BS EN 14730-1-2006 Railway applications - Track - Aluminothermic welding of rails - Approval of welding processes《轨道交通 轨道 铁轨的铝热剂焊接 焊接过程的验收》.pdf

1、BRITISH STANDARDBS EN14730-1:2006Railway applications Track Aluminothermic welding of rails Part 1: Approval of welding processesThe European Standard EN 14730-1:2006 has the status of a British StandardICS 25.160.10; 45.080g49g50g3g38g50g51g60g44g49g42g3g58g44g55g43g50g56g55g3g37g54g44g3g51g40g53g4

2、8g44g54g54g44g50g49g3g40g59g38g40g51g55g3g36g54g3g51g40g53g48g44g55g55g40g39g3g37g60g3g38g50g51g60g53g44g42g43g55g3g47g36g58Licensed Copy: Wang Bin, na, Mon Nov 06 02:54:15 GMT+00:00 2006, Uncontrolled Copy, (c) BSIBS EN 14730-1:2006This British Standard was published under the authority of the Stan

3、dards Policy and Strategy Committee on 31 August 2006 BSI 2006ISBN 0 580 48704 0National forewordThis British Standard is the official English language version of EN 14730-1:2006. The UK participation in its preparation was entrusted to Technical Committee RAE/2, Railway track components, which has

4、the responsibility to: A list of organizations represented on this committee can be obtained on request to its secretary.Cross-referencesThe British Standards which implement international or European publications referred to in this document may be found in the BSI Catalogue under the section entit

5、led “International Standards Correspondence Index”, or by using the “Search” facility of the BSI Electronic Catalogue or of British Standards Online.This publication does not purport to include all the necessary provisions of a contract. Users are responsible for its correct application. Compliance

6、with a British Standard does not of itself confer immunity from legal obligations. aid enquirers to understand the text; present to the responsible international/European committee any enquiries on the interpretation, or proposals for change, and keep UK interests informed; monitor related internati

7、onal and European developments and promulgate them in the UK.Summary of pagesThis document comprises a front cover, an inside front cover, the EN title page, pages 2 to 49 and a back cover.The BSI copyright notice displayed in this document indicates when the document was last issued.Amendments issu

8、ed since publicationAmd. No. Date CommentsLicensed Copy: Wang Bin, na, Mon Nov 06 02:54:15 GMT+00:00 2006, Uncontrolled Copy, (c) BSIEUROPEAN STANDARDNORME EUROPENNEEUROPISCHE NORMEN 14730-1August 2006ICS 25.160.10; 45.080English VersionRailway applications - Track - Aluminothermic welding of rails

9、-Part 1: Approval of welding processesApplications ferroviaires - Soudage des rails paraluminothermie - Partie 1 : Approbation des procds desoudageBahnanwendungen - Oberbau - AluminothermischesSchweien von Schienen - Teil 1: Zulassung derSchweiverfahrenThis European Standard was approved by CEN on 1

10、2 June 2006.CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this EuropeanStandard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such nationalstandards may be obt

11、ained on application to the Central Secretariat or to any CEN member.This European Standard exists in three official versions (English, French, German). A version in any other language made by translationunder the responsibility of a CEN member into its own language and notified to the Central Secre

12、tariat has the same status as the officialversions.CEN members are the national standards bodies of Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France,Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portug

13、al, Romania,Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.EUROPEAN COMMITTEE FOR STANDARDIZATIONCOMIT EUROPEN DE NORMALISATIONEUROPISCHES KOMITEE FR NORMUNGManagement Centre: rue de Stassart, 36 B-1050 Brussels 2006 CEN All rights of exploitation in any form and by any means rese

14、rvedworldwide for CEN national Members.Ref. No. EN 14730-1:2006: ELicensed Copy: Wang Bin, na, Mon Nov 06 02:54:15 GMT+00:00 2006, Uncontrolled Copy, (c) BSIEN 14730-1:2006 (E) 2 Contents Page Foreword. 4 Introduction 5 1 Scope 6 2 Normative references . 6 3 Terms and definitions. 6 4 Information to

15、 be supplied by the railway authority . 7 5 Approval procedure 8 5.1 General. 8 5.2 Process identification. 8 5.3 General requirements. 8 5.4 Initial compliance testing . 9 5.5 Extension of initial compliance testing 10 5.6 Documents to be submitted with the request for approval 11 5.6.1 The process

16、 manual . 11 5.6.2 Drawing with the required measurements . 11 5.6.3 Chemical analysis ranges and tolerances 12 5.7 Preparation and allocation of test welds 12 6 Re-approval following process changes 13 7 Laboratory tests 16 7.1 Visual surface examination 16 7.1.1 As cast weld surface. 16 7.1.2 Grou

17、nd weld surface 16 7.1.3 Visible heat affected zone 17 7.2 Running surface hardness test . 17 7.3 Slow bend test. 18 7.4 Internal examination . 18 7.4.1 Weld soundness 18 7.4.2 Fusion zone shape and dimension 21 7.4.3 Microscopic examination . 22 7.4.4 Heat softened zone width. 22 7.5 Fatigue test 2

18、2 7.6 Chemical analysis. 23 Annex A (informative) Steps in approval 25 Annex B (informative) Suggested sequence of laboratory tests 26 Annex C (normative) Ultrasonic testing procedure for aluminothermic welds in rail . 27 C.1 A test of the head zone of the weld (non-planar defects). 27 C.2 A test of

19、 the head zone of the weld (planar defects). 27 C.3 A test of the head and web zone of the weld (planar defects) . 27 C.4 A test of the middle zone of the foot of the weld. 27 C.5 A test of the ankle zone of the foot of the weld . 27 C.6 A test of the toe zone of the foot of the weld . 28 Annex D (n

20、ormative) Procedure for FRY etching 29 Annex E (normative) Procedure for measurement of surface hardness 30 Annex F (normative) Procedure for slow bend test 31 Licensed Copy: Wang Bin, na, Mon Nov 06 02:54:15 GMT+00:00 2006, Uncontrolled Copy, (c) BSIEN 14730-1:2006 (E) 3 Annex G (normative) Procedu

21、re for recording test weld fracture face defects . 32 Annex H (normative) Ultrasonic inspection procedure on aluminothermic welds to be sectioned . 34 H.1 Principle . 34 H.2 Apparatus 34 H.3 Preparation of samples 34 H.4 Calibration . 34 H.5 Testing 35 H.6 Reporting . 35 Annex I (normative) Procedur

22、e for microscopic examination of the visible heat affected zone and fusion zone of welds 36 Annex J (normative) Procedure for measurement of the heat softened zone width . 37 J.1 Measurement of hardness 37 J.2 Evaluation of hardness data 38 J.2.1 General. 38 J.2.2 Mean hardness of parent rail . 38 J

23、.2.3 Measurement hardness line. 38 J.2.4 Heat softened zone width measurement 39 J.2.5 Parent rail hardness variation . 39 Annex K (normative) Fatigue test methods for aluminothermic welds. 40 K.1 Scope 40 K.2 Test equipment 40 K.3 Calibration procedure. 41 K.3.1 General. 41 K.3.2 Test piece. 41 K.3

24、.3 Test piece preparation 41 K.3.4 Instrumentation . 42 K.3.5 Procedure 42 K.4 Fatigue test method 45 K.4.1 General. 45 K.4.2 Staircase testing method . 45 K.4.3 Example of the data analysis of a fatigue strength determination by the staircase method . 47 K.4.4 Past-the-post testing method 48 Annex

25、L (informative) Adeviations 49 Licensed Copy: Wang Bin, na, Mon Nov 06 02:54:15 GMT+00:00 2006, Uncontrolled Copy, (c) BSIEN 14730-1:2006 (E) 4 Foreword This document (EN 14730-1:2006) has been prepared by Technical Committee CEN/TC 256 “Railway applications”, the secretariat of which is held by DIN

26、. This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by February 2007, and conflicting national standards shall be withdrawn at the latest by February 2007. The European Standard EN 14730 “Railway appli

27、cations Track Aluminothermic welding of rails“ is composed of two parts. Part 1: Approval of welding processes Part 2: Qualification of aluminothermic welders, approval of contractors and acceptance of welds According to the CEN/CENELEC Internal Regulations, the national standards organizations of t

28、he following countries are bound to implement this European Standard: Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Sloven

29、ia, Spain, Sweden, Switzerland and United Kingdom. Licensed Copy: Wang Bin, na, Mon Nov 06 02:54:15 GMT+00:00 2006, Uncontrolled Copy, (c) BSIEN 14730-1:2006 (E) 5 Introduction This standard defines the approval procedure for aluminothermic welding processes for rail welding through laboratory tests

30、 of welds produced in a workshop. This laboratory approval will provide the railway authority with sufficient information for tests in the track if required. Licensed Copy: Wang Bin, na, Mon Nov 06 02:54:15 GMT+00:00 2006, Uncontrolled Copy, (c) BSIEN 14730-1:2006 (E) 6 1 Scope This standard defines

31、 the laboratory tests and requirements for approval of an aluminothermic welding process using welds produced in workshop conditions. It applies to the joining of new, Vignole rails as described in EN 13674-1 of the same profile and steel grade. Compliance with the requirements of this standard does

32、 not of itself ensure the suitability of a welding process for specific conditions of track and traffic. The standard does not cover welds made between different rail sections, differently worn rails and different rail grades. In addition to the definitive requirements this standard also requires th

33、e items detailed in Clause 4 to be documented. For compliance with this standard, it is important that both the definitive requirements and the documented items be satisfied. 2 Normative references The following referenced documents are indispensable for the application of this document. For dated r

34、eferences, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 473, Non destructive testing Qualification and certification of NDT personnel General principles EN 13674-1, Railway applications Track Rail Part 1:

35、 Vignole railway rails 46 kg/m and above EN ISO 6506-1, Metallic materials - Brinell hardness test - Part 1: Test method (ISO 6506-1:2005) EN ISO 6507-1, Metallic materials - Vickers hardness test - Part 1: Test method (ISO 6507-1:2005) EN ISO 7500-1:2004, Metallic materials Verification of static u

36、niaxial testing machines Part 1: Tension/compression testing machines Verification and calibration of the force-measuring system (ISO 7500-1:2004) 3 Terms and definitions For the purposes of this document, the following terms and definitions apply. 3.1 fusion zone area of the weld which has been in

37、a liquid state and which is revealed by etching sections cut through the weld 3.2 visible heat-affected zone HAZ areas on either side of the fusion zone within which rail steel microstructure has been visibly modified by the heat of the welding process as revealed by FRY macro-etching Licensed Copy:

38、 Wang Bin, na, Mon Nov 06 02:54:15 GMT+00:00 2006, Uncontrolled Copy, (c) BSIEN 14730-1:2006 (E) 7 3.3 heat softened zone part of the HAZ characterised by a lower hardness 3.4 flashing flat fin of weld metal located on the rail surface adjacent to the weld collar caused by gaps between the mould and

39、 the rail 3.5 surface defect any defect visible on the weld surface after normal finishing operations 3.6 internal defect any defect that is revealed by sectioning or on a fracture face following bend or fatigue testing that has not already been identified as a surface defect 3.7 stress range stress

40、 range for the fatigue test is the maximum stress minus minimum stress 3.8 railway authority either the railway regulator or the owner of a railway infrastructure or the custodian with a delegated responsibility for a railway infrastructure 3.9 process supplier company which provides an approved alu

41、minothermic welding process in accordance with this standard and which is approved by the railway authority to supply consumables and tools for the execution of aluminothermic welds 4 Information to be supplied by the railway authority The following information shall be fully documented by the railw

42、ay authority. For compliance with the standard both the definitive requirements specified throughout the standard and the following documented items shall be satisfied. a) Any limitations on the type of pre-heating. b) Maximum permissible numbers and/or dimensions of slag or sand inclusions on the a

43、s-cast weld surface. c) Any limitation on the weld collar geometry affected by riser removal (other than that on the ground rail head). d) The maximum size and number of pores to be permitted on the ground surfaces if the railway authoritys requirements are more severe than those in 7.1.2. e) Any ad

44、ditional non-destructive testing requirements. f) Which of the width levels of visible heat affected zone is required (7.1.3). g) Which of the two formulae for minimum fracture load shall apply for R320Cr rail grade (7.3). Licensed Copy: Wang Bin, na, Mon Nov 06 02:54:15 GMT+00:00 2006, Uncontrolled

45、 Copy, (c) BSIEN 14730-1:2006 (E) 8 h) Any limit on the depth of the weld collars edge (less than 2 mm) that may remain unfused to the rail surface. i) Which of the width levels of heat-softened zone is required (7.4.4). j) The fatigue requirement in terms of the mean and of the standard deviation o

46、f the fatigue strength for the staircase method of testing or the minimum value of upper stress in the rail foot for past the post testing (7.5.2). k) Which of the two hardness ranges for R260 rail grade specified in 7.2, Table 5 is required. 5 Approval procedure 5.1 General An outline of the steps

47、required for compliance to this standard is given in informative Annex A. 5.2 Process identification The approval shall involve a single process identified by: a) The process name. b) A drawing of the pouring system. c) The characteristic geometry of the weld collar and riser configuration as given

48、in 5.6.2 and Figure 1. d) The process manual in accordance with 5.6.1. 5.3 General requirements The following general requirements shall be met. a) The process shall be capable of being carried out on track where the maximum can be 180 mm. It shall be capable of being carried out in track, at or nea

49、r trackside or in a workshop. b) The aluminothermic welding portion shall be packed to avoid the risk of moisture contamination in proscribed storage conditions. The portion shall be identified by markings on the package. c) The mould shall be pre-fabricated for the rail profiles to be welded and be identified by markings on the package. d) The crucible shall be tapped automatically (automatic tapping) and shall have a device to limit spattering. e) Pre-heating shall comply with any limitations of the railway authority as specified in Clause 4