1、 ISO 2016 Flat bottom (Vignole) railway rails INTERNATIONAL STANDARD ISO 5003 Second edition 2016-03-01 Reference number ISO 5003:2016(E)43 kg/m and above Rails Vignole de masse suprieure ou gale 43 kg/m ISO 5003:2016(E)ii ISO 2016 All rights reserved COPYRIGHT PROTECTED DOCUMENT ISO 2016, Published
2、 in Switzerland All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized otherwise in any form or by any means, electronic or mechanical, including photocopying, or posting on the internet or an intranet, without prior written permission. Permission
3、can be requested from either ISO at the address below or ISOs member body in the country of the requester. ISO copyright office Ch. de Blandonnet 8 CP 401 CH-1214 Vernier, Geneva, Switzerland Tel. +41 22 749 01 11 Fax +41 22 749 09 47 copyrightiso.org www.iso.org ISO 5003:2016(E)Foreword v 1 Scope .
4、 1 2 Normative references 1 3 T erms and definitions . 1 4 Information to be supplied by the purchaser. 2 5 Test methods . 3 5.1 Test items, testing frequency and test methods . 3 5.2 Chemical composition 3 5.3 Hydrogen content . 4 5.4 Total oxygen content 4 5.5 Tensile test 4 5.6 Hardness . 4 5.6.1
5、 General requirements 4 5.6.2 Surface hardness 4 5.6.3 Internal hardness 5 5.7 Microstructure 5 5.8 Decarburization . 5 5.9 Non-metallic inclusions . 5 5.9.1 General requirements 5 5.9.2 Testing methods . 5 5.10 Macrostructure . 5 5.11 Ultrasonic test 6 5.11.1 Testing area 6 5.11.2 Sensitivity requi
6、rements . 6 5.11.3 Calibration rails. 6 5.12 Residual stress . 6 5.12.1 Test sample rail . 6 5.12.2 Test pieces . 6 5.12.3 Test method 6 5.13 Fracture toughness (K Ic ) . 6 5.13.1 Test sample . 6 5.13.2 Test pieces test method 7 5.14 Fatigue crack growth rate 7 5.14.1 Test sample rail . 7 5.14.2 Tes
7、t pieces . 7 5.14.3 Test method 7 5.14.4 Number of tests and test conditions . 7 5.15 Fatigue test . 7 5.15.1 Test sample rail . 7 5.15.2 Test pieces . 8 5.15.3 Test method 8 5.15.4 Number of tests and test conditions . 8 5.16 Variation of centre line running surface hardness of heat-treated rails .
8、 8 6 Tolerances for dimension, shape, length and weight . 8 6.1 Dimension, shape and length tolerance 8 6.2 Straightness, surface flatness and twist 8 6.3 Weight . 9 7 Technical requirements .14 7.1 Manufacturing methods .14 7.2 Chemical composition .14 7.3 Mechanical properties .16 7.4 Microstructu
9、re .17 ISO 2016 All rights reserved iii Contents Page ISO 5003:2016(E)7.5 Decarburization 17 7.6 Non-metallic inclusions 18 7.7 Macrostructure 18 7.8 Ultrasonic test .18 7.9 Surface quality 18 7.10 Residual stress . .19 7.11 Fracture toughness .19 7.12 Fatigue crack growth rate .20 7.13 Fatigue test
10、 20 8 Inspection requirements 20 8.1 Inspection and acceptance.20 8.2 Retest and justification .20 9 Identification .21 9.1 Branding 21 9.2 Hot stamping .21 9.3 Cold stamping .21 9.4 Other identification 21 10 C ertification 22 11 Quality assurance system .22 Annex A (normative) Steel grades 33 Anne
11、x B (normative) Method for determination of tensile strength and elongation for as- rolled rails by a correlation 35 Annex C (normative) Microscopic examination of rail steels using standard diagrams to assess the content of non-metallic inclusions 37 Annex D (informative) Rail pr ofile 42 Annex E (
12、normative) Method for the determination of rail foot surface longitudinal residual stresses 43 Annex F (normative) Standard test method for the determination of the plane strain fracture toughness (K Ic ) of rails . 46 Annex G (normative) Pr ofile and drilling g auges .51 Annex H (normative) Standar
13、d diagrams for the check of the macrostructure of rails in accordance with ISO 4969 .63 Annex I (normative) Limiting sulfur prints 79 Bibliography .93 iv ISO 2016 All rights reserved ISO 5003:2016(E) Foreword ISO (the International Organization for Standardization) is a worldwide federation of natio
14、nal standards bodies (ISO member bodies). The work of preparing International Standards is normally carried out through ISO technical committees. Each member body interested in a subject for which a technical committee has been established has the right to be represented on that committee. Internati
15、onal organizations, governmental and non-governmental, in liaison with ISO, also take part in the work. ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of electrotechnical standardization. The procedures used to develop this document and those intende
16、d for its further maintenance are described in the ISO/IEC Directives, Part 1. In particular the different approval criteria needed for the different types of ISO documents should be noted. This document was drafted in accordance with the editorial rules of the ISO/IEC Directives, Part 2 (see www.is
17、o.org/directives). Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of any patent rights identified during the development of the document wil
18、l be in the Introduction and/or on the ISO list of patent declarations received (see www.iso.org/patents). Any trade name used in this document is information given for the convenience of users and does not constitute an endorsement. For an explanation on the meaning of ISO specific terms and expres
19、sions related to conformity assessment, as well as information about ISOs adherence to the WTO principles in the Technical Barriers to Trade (TBT), see the following URL: Foreword Supplementary information. The committee responsible for this document is ISO/TC 17, Steel, Subcommittee SC 15, Railway
20、rails, rail fasteners, wheels and wheelsets. This second edition cancels and replaces the first edition (ISO 5003:1980), which has been technically revised. ISO 2016 All rights reserved v Flat bottom (Vignole) railway rails 43kg/m and above 1 Scope This International Standard specifies the terms and
21、 definitions, information to be supplied by the purchaser, tolerances for dimensions, length, technical requirements, inspection rules, identification, certification, and a quality assurance system for as-rolled and heat-treated steel rails for railways. This International Standard specifies flat bo
22、ttom (vignole) railway rails with linear mass of 43 kg/m and above, for conventional and high-speed railway track usage. There are 19 pearlitic steel grades specified, covering a 200 HBW to 400 HBW hardness range and including “non-heat-treated” carbon manganese steels, “non-heat-treated” alloy stee
23、ls, “heat-treated” carbon manganese, and “heat-treated” low alloy steels. 2 Normative references The following documents, in whole or in part, are normatively referenced in this document and are indispensable for its application. For dated references, only the edition cited applies. For undated refe
24、rences, the latest edition of the referenced document (including any amendments) applies. ISO 1099, Metallic materials Fatigue testing Axial force-controlled method ISO 3887, Steels Determination of depth of decarburization ISO 4967, Steel Determination of content of non-metallic inclusions Microgra
25、phic method using standard diagrams ISO 4968:1979, Steel Macrographic examination by sulfur print (Baumann method) ISO 4969:2015, Steel Etching method for macroscopic examination ISO 6506-1, Metallic materials Brinell hardness test Part 1: Test method ISO 6892-1, Metallic materials Tensile testing P
26、art 1: Method of test at room temperature ISO 12108, Metallic materials Fatigue testing Fatigue crack growth method ASTM E45, Standard test methods for determining the inclusion content of steel ASTM E399, Standard Test Method for Linear-Elastic Plane-Strain Fracture Toughness Klc of Metallic Materi
27、als 3 T erms a nd definiti ons For the purposes of this document, the following terms and definitions apply. 3.1 heat liquid steel melt tapped out of a converter or electric arc furnace which includes, after continuous casting, a given number of blooms relating to the weight of the heat and the exte
28、nsion of the mixing zone Note 1 to entry: In the case of sequence casting, the blooms belonging to the mixing zone should be clearly defined. INTERNATIONAL ST ANDARD ISO 5003:2016(E) ISO 2016 All rights reserved 1 ISO 5003:2016(E) 3.2 sequence any number of heats, of the same steel grade, which unde
29、rgo continuous casting in tundishes Note 1 to entry: Tundishes can be used in parallel, if the caster has many strands. 3.3 heat-treated rail rail that has undergone accelerated cooling from austenitizing temperature during the metallurgical transformation period 3.4 off-line heat-treated rail all r
30、olled rail that has undergone re-austenitization for heat treatment purposes 3.5 online heat-treated rail heat-treated rail that has not undergone re-austenitization after rolling 3.6 rolling process process between the blooms leaving the heating furnace and exiting the finishing pass 3.7 isothermal
31、 treatment process process whereby blooms are held for a period of time at an elevated temperature for reducing the hydrogen content Note 1 to entry: For maximum efficiency, this is as near to (but below) the pearlite to austenite transformation temperature as is practically possible. Note 2 to entr
32、y: This process is sometimes referred to as “sub-critical” diffusion annealing. 3.8 rail running surface curved surface of the rail head Note 1 to entry: It may also refer to any area between both gauge corners (transition points of the head inclination and the first head radius). 4 Information to b
33、e supplied by the purchaser The purchaser shall provide the supplier with the following information at the time of enquiry or order: a) the rail profile (by submitting a drawing) and the profile tolerances as defined for the dimensions listed in Table 3; b) the steel grade (see 7.2 and Annex A); c)
34、the straightness class “A” or “B” of rail (see Table 5); d) the non-metallic inclusion determination method and if applicable: the class “1” or “2” of rail (see Table 13); e) the determination of the macrostructure (see 5.10); f) the lengths of rail (see Table 4 and 6.3); g) undrilled or drilled rai
35、l ends to take fish bolts, and location and dimensions of holes when required (see Table 4); h) paint code requirements (see 9.4.4).2 ISO 2016 All rights reserved ISO 5003:2016(E) 5 Test methods 5.1 Test items, testing frequency and test methods Test items, sampling position, sampling numbers and te
36、st methods shall be as given in Table 1 and Table 2. Table 1 Testing frequency for acceptance testing Test items As-rolled rails Heat-treated rails Relevant subclause Chemical composition One per heat One per heat 5.2 Hydrogen One per heat (two tests from first heat in sequence) One per heat (two te
37、sts from first heat in sequence) 5.3 Total oxygen One per sequence a One per sequence a 5.4 Tensile One per heat a,b,d One per heat a,c 5.5 Hardness One per heat a,b One per heat a,c 5.6 Microstructure Not required for grades HR200, HR220, HR235 and HR260A. One per 1 000 tons or part thereof for gra
38、des HR260B,HR280,HR310A, HR310B,HR320,HR325 a,b One per 100 tons of heat-treated rail a,c 5.7 Decarburization One per 1 000 tons or part thereof a,b One per 500 tons or part thereof a,c 5.8 Non-metallic inclu- sions One per sequence b One per sequence b or c 5.9 Macrostructure One per 500 tons or pa
39、rt thereof a,b One per 500 tons or part thereof a,b or c 5.10 Dimension Whole length Whole length 6.1 Straightness Whole length Whole length 6.2 Surface quality Whole length Whole length 7.9 Ultrasonic test Whole length Whole length 5.11 aSamples shall be taken at random. When different rail grades
40、are casted in the same sequence, the samples shall be taken outside the mixing zone. bSamples shall be cut after rolling. cSamples shall be cut after heat-treating for heat-treated rails. dOne calculation per heat and one testing per 2 000 tons if agreed between purchaser and manufacturer Table 2 Te
41、sting frequency for periodic tests Test items As-rolled rails and Heat-treated rails Relevant subclause Residual stress Tests shall be done for all grades at least once every 5 years or after any relevant change in the produc- tion process. The manufacturer shall only carry out testing on a 60 kg/m
42、profile or the heaviest section produced. 5.12 Fracture toughness (K Ic ) 5.13 Fatigue crack growth rate 5.14 Fatigue test 5.15 Longitudinal hardness test Heat-treated rails 5.16 5.2 Chemical composition The chemical composition shall be determined on the liquid. ISO 2016 All rights reserved 3 ISO 5
43、003:2016(E) When the solid chemical composition is to be checked as a requirement of the purchaser, this shall be carried out at the position of the tensile test piece shown in Figure 1. 5.3 Hydrogen content The hydrogen content of the liquid steel shall be measured by determining the pressure of hy
44、drogen in the steel using an online immersion probe system or the method agreed between the purchaser and manufacturer. At least two liquid samples shall be taken from the first heat of any sequence using a new tundish and one from each of the remaining heats and analysed for hydrogen content (see T
45、able 1). The first sample from the first heat in a sequence shall be taken from the tundish at the time of the maximum hydrogen concentration. When testing of rails is required rail samples shall be taken at the hot saw at a frequency of one per heat at random. However on the first heat in a sequenc
46、e, the rail sample shall be from the last part of a first bloom teemed on any strand. Hydrogen determination shall be carried out on samples taken from the centre of the rail head, and determined by automatic machine. 5.4 Total oxygen content The total oxygen content can be determined in the liquid
47、or solid. If the total oxygen content is determined from the solid rail head, the testing positions are shown in Figure 2. 5.5 Tensile test Test samples shall be taken from the rail head as shown in Figure 1. The tensile properties shall be determined in accordance with ISO 6892-1 by using a round t
48、ensile test piece with the dimensions as follows: diameter 10 mm; gauge length 50 mm. In the case of dispute, the tensile test pieces shall be maintained at a temperature of 200 C for 6 h before testing. For as-rolled rails, the tensile strength and elongation may be determined as agreed between the
49、 purchaser and manufacturer by a correlation to the chemical composition based on the statistical data analysis. The method to be applied is shown in Annex B. 5.6 Hardness 5.6.1 General requirements Brinell hardness tests (HBW) shall be carried out in accordance with ISO 6506-1. The method used is at the discretion of the manufacturer. In case of dispute, the test shall be done using HBW 2,5/187,5. 5.6.2 Surface hardness The surface hardness shall be tested at position RS as shown in Figure 3.4 ISO 2016 All rights r
