 Knuckles must survive at least 600,000 cycles, with no individual knuckle failing
below 400,000 cycles.

Table 4.1 - Knuckle Fatigue Test Load Cycles

Number of Cycles (Sinusoidal Total Elapsed Cycle Load Range (Min-

1 4 4 18–283 kips

2 2 6 18–265 kips

3 7 13 18–245 kips

4 10 23 18–227 kips

5 31 54 18–209 kips

6 77 131 18–189 kips

7 65 196 18–171 kips

8 73 269 18–154 kips

9 89 358 17–133 kips

10 105 463 17–115 kips

11 129 592 17–97 kips

12 187 779 17–79 kips

13 279 1058 15–59 kips

 ±5% margin of error for minimum loads.

 ±2% margin of error for maximum loads.

4.5 Failure Criteria

 Test continues until failure or until the applicant withdraws.

 Failure is defined as separation of any knuckle segment from the parent structure.

 To reapply, manufacturers must explain design modifications.

5. Reporting Requirements

5.1 Test Reports

 Required for certification approval.

 Must include:

o Test procedures, results, and failure descriptions.

o Cycles to failure for each knuckle.

o Photographs and observations.

 Reports must be reviewed by the o icial observer and submitted to TTCI Chief—
Technical Standards.

5.2 Second-Phase Reporting

 Additional data on tested knuckles, archived for future reference.

 Required data includes:

o Internal solidity levels (per M-211).

o Chemical composition.

o Mechanical properties (including impact resistance).

o Grain size.

o Manufacturer, model number, serial number, cast date.

o Weight.

o Metal thickness measurements for:

 Throat area.
  Distance between C-10 pin hole and pulling face.

 Wall thickness at tail near pulling lugs.

 Manufacturers must retain test data for 6 years and provide it to CSTCC if failures
occur.

6. Marking Requirements

 Approved knuckles must have a "V" appended to their catalog number.

o Example: E50BE → E50BEV.