The document discusses how SpiralWeld technologies were used to remanufacture brake pull rods for steam locomotives being restored by a preservation society. The rods were corroded and worn, rendering their threads unusable. SpiralWeld analyzed the metal, machined the rods to remove damaged threads, applied overlay welding to rebuild the threads, and machined the rods to their original specifications. This process preserved the original parts and allowed the locomotives to be restored closer to their original condition, helping the preservation society's efforts.

1. Steam Preservation:
The Remanufacturing of brake pull rods
A solution to preserving Steam Locomotives through Remanufacturing.

2. Introduction…
• There are numerous preservation societies across the UK.
• Some of the parts or components of the engines are so old it is sometimes
believed that they are too delicate to repair or past restoration, or drawings
for the components are lost, eliminating the possibility of it being
reconstructed.
• How can an engine ever be restored to its original glory without original
parts?
• The answers can be found in SpiralWeld™ technologies and methods; where
re-engineering can be used to make new CAD drawings, and remanufacturing
can restore the damaged parts no matter how ‘irreversibly damaged’ they may
seem.

3. The Challenge…
• SpiralWeld™ was contacted by a preservation society based in the
South East, who are in the ongoing process of restoring numerous
steam locomotives.
• They were looking for a recovery method which could remanufacture
the brake pull rods. This enables the part to be used for service rather
than manufacturing a new part, which helps to preserve the
locomotive as close to the original as possible.
• The cycles of corrosion and wear over many years has caused the load
bearing thread of the brake rod to become unfit for further use in its
critical function of operating locomotive brakes.

4. Brake Pull Rod ‘A’
Damage to Brake Pull Rod ‘A’

5. Brake Pull Rod ‘B’
Damage to Brake Pull Rod ‘B’

6. Solving the problem…
• The first step taken to ReManufacture™ the component was to
determine its metal composition. This is done through SpiralWeld’s
XRF analysis.
• This gives us the ability to ascertain the right materials and to ensure
to correct procedures are used when ReManufacturing™ the rods.
• The pull rods were then machined to remove the remains of the
existing threads and the underlying material to a depth which then
allows for a SpiralWeld Overlay.

7. Brake pull rods after initial machine…
Brake Pull Rod ‘A’
Brake Pull Rod ‘B’

8. A successful outcome…
• Once the SpiralWeld™ overlay was applied the pull rod was machined
ready for NDT to prove the integrity of the weld. This process of
welding, machining and NDT was repeated to ensure that the
recovery of the component was completed to the highest standards.
• The customer chose to re-cut the threads themselves as they are able
to do this in-house. However we are able to reproduce threads to the
many thread forms used over many years of change. Generally the
recovery of these components takes around 2-3 weeks, however in an
emergency these can be completed in 3-4 days.

9. Finished…
ReManufactured™ Brake Pull Rod ‘A’
ReManufactured™ Brake Pull Rod ‘B’

10. Conclusion…
This case study has set out to show an example of a service SpiralWeld™ can provide
steam preservation societies in restoring Locomotives. As well as providing recovery
methods for this component there are various other components that also can be
recovered.
We realise most preservation societies are done on a charitable basis, as such we try our
best to accommodate to the restrictions in their budgets.
If there is any more information you require please feel free to contact us
Tel: 02380 228801 Email :technology@spiralweld.co.uk www.spiralweld.co.uk