A knuckle of a coupler of a rail vehicle includes a main body including a recess formed in one or more surfaces. One or more weld fillers are disposed within the recess. A method of forming a knuckle of a coupler of a rail vehicle includes forming a recess in one or more surfaces of a main body, and disposing one or more weld fillers within the recess.

An energy absorption system for a railcar having an elongated sill with front and rear stops defining a pocket therebetween. To facilitate use of known railcar structures, the energy absorption system can be used in combination with a railcar also having a sill with center stops disposed between the front and rear stops. A coupler having a head portion and a shank portion is arranged in operable combination with the energy absorption system. The energy absorption system also includes a first cushioning assembly positioned in the sill pocket. A first follower is urged toward and engageable with the front stops under the influence of the first cushioning assembly and is operably engageable with a free end of the shank portion of the coupler. A second cushioning assembly is positioned in generally axial alignment with first cushioning assembly. A second follower is positioned and normally urged by the energy absorption system toward and configured to engage with the center stops. An axially elongated yoke encompasses the first and second cushioning assemblies, terminates in an open forward end, and is coupled to the shank portion of the coupler. The first and second cushioning assemblies act in series relative to each other to absorb and cushion impact forces directed against them when the energy absorption system operates in a buff direction. Advantageously, the second follower acts in concert with the center stops and the second cushioning assembly to minimize excessive system cycles while better dissipating train action energy when the energy absorption system operates in a draft direction.

A railcar end unit is operable to be mounted in a center sill between buff and draft sill stops. The buff and draft end bodies are configured to be shiftably mounted relative to the center sill to engage the respective sill stops and to shift axially relative to one another along a unit axis. The end unit includes a buff spring pack operably mounted between the end bodies and compressible along the unit axis from a neutral condition to a compressed condition.

A knuckle pin, coupling system, and method for producing a knuckle pin are provided, the knuckle pin having a cylindrical body with a longitudinal slot therein separating vertical edges of the cylindrical body, with one or more first retaining elements that span outward of the cylindrical body, and a second retainer that includes one or more of opposing apertures, and bendable legs. A method for producing the knuckle pin is provided, where a blank is stamped into a workpiece that corresponds to the pin to be produced, and the stamped workpiece is rolled to produce the pin with the slot.

A knuckle pin, coupling system, and method for producing a knuckle pin are provided, the knuckle pin having a cylindrical body with a longitudinal slot therein separating vertical edges of the cylindrical body, with one or more first retaining elements that span outward of the cylindrical body, and a second retainer that includes one or more of opposing apertures, and bendable legs. A method for producing the knuckle pin is provided, where a blank is stamped into a workpiece that corresponds to the pin to be produced, and the stamped workpiece is rolled to produce the pin with the slot.

A railcar end unit is operable to be mounted in a center sill between buff and draft sill stops. The buff and draft end bodies are configured to be shiftably mounted relative to the center sill to engage the respective sill stops and to shift axially relative to one another along a unit axis. The end unit includes a buff spring pack operably mounted between the end bodies and compressible along the unit axis from a neutral condition to a compressed condition.

A method for manufacturing railcar coupler headcores includes providing a first corebox having internal walls defining at least in part perimeter boundaries of at least one rotor core cavity. The method further comprises at least partially filling the at least one rotor core cavity with a first sand resin to form at least one rotor core. The method also includes providing a second corebox having internal walls defining at least in part perimeter boundaries of at least one headcore cavity. The at least one rotor core is positioned within the second corebox. The method also comprises at least partially filling the at least one headcore cavity with a second sand resin to form at least one headcore.

A railroad coupler knuckler meets AAR contour requirements and it includes unique external weight reducing features that strategically reduce weight without compromising strength or fatigue life. The design of the railroad knuckle of the present invention allows for formation of the knuckle through forging or coreless casting techniques and thus allows for the use of a better grade of steel compared to AAR Grade E and such forged or cast knuckle will yield much higher fatigue life compared to cast knuckles.

A railroad coupler knuckler meets AAR contour requirements and it includes unique external weight reducing features that strategically reduce weight without compromising strength or fatigue life. The design of the railroad knuckle of the present invention allows for formation of the knuckle through forging or coreless casting techniques and thus allows for the use of a better grade of steel compared to AAR Grade E and such forged or cast knuckle will yield much higher fatigue life compared to cast knuckles.

The coupler system of a railway car truck is constructed such that basic overall appearance may be maintained, but the actual material of which it is constructed is changed. According to one embodiment, the coupler is constructed from cast austempered ductile iron; whereas cast iron has a density, 0.26 lbs/in{circumflex over ( )}3, which is approximately 8% less than steel, 0.283 lbs/in{circumflex over ( )}3, thereby allowing for a reduction in weight over steel. A suitable austempering process is used to produce the austempered metal coupler and components thereof. A second benefit of embodiments of the present invention provides for a more efficient use of materials, meaning less metal is used to make the same final shape, as a way of reducing the coupler weight. Both factures combined allow for a lighter weight coupler, while utilizing the standard designs. Alternate coupler configurations are disclosed for further reducing coupler weight.