1、March 2017 English price group 17No part of this translation 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!%c+“2640892www.d
2、in.deDIN EN 16771Railway applications Infrastructure Aluminothermic welding of grooved rails;English version EN 16771:2016,English translation of DIN EN 16771:2017-03Bahnanwendungen Infrastruktur Aluminothermisches Schweien von Rillenschienen;Englische Fassung EN 16771:2016,Englische bersetzung von
3、DIN EN 16771:2017-03Applications ferroviaires Infrastructures Soudage par aluminothermie des rails gorge;Version anglaise EN 16771:2016,Traduction anglaise de DIN EN 16771:2017-03www.beuth.deDTranslation by DIN-Sprachendienst.In case of doubt, the German-language original shall be considered authori
4、tative.Document comprises 38 pages 03.17 2 A comma is used as the decimal marker. National foreword This document (EN 16771:2016) has been prepared by Technical Committee CEN/TC 256 “Railway applications” (Secretariat: DIN, Germany). The responsible German body involved in its preparation was DIN-No
5、rmenausschuss Fahrweg und Schienenfahrzeuge (DIN Standards Committee Railway), Subcommittee NA 087-00-01-01 UA Schienen-schweien. This standard is based on the English reference version. DIN EN 16771:2017-03 EUROPEAN STANDARD NORME EUROPENNE EUROPISCHE NORM EN 16771 November 2016 ICS 25.160.10; 93.1
6、00 English Version Railway applications - Infrastructure - Aluminothermic welding of grooved rails Applications ferroviaires - Infrastructures - Soudage par aluminothermie des rails gorge Bahnanwendungen - Infrastruktur - Aluminothermisches Schweien von Rillenschienen This European Standard was appr
7、oved by CEN on 15 July 2016. CEN members are bound to comply with 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 s
8、tandards may be obtained on application to the CEN-CENELEC Management 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 an
9、d notified to the CEN-CENELEC Management Centre has the same status as the official versions. CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hunga
10、ry, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and United Kingdom. EUROPEAN COMMITTEE FOR STANDARDIZATION COMIT EUROPEN DE NORMALISATION EUROPISCHES KOMITEE FR NORMUNG CEN-CENEL
11、EC Management Centre: Avenue Marnix 17, B-1000 Brussels 2016 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members. Ref. No. EN 16771:2016 EEN 16771:2016 (E) 2 Contents Page European foreword. 4 Introduction 5 1 Scope 6 2 Normative references 6 3 Ter
12、ms and definitions . 6 4 Information to be supplied by the railway authority 7 5 Approval procedure . 7 5.1 General 7 5.2 Process identification 7 5.3 General requirements . 7 5.4 Documents to be submitted with the request for approval . 8 5.5 Initial compliance testing . 9 5.6 Extension of initial
13、compliance testing 11 5.7 Preparation and allocation of test welds . 11 6 Re-approval following process changes 12 7 Laboratory tests 15 7.1 Visual surface examination 15 7.1.1 Ascast weld surface . 15 7.1.2 Ground weld surface . 15 7.2 Running surface hardness test 16 7.3 Slow bend test . 16 7.4 In
14、ternal examination 17 7.4.1 Weld soundness 17 7.4.2 Fusion zone Shape and dimension 19 7.4.3 Microscopic examination 19 7.4.4 Heat softened zone width 20 7.5 Chemical analysis . 20 Annex A (informative) Steps in approval . 22 Annex B (informative) Suggested sequence of laboratory tests 24 Annex C (i
15、nformative) Procedure for FRY etching 25 Annex D (normative) Procedure for measurement of surface hardness 26 Annex E (normative) Procedure for slow bend test . 27 Annex F (normative) Procedure for recording test weld fracture face defects 29 Annex G (normative) Ultrasonic inspection procedure on al
16、uminothermic welds to be sectioned . 30 G.1 Principle 30 G.2 Apparatus 30 G.3 Preparation of samples 30 G.4 Calibration 30 DIN EN 16771:2017-03EN 16771:2016 (E) 3 G.5 Testing 30 G.6 Reporting . 31 Annex H (normative) Procedure for microscopic examination of the visible heat affected zone and fusion
17、zone of welds . 32 Annex I (normative) Procedure for measurement of the heat softened zone width 33 I.1 Measurement of hardness . 33 I.2 Evaluation of hardness data . 34 Bibliography . 36 DIN EN 16771:2017-03 EN 16771:2016 (E) 4 European foreword This document (EN 16771:2016) has been prepared by Te
18、chnical 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, at the latest by May 2017, and conflicting national standards shall be
19、withdrawn at the latest by May 2017. Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. CEN shall not be held responsible for identifying any or all such patent rights. According to the CEN-CENELEC Internal Regulations, the national
20、standards organisations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuani
21、a, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom. DIN EN 16771:2017-03 EN 16771:2016 (E) 5Introduction This standard defines the approval procedure for aluminothermic welding processes for grooved rail
22、 welding through laboratory tests of welds produced in a workshop. This laboratory approval will provide the railway authority with sufficient information for tests in the track if required. DIN EN 16771:2017-03 EN 16771:2016 (E) 6 1 Scope This standard defines the laboratory tests and requirements
23、for approval of an aluminothermic welding process using welds produced in workshop conditions. It applies to the joining of new, grooved rails as described in EN 14811 of the same profile and steel grade. Welding of construction profiles and machined profiles are not covered in this standard. Compli
24、ance with the requirements of this standard does not in 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, worn rails or different rail grades. In addition to the definitive requirem
25、ents, this standard also requires the 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 documents, in whole or in part, are normatively refe
26、renced in this document and are indispensable for its application. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 14811, Railway applications Track Special purpose rail Grooved and ass
27、ociated construction EN ISO 6506-1, Metallic materials - Brinell hardness test - Part 1: Test method (ISO 6506-1) EN ISO 6507-1, Metallic materials - Vickers hardness test - Part 1: Test method (ISO 6507-1) EN ISO 9712, Non-destructive testing - Qualification and certification of NDT personnel (ISO
28、9712) 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 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
29、fusion zone within the rail steel microstructure has been visibly modified by the heat of the welding process as revealed by Fry macro-etching 3.3 heat softened zone part of the HAZ (Heat Affected Zone) characterised by a lower hardness 3.4 flashing flat fin of weld metal located on the rail surface
30、 adjacent to the weld collar caused by gaps between the mould and the rail DIN EN 16771:2017-03 EN 16771:2016 (E) 7 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 followin
31、g bend testing that has not already been identified as a surface defect 3.7 railway authority railway regulator, or owner of a railway infrastructure, or custodian with a delegated responsibility for a railway infrastructure 3.8 process supplier company which provides an approved aluminothermic weld
32、ing process in accordance with this standard 4 Information to be supplied by the railway authority The following information shall be fully documented by the railway authority. For compliance with the standard both the definitive requirements specified throughout the standard and the following docum
33、ented items shall be satisfied: a) which of the width levels of heat-softened zone is required (7.4.4); b) limitations on the pre-heat to comply with the railway authority regulations. 5 Approval procedure 5.1 General An outline of the steps required for compliance to this standard is given in infor
34、mative 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 and the casting system; c) the characteristic geometry of the weld collar and riser configuration as given in 5.4.2 and Figure 1; d) the proce
35、ss manual in accordance with 5.4.1. 5.3 General requirements The following requirements shall be met: a) the process shall be capable of being carried out on track and at or near trackside or in a workshop; DIN EN 16771:2017-03 EN 16771:2016 (E) 8 b) the aluminothermic welding portion shall be packe
36、d to avoid the risk of moisture contamination in prescribed 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 automatica
37、lly (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, b). 5.4 Documents to be submitted with the request for approval When applying for approval, the following documents shall be submit
38、ted: 5.4.1 The process manual. The supplier shall produce a manual identifying all the consumable materials and equipment used, as well as the operating method to be followed for all steps of welding. The approval procedure for laboratory tests will not include means of alignment or finishing operat
39、ions. The manual shall specify the critical parameters of the welding process and their safe bounds, and shall include the following: a) number of people required to carry out the operations; b) diagram of equipment; c) portion for each rail grade and profile; d) rail end preparation requirements; e
40、) nominal gap shall have a tolerance of 2 mm for a 30 mm gap and 3 mm for 30 mm to 50 mm gaps and 5 mm for 50 mm gaps; f) preheating details; g) range of ignition to tap times for the portions; h) critical process timings; i) time (or temperature) before trains can pass; j) safety information. 5.4.2
41、 Drawing with the required measurements. A drawing, as illustrated in Figure 1, which provides the measurements listed below: a) weld collar width (W1). The development of the weld collar shall be fully dimensioned around the weld; b) maximum depth of collar at section B-B (D1 and D2); c) minimum de
42、pth of collar at section B-B (d1 and d2); d) riser cross section at foot; DIN EN 16771:2017-03 EN 16771:2016 (E) 9 e) riser cross section at neutral axis; f) number of risers; g) position of risers. The dimensions W, D and d and cross sectional areas of the risers shall be the nominal dimensions tak
43、en from the drawing of the pattern used to produce the moulds. Key 1 figure showing the width of the weld collar around the weld 2 riser cross section on the neutral axis mm23 25 % of the foot width 4 riser cross section at the foot mm25 longitudinal axis under the rail foot Figure 1 Dimensions take
44、n from mould pattern 5.4.3 Chemical analysis ranges and tolerances. The chemical analysis ranges and tolerances shall be in accordance with 7.5.1. 5.5 Initial compliance testing a) For the purposes of approval the standard, rail profiles (see EN 14811) shall be grouped as follows. DIN EN 16771:2017-
45、03 EN 16771:2016 (E) 10 Table 1 Rail profile groups 1 New names Former names 57R1 Ph 37 59R1 Ri 59-R10, Ri 59 59R2 Ri 59-R13, Ri 59N 60R1 Ri 60-R10, Ri 60 60R2 Ri 60-R13, Ri 60 N 60R3 Ri 210/95+80 62R1 NP4aM 62R2 NP4aS 63R1 Ri 210/95+80a 67R1 Ph 37a 68G1 70 G Table 2 Rail profile groups 2 New names
46、Former names 46G1 60 G 51R1 Ri 52-R13, Ri 52 52R1 Ri Ir 53R1 Ri 53-R13, Ri 53 55G1 35 GP 55G2 41 GP 56R1 Ri lc b) Initial compliance with the present standard shall be achieved by undertaking the tests specified in category 1 of Table 3 using not heat treated rail, by using either R200 or R220G1 or
47、R260 grade. Results are valid for the three grades of all rail profiles in either group 1 or group 2. Compliance with all the criteria specified and with the railway authoritys documented requirements specified in Clause 4 shall be demonstrated. A test sequence is outlined in informative Annex B. A
48、test specimen can be used for several different tests. DIN EN 16771:2017-03 EN 16771:2016 (E) 11 Table 3 Testing scheme Test Section reference Number of tests Category 1aCategory 2bA Hardness test 7.2 6 5 B Surface examination Visual 7.1.1 7.1.2 6 5 C Slow Bend Test 7.3 6 3 D Ultrasonic inspection A
49、nnex G 7.4.1.1 2 Nil E Weld soundness 7.4.1 7.3 2 (2) Nil F Fusion Zone Shape and Dimensions 7.4.2 2 Nil G Chemical analysis 7.5 3 3 H Heat softened zone Hardness distribution 7.4.4 2 2 I Structure Fusion Zone Heat affected zone 7.4.3.3 7.4.3.2 2 2 1 1 NOTE () indicates weld soundness evaluation of the fracture face of the slow bend test specimens. aCategory 1 Initial tests to be conducted using not heat treated grade on one rail profile from group 1 or
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