Importance

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Abstract

An axle and wheel assembly particularly adapted for railcar usage is disclosed as having a metal-foam construction that is light in weight but of a relatively high strength. The axle includes an elongated hollow steel outer axle member and an elongated hollow steel inner axle member received within the outer axle member with the foam injected therebetween so as to cure and bond to the members and function as a load bearing element therebetween. Adhesion between the axle members and the foam is increased by applying an adhesive to the members prior to the injection of the foam. An intermediate portion of the outer axle member between ends of the axle includes outwardly deformed ribs that increase the cross-sectional area thereof without increasing the weight to enhance the lightweight and high strength characteristics of the axle. The wheel includes an outer skin of steel members including a pair of discs and a central hub all of which are secured to each other to define a cavity in which the foam is received and bonded to the skin. Injection of the foam for curing within the cavity or preforming of the foam and positioning thereof between the skin members may be performed to construct the wheel and, in either case, adhesive applied to the skin members secures the foam in part or totally to the skin members. An axially extending rim mounting surface on one of the discs mounts a steel wheel rim which rolls over a rail on which the wheel travels. Annular ribs formed unitary with the rim are spaced along the wheel axle and have inner ends that engage the rim surface to mount the rim while limiting heat transfer from the rim to the skin. Radially extending ribs of the discs project axially and provide strengthening of the wheel. Mounting of the wheel hub on the axle is at a mounting surface of the axle end located inwardly from a distal axle end bearing surface.

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First Claim