DIN EN 14587-1-2007 Railway applications - nTrack - nFlash butt welding of rails - nPart 1 New R220 R260 R260Mn and R350HT grade rails in a fixed plant nEnglish version EN 14587-1 .pdf

1、September 2007DEUTSCHE NORM English price group 16No part of this standard may be reproduced without prior permission ofDIN Deutsches Institut fr Normung e. V., Berlin. Beuth Verlag GmbH, 10772 Berlin, Germany,has the exclusive right of sale for German Standards (DIN-Normen).ICS 25.160.10; 93.100!$I

2、3“1381657www.din.deDDIN EN 14587-1Railway applications Track Flash butt welding of rails Part 1: New R220, R260, R260Mn and R350HT grade rails in a fixed plantEnglish version of DIN EN 14587-1:2007-09Bahnanwendungen Oberbau Abbrennstumpfschweien von Schienen Teil 1: Schweien neuer Schienen derStahls

3、orte R220, R260, R260Mn und R350HT in einer stationren AnlageEnglische Fassung DIN EN 14587-1:2007-09www.beuth.deDocument comprises 40 pages 11.07DIN EN 14587-1:2007-09 2 National foreword This standard has been prepared by Technical Committee CEN/TC 256 “Railway applications”, the Secretariat of wh

4、ich is held by DIN (Germany). The responsible German body involved in its preparation was the Normenausschuss Fahrweg und Schienen-fahrzeuge (Rail Track and Vehicle Standards Committee), Technical Committee NA 087-01-01 AA Schienen-schweien. EUROPEAN STANDARD NORME EUROPENNE EUROPISCHE NORM EN 14587

5、-1 June 2007 ICS 25.160.10; 93.100 English Version Railway applications - Track - Flash butt welding of rails - Part 1: New R220, R260, R260Mn and R350HT grade rails in a fixed plant Applications ferroviaires - Voie - Soudage des rails par tincelage - Partie 1: Rails neufs de nuances R220, R260, R26

6、0Mn et R350HT dans une installation fixe Bahnanwendungen - Oberbau - Abbrennstumpfschweien von Schienen -Teil 1: Schweien neuer Schienen der Stahlsorte R220, R260, R260Mn und R350HT in einer stationren Anlage This European Standard was approved by CEN on 3 May 2007. CEN members are bound to comply w

7、ith the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the CEN Management

8、Centre or to any CEN member. This European Standard exists in three official versions (English, French, German). A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the CEN Management Centre has the same status as the off

9、icial versions. CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland, France,Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Sl

10、ovenia, Spain, Sweden, Switzerland and United Kingdom. EUROPEAN COMMITTEE FOR STANDARDIZATION COMIT EUROPEN DE NORMALISATION EUROPISCHES KOMITEE FR NORMUNG Management Centre: rue de Stassart, 36 B-1050 Brussels 2007 CEN All rights of exploitation in any form and by any means reserved worldwide for C

11、EN national Members. Ref. No. EN 14587-1:2007: EEN 14587-1:2007 (E) 2 Contents Page Foreword4 Introduction .5 1 Scope 6 2 Normative references 6 3 Terms and definitions .6 4 Quality management system7 5 Requirements for the welding process .8 5.1 General8 5.2 Clamping force.8 5.3 Pre-heating .8 5.4

12、Flashing 8 5.5 Upsetting 8 5.6 Upset current8 5.7 Unclamping 8 5.8 Welding parameters 8 5.9 Steps across the weld .9 5.10 Removal of excess upset10 5.11 Post-weld heat treatment 12 5.12 Rail end preparation and horizontal alignment requirements 12 6 Procedure approval .12 6.1 General12 6.2 Informati

13、on to be supplied by the purchaser .12 6.3 Sample preparation .12 6.4 Approval tests13 6.4.1 Visual inspection .13 6.4.2 Weld trimming13 6.4.3 Weld straightness and flatness13 6.4.4 Magnetic particle or dye penetrant inspection .13 6.4.5 Bend testing .13 6.4.6 Macro examination 13 6.4.7 Micro examin

14、ation .14 6.4.8 Hardness testing14 6.4.9 Fatigue testing .15 6.5 Test result report .15 7 Approval of other rail profiles or grades.15 7.1 General15 7.2 Sample preparation .15 7.3 Approval tests15 7.4 Test result report .15 8 Approval of the Welding Contractor15 8.1 General15 8.2 Welding procedure 1

15、5 8.3 Operators15 8.4 Supervision 16 8.5 Weld Inspection .16 8.6 Equipment 16 9 Weld production following procedure approval.16 9.1 Weld production.16 9.2 Information to be supplied by the purchaser .16 EN 14587-1:2007 (E) 3 9.3 Rail end preparation and horizontal rail alignment requirements17 9.4 W

16、eld parameter monitoring17 9.5 Weld identification.17 9.6 Visual inspections .17 9.7 Steps across the weld.17 9.8 Finishing.17 9.8.1 Correction of vertical and horizontal weld alignment17 9.8.2 Profile finishing of the rail head.17 9.9 Weld straightness and flatness18 9.10 Bend testing .19 9.10.1 Ge

17、neral19 9.10.2 Additional bend test 19 9.10.3 Bend test procedure19 9.10.4 Interpretation of results 19 9.10.5 Retesting 20 9.11 Documentation.20 Annex A (normative) Bend test requirements21 Annex B (normative) Test weld fracture faces Recording of defects.23 Annex C (normative) Fatigue test method

18、for flash butt welds .25 C.1 Scope 25 C.2 Test equipment 25 C.3 Calibration procedure .27 C.3.1 General27 C.3.2 Test piece .27 C.3.3 Test piece preparation 27 C.3.4 Instrumentation27 C.3.5 Procedure .27 C.4 Fatigue test method.31 C.4.1 General31 C.4.2 Staircase testing method31 C.4.3 Example of the

19、data analysis of a fatigue strength determination by the staircase method 33 C.4.4 Past-the-post testing method.34 Annex D (normative) Macro examination and micro examination.36 D.1 Macro examination 36 D.2 Micro examination .36 Annex E (normative) Hardness testing.37 Bibliography38 EN 14587-1:2007

20、(E) 4 Foreword This document (EN 14587-1:2007) has been prepared by Technical Committee CEN/TC 256 “Railway applications”, the secretariat of which is held by DIN. This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, a

21、t the latest by December 2007, and conflicting national standards shall be withdrawn at the latest by December 2007. This document is one of a series of three parts of the EN 14587 Railway applications Track Flash butt welding of rails. The list of parts is as follows: Part 1: New R220, R260, R260Mn

22、 and R350HT grade rails in a fixed plant Part 2: New R220, R260, R260Mn and R350HT grade rails by mobile welding machines at sites other than a fixed plant Part 3: Welding in association with crossing construction According to the CEN/CENELEC Internal Regulations, the national standards organization

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

24、Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom. EN 14587-1:2007 (E) 5 Introduction This part of EN 14587 has five main topics: a) requirements of a welding process; b) procedure approval for a fixed plant; c) approval of other rail profiles or grade; d) approval of the welding con

25、tractor; e) weld production following approval. This part of EN 14587 has been occasioned by a European Directive that will permit the freedom of an open European market. To enable this perception to become a reality, it is essential a standard is in place that satisfies the needs of the infrastruct

26、ure owners or custodians and reflects the production capabilities of the manufacturers in technical and quality terms. EN 14587-1:2007 (E) 6 1 Scope This European Standard specifies requirements for the approval of a welding process in a fixed plant, together with the requirements for subsequent wel

27、ding production. It applies to new Vignole railway rails R220, R260, R260Mn and R350HT grade rails of 46 kg/m and above, as contained in EN 13674-1, welded by flash butt welding in a fixed plant and intended for use on railway infrastructure. This European Standard applies to the welding of rails in

28、to welded strings. 2 Normative references The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 571-

29、1, Non destructive testing Penetrant testing Part 1: General principles EN 1290, Non-destructive examination of welds Magnetic particle examination of welds EN 13674-1, Railway applications Track Rail Part 1: Vignole railway rails 46 kg/m and above EN ISO 6507-1, Metallic materials Vickers hardness

30、test Part 1: Test method (ISO 6507-1:2005) EN ISO 7500-1:2004, Metallic materials Verification of static uniaxial 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 thi

31、s document, the following terms and definitions apply. 3.1 as welded condition rails that have been welded and trimmed only 3.2 contractor company approved by a railway authority to provide staff and machinery to execute the production of FB weld in a fixed plant NOTE This may include staff and mach

32、inery from within the railway authority 3.3 die burn damage caused by localised overheating on the surface of the rail caused by poor contact between the rail and the electrode during welding 3.4 dressing removing trimmed upset by grinding or other similar process 3.5 finished condition welded, trim

33、med, dressed and profile finished EN 14587-1:2007 (E) 7 3.6 fixed plant stationary production line for flash butt welding of rails 3.7 flat spot process driven discontinuity showing as a small lens like shape in vertical longitudinal section, or a generally circular/elliptical shape having a localis

34、ed smooth texture when viewed in a vertical transverse section 3.8 lack of bond area of incomplete fusion between the rails in the joint. This may appear as crack like or line discontinuity at the interface either on the surface after removal of the upset or in a weld section 3.9 profile finishing o

35、peration by which the rail head or relevant part of the rail head at the weld is returned to rail profile NOTE The operation can be by grinding, milling, planing or any other suitable means. 3.10 purchaser purchaser of the welds 3.11 railway authority either the railway regulator or the owner of a r

36、ailway infrastructure or the custodian with a delegated responsibility for a railway infrastructure 3.12 trimmed upset metal remaining around the rail profile following trimming 3.13 trimming removal of upset 3.14 upset metal extruded around the rail profile as a result of forging 3.15 welded string

37、 long rail comprising a number of shorter rails flashbutt welded together 3.16 welding process part of the sequence from the selection of the rail prior to welding through to the finishing of the welded string 4 Quality management system The contractor shall operate an independently approved and aud

38、ited quality management system. A quality management system conforming to EN ISO 9001 will be deemed to satisfy the requirements. Additionally, a product quality plan shall be validated by the purchaser. EN 14587-1:2007 (E) 8 5 Requirements for the welding process 5.1 General All welding shall be ca

39、rried out on a flash butt welding machine (FBWM) using an automatic, programmed welding sequence. 5.2 Clamping force Rails shall be secured in the FBWM by clamps of such a surface shape or contour, that when a clamping force is exerted on the rails, it shall not damage the rail in such a way that su

40、bsequent cracking in the rail in operation is generated, see 6.4.1. 5.3 Pre-heating The fronts of the heating area shall progress uniformly perpendicularly to the running surface during the whole cycle. There shall be no evidence of local melting on the ends of the rails during pre-heating. 5.4 Flas

41、hing Once initiated, flashing shall be continuous. 5.5 Upsetting Upsetting shall immediately follow flashing. Sufficient forging pressure shall be applied to ensure that voids are closed and oxides are expelled such that they are kept to a minimum at the weld interface. The weld interface shall exte

42、nd into the upset. 5.6 Upset current The upset welding current shall be maintained until the rapid forge has finished and the progressive forging commences. 5.7 Unclamping In order to maintain the alignment, the time between completion of forging and unclamping shall be a minimum of 4 s. 5.8 Welding

43、 parameters 5.8.1 The welding machine and/or management system equipment shall be capable of displaying the following; a) programme identification and setting details; b) welding current; c) upset force or pressure; d) displacement; e) welding time. 5.8.2 The welding parameters shall be determined d

44、uring procedural trials. Once approval has been granted, the welding parameters shall not be changed, with the exception of changes concerning the environments in 5.8.4. EN 14587-1:2007 (E) 9 5.8.3 The welding parameters shall be monitored and recorded. These records shall be referenced to the appro

45、priate welds. 5.8.4 The welding parameters shall permit the production of welds without any alteration to the program, at rail temperatures of 10 C and above. Alterations of preheating parameters due to various rail temperatures are not considered as alterations to the welding program. A bending tes

46、t according to 6.4.5 shall be carried out in this case. NOTE Owing to extreme variations in seasonal temperatures, the manufacturer may request the use of alternative welding programs. 5.9 Steps across the weld 5.9.1 Any step between the rails across the weld in the trimmed but not dressed condition

47、 shall not exceed those dimensions shown in Table 1. 5.9.2 Checks shall be made at a position 20 mm on each side of the weld upset centreline using a 1 m nibbed straight edge and feeler shims as shown in Figure 1. Table 1 Maximum permitted steps Position of step on the rail Maximum permitted step (i

48、n mm) Vertically on the longitudinal centreline of the running surface 0,5 Horizontally on the aligned face or edge 14 mm below the running surface 0,5 Horizontally on the edge of the rail foot 2,0 NOTE Where the step arises from the rail dimensions the rail foot tips may be dressed locally to achie

49、ve this requirement. EN 14587-1:2007 (E) 10 Dimensions in millimetres Detail Z Key A running surface B nibbed straight edge C weld upset centre line NOTE Step = |x-y| mm. Figure 1 Measurement of the step 5.10 Removal of excess upset 5.10.1 Excess upset shall be automatically trimmed. 5.10.2 Removal of the excess upset shall not cause any mechanical or thermal damage to the rails. 5.10.3 The surface of the trimmed area shall be free from visible cracking. 5.10.4 The weld shall be in compression during the removal of excess ups