1、BRITISH STANDARDBS EN 14587-1:2007Railway applications Track Flash butt welding of rails Part 1: New R220, R260, R260Mn and R350HT grade rails in a fixed plantThe European Standard EN 14587-1:2007 has the status of a British StandardICS 25.160.10; 45.080; 93.100g49g50g3g38g50g51g60g44g49g42g3g58g44g
2、55g43g50g56g55g3g37g54g44g3g51g40g53g48g44g54g54g44g50g49g3g40g59g38g40g51g55g3g36g54g3g51g40g53g48g44g55g55g40g39g3g37g60g3g38g50g51g60g53g44g42g43g55g3g47g36g58BS EN 14587-1:2007This British Standard was published under the authority of the Standards Policy and Strategy Committee on 31 July 2007 B
3、SI 2007ISBN 978 0 580 53694 6National forewordThis British Standard was published by BSI. It is the UK implementation of EN 14587-1:2007. The UK participation in its preparation was entrusted by Technical Committee RAE/2, Railway track components, to Panel RAE/2/-/1, Rails and steel sleepers.A list
4、of organizations represented on this committee can be obtained on request to its secretary.This publication does not purport to include all the necessary provisions of a contract. Users are responsible for its correct application.Compliance with a British Standard cannot confer immunity from legal o
5、bligations.Amendments issued since publicationAmd. No. Date CommentsEUROPEAN STANDARDNORME EUROPENNEEUROPISCHE NORMEN 14587-1June 2007ICS 25.160.10; 93.100English VersionRailway applications - Track - Flash butt welding of rails - Part 1:New R220, R260, R260Mn and R350HT grade rails in a fixedplantA
6、pplications ferroviaires - Voie - Soudage des rails partincelage - Partie 1: Rails neufs de nuances R220, R260,R260Mn et R350HT dans une installation fixeBahnanwendungen - Oberbau - Abbrennstumpfschweienvon Schienen -Teil 1: Abbrennstumpfschweien neuerSchienen der Gte R220, R260, R260Mn und R350HT i
7、neinem SchweiwerkThis European Standard was approved by CEN on 3 May 2007.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 bibliogra
8、phical references concerning such nationalstandards may be obtained on application to the CEN 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 translationunder the responsibility of a CE
9、N member into its own language and notified to the CEN Management Centre has the same status as theofficial versions.CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland,France, Germany, Greece, Hungary, Iceland, Ireland, Ital
10、y, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal,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 Br
11、ussels 2007 CEN All rights of exploitation in any form and by any means reservedworldwide for CEN 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 Req
12、uirements for the welding process .8 5.1 General8 5.2 Clamping force.8 5.3 Pre-heating .8 5.4 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
13、 and horizontal alignment requirements 12 6 Procedure approval .12 6.1 General12 6.2 Information 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
14、 penetrant inspection .13 6.4.5 Bend testing .13 6.4.6 Macro examination 13 6.4.7 Micro examination .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
15、result report .15 8 Approval of the Welding Contractor15 8.1 General15 8.2 Welding procedure 15 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
16、14587-1:2007 (E) 3 9.3 Rail end preparation and horizontal rail alignment requirements17 9.4 Weld 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 fini
17、shing of the rail head.17 9.9 Weld straightness and flatness18 9.10 Bend testing .19 9.10.1 General19 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 (normat
18、ive) Test weld fracture faces Recording of defects.23 Annex C (normative) Fatigue test method 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
19、 Fatigue test method.31 C.4.1 General31 C.4.2 Staircase testing method31 C.4.3 Example of the 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
20、 Micro examination .36 Annex E (normative) Hardness testing.37 Bibliography38 EN 14587-1:2007 (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
21、status of a national standard, either by publication of an identical text or by endorsement, at 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 Trac
22、k Flash butt welding of rails. The list of parts is as follows: Part 1: New R220, R260, R260Mn 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 const
23、ruction According to the CEN/CENELEC Internal Regulations, the national standards organizations 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,
24、 Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, 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
25、for a fixed plant; c) approval of other rail profiles or grade; d) approval of the welding contractor; 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
26、 a reality, it is essential a standard is in place that satisfies the needs of the infrastructure 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 app
27、roval of a welding process in a fixed plant, together with the requirements for subsequent welding 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 intende
28、d for use on railway infrastructure. This European Standard applies to the welding of rails into 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 referen
29、ces, the latest edition of the referenced document (including any amendments) applies. EN 571-1, 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
30、1: Vignole railway rails 46 kg/m and above 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 uniaxial testing machines Part 1: Tension/compression testing machines Verification and calibration o
31、f 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 as welded condition rails that have been welded and trimmed only 3.2 contractor company approved by a railway authority to provide staff and machin
32、ery to execute the production of FB weld in a fixed plant NOTE This may include staff and machinery 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 r
33、emoving trimmed upset by grinding or other similar process 3.5 finished condition welded, trimmed, 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 sha
34、pe in vertical longitudinal section, or a generally circular/elliptical shape having a localised 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
35、 either on the surface after removal of the upset or in a weld section 3.9 profile finishing operation 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
36、purchaser of the welds 3.11 railway authority either the railway regulator or the owner of a railway infrastructure or the custodian with a delegated responsibility for a railway infrastructure 3.12 trimmed upset metal remaining around the rail profile following trimming 3.13 trimming removal of ups
37、et 3.14 upset metal extruded around the rail profile as a result of forging 3.15 welded string 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 str
38、ing 4 Quality management system The contractor shall operate an independently approved and audited 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
39、 14587-1:2007 (E) 8 5 Requirements for the welding process 5.1 General All welding shall be carried 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 whe
40、n a clamping force is exerted on the rails, it shall not damage the rail in such a way that subsequent 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. The
41、re shall be no evidence of local melting on the ends of the rails during pre-heating. 5.4 Flashing 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 expe
42、lled such that they are kept to a minimum at the weld interface. The weld interface shall extend 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
43、, the time between completion of forging and unclamping shall be a minimum of 4 s. 5.8 Welding 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
44、pressure; d) displacement; e) welding time. 5.8.2 The welding parameters shall be determined during 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 weld
45、ing parameters shall be monitored and recorded. These records shall be referenced to the appropriate 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 var
46、ious rail temperatures are not considered as alterations to the welding program. A bending test 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
47、weld 5.9.1 Any step between the rails across the weld in the trimmed but not dressed condition 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 Fi
48、gure 1. Table 1 Maximum permitted steps Position of step on the rail Maximum permitted step (in 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 Whe
49、re the step arises from the rail dimensions the rail foot tips may be dressed locally to achieve 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 visib
