1、raising standards worldwideNO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAWBSI Standards PublicationBS EN 14587-3:2012Railway applications Track Flash butt welding of railsPart 3: Welding in association with crossingconstructionBS EN 14587-3:2012 BRITISH STANDARDNational forewo
2、rdThis British Standard is the UK implementation of EN 14587-3:2012. The UK participation in its preparation was entrusted to TechnicalCommittee RAE/2, Railway Applications - Track.A list of organizations represented on this committee can beobtained on request to its secretary.This publication does
3、not purport to include all the necessaryprovisions of a contract. Users are responsible for its correctapplication. The British Standards Institution 2012. Published by BSI StandardsLimited 2012 ISBN 978 0 580 65807 5 ICS 25.160.10; 93.100 Compliance with a British Standard cannot confer immunity fr
4、omlegal obligations.This British Standard was published under the authority of theStandards Policy and Strategy Committee on 31 October 2012. Amendments issued since publicationDate T e x t a f f e c t e dBS EN 14587-3:2012EUROPEAN STANDARD NORME EUROPENNE EUROPISCHE NORM EN 14587-3 September 2012 I
5、CS 25.160.10; 93.100 English Version Railway applications - Track - Flash butt welding of rails - Part 3: Welding in association with crossing construction Applications ferroviaires - Voie - Soudage des rails par tincelage - Partie 3: Soudure associe la fabrication des coeurs de voie Bahnanwendungen
6、 - Oberbau - Abbrennstumpfschweien von Schienen - Teil 3: Schweien im Zusammenhang mit Herzstckkonstruktionen This European Standard was approved by CEN on 6 July 2012. CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European S
7、tandard 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-CENELEC Management Centre or to any CEN member. This European Standard exists in three official versions (Eng
8、lish, 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-CENELEC Management Centre has the same status as the official versions. CEN members are the national standards bodies of Austria, Belgium,
9、 Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerlan
10、d, Turkey and United Kingdom. EUROPEAN COMMITTEE FOR STANDARDIZATION COMIT EUROPEN DE NORMALISATION EUROPISCHES KOMITEE FR NORMUNG Management Centre: Avenue Marnix 17, B-1000 Brussels 2012 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members. Ref. N
11、o. EN 14587-3:2012: EBS EN 14587-3:2012EN 14587-3:2012 (E) 2 Contents Page Foreword 4Introduction .51 Scope 62 Normative references 63 Terms and definitions .64 Information to be supplied for approval of procedure.84.1 By the purchaser84.2 By the manufacturer 85 Approval of the manufacturer 85.1 Gen
12、eral 85.2 Welding procedure 85.3 Operators 95.4 Supervision 95.5 Weld Inspection .95.6 Equipment 95.7 Quality assurance 96 Requirements for the welding process .96.1 General 96.2 Workpiece preparation 96.3 Clamping force 106.4 Initial burn-off 106.5 Preheating . 106.6 Final flashing . 106.7 Upsettin
13、g . 106.8 Post-weld treatment 116.8.1 Before unclamping . 116.8.2 After removal from machine 116.9 Welding parameters . 116.10 Removal of upset and correction of weld alignment 117 Profile finishing of the weld . 118 Weld geometry and dimensions 128.1 General . 128.2 Alignment and flatness across th
14、e weld 128.3 Foot dimensions . 139 Weld identification 1310 Procedure approval 1310.1 General . 1310.2 Test weld specimen preparation . 1410.3 Number of specimens 1410.4 Approval tests . 1410.4.1 General . 1410.4.2 Weld geometry and dimensions 1410.4.3 Visual inspection 1410.4.4 Surface finish 1410.
15、4.5 Liquid penetrant testing and magnetic particle testing 1410.4.6 Internal soundness . 1510.4.7 Bend testing 1510.4.8 Fatigue testing 1510.4.9 Macro-examination . 15BS EN 14587-3:2012EN 14587-3:2012 (E) 3 10.4.10 Micro-examination . 1610.4.11 Hardness testing 1610.5 Test result report . 1710.6 Val
16、idity of approval 1711 Approval of other rail profiles or grades . 1711.1 General 1711.2 Sample preparation . 1711.3 Approval tests 1711.4 Test result report . 1812 Track trials 1812.1 General 1812.2 Track trial test result report 1813 Weld production following procedure approval . 1813.1 Weld produ
17、ction 1813.2 Weld parameter monitoring 1813.3 Visual inspections . 1813.4 Weld geometry and dimensions 1913.5 Liquid penetrant testing and magnetic particle testing . 1913.6 Internal soundness 1913.7 Bend Testing 1913.7.1 General 1913.7.2 Additional test requirements 1913.7.3 Bend test procedure 191
18、3.7.4 Interpretation of results 2013.7.5 Retesting 2013.7.6 Documentation . 20Annex A (informative) Example of Flat spot and Bright spot . 21Annex B (normative) Bend test requirements 22Annex C (normative) Test weld fracture faces Recording of defects . 24Annex D (normative) Fatigue test method for
19、flash butt welds . 26D.1 Scope 26D.2 Test equipment 26D.3 Calibration procedure . 28D.3.1 General 28D.3.2 Test piece . 28D.3.3 Test piece preparation 28D.3.4 Instrumentation 28D.3.5 Procedure . 28D.4 Fatigue test method . 32D.4.1 General 32D.4.2 Staircase testing method 32D.4.3 Example of the data a
20、nalysis of a fatigue strength determination by the staircase method 35D.4.4 Past-the-post testing method . 35Annex E (normative) Macro-examination and micro-examination. 37E.1 Macro examination 37E.2 Micro examination . 37Annex F (normative) Hardness testing . 39Annex G (normative) Ultrasonic testin
21、g non-austenitic materials . 40G.1 Reference line (DAC) generation Reference block . 40G.2 Reference line (DAC) generation and acceptance criteria 40Bibliography 42BS EN 14587-3:2012EN 14587-3:2012 (E) 4 Foreword This document (EN 14587-3:2012) has been prepared by Technical Committee CEN/TC 256 “Ra
22、ilway 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 March 2013, and conflicting national standards shall be withdrawn at the latest by Mar
23、ch 2013. Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. CEN and/or CENELEC shall not be held responsible for identifying any or all such patent rights. This document has been prepared under a mandate given to CEN by the European
24、Commission and the European Free Trade Association. 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 and R350HT grade rails in a fixed plant Part 2: New R220, R260
25、, R260Mn and R350HT grade rails by mobile welding machines at sites other than a fixed plant Part 3: Welding in association with crossing construction (the present standard) According to the CEN/CENELEC Internal Regulations, the national standards organisations of the following countries are bound t
26、o 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, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, R
27、omania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom. BS EN 14587-3:2012EN 14587-3:2012 (E) 5 Introduction This part of EN 14587 has four main topics: requirements of a welding process; procedure approval for a fixed plant; approval of other rail profiles or grades;
28、weld production following approval. This European Standard satisfies the needs of the railway authority. The manufacturer should achieve the specified requirements of this European Standard. BS EN 14587-3:2012EN 14587-3:2012 (E) 6 1 Scope This European Standard specifies requirements for the approva
29、l of a welding process in a fixed plant, together with the requirements for subsequent welding production. This European Standard applies to new Vignole rails welded by flash butt welding to crossing components in a fixed plant, and intended for use on railway infrastructures. 2 Normative references
30、 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 references, the latest edition of the referenced document (including any amendments) applies. EN 571
31、-1, Non-destructive testing Penetrant testing Part 1: General principles EN 1371-1, Founding Liquid penetrant testing Part 1: Sand, gravity die and low pressure die castings EN 13674-1, Railway applications Track Rail Part 1: Vignole railway rails 46 kg/m and above EN 13674-2, Railway applications T
32、rack Rail Part 2: Switch and crossing rails used in conjunction with Vignole railway rails 46 kg/m and above EN 13674-4, Railway applications Track Rail Part 4: Vignole railway rails from 27 kg/m to, but excluding 46 kg/m EN 14587-1:2007, Railway applications Track Flash butt welding of rails Part 1
33、: New R220, R260, R260Mn and 350HT grade rails in a fixed plant EN ISO 6507-1, Metallic materials Vickers hardness test Part 1: Test method (ISO 6507-1) EN ISO 11666, Non-destructive testing of welds Ultrasonic testing Acceptance levels (ISO 11666) EN ISO 17638, Non-destructive testing of welds Magn
34、etic particle testing (ISO 17638) EN ISO 17640, Non-destructive testing of welds Ultrasonic testing Techniques, testing levels, and assessment (ISO 17640) EN ISO 23279, Non-destructive testing of welds Ultrasonic testing Characterization of indications in welds (ISO 23279) 3 Terms and definitions Fo
35、r the purposes of this document, the following terms and definitions apply. 3.1 manufacturer company that joins rails to rails, rails to crossings and rails to crossing components by flash butt welding in a fixed plant 3.2 purchaser buyer of the flashbutt welded crossings working in accordance with
36、the requirements of the railway authority 3.3 railway infrastructure permanent way of national or private railways BS EN 14587-3:2012EN 14587-3:2012 (E) 7 3.4 fixed plant stationary machine for flash butt welding of rails to rails, rails to crossings and rails to crossing components 3.5 die burn dam
37、age caused by localised overheating on the electrode contact surfaces 3.6 upset metal extruded around the rail profile as a result of forging 3.7 specimen portion detached from a welded component or a welded joint and prepared as required for testing 3.8 profile finishing operation by which the rail
38、 or relevant part of the component at the weld is returned to original profile, by removal of upset material Note 1 to entry: This operation can be achieved by grinding, milling, planing or any other suitable means. 3.9 finished condition welded and profile finished 3.10 flat spot feature having a l
39、ocalised smooth texture when viewed in a vertical transverse section (see Annex A) Note 1 to entry: When viewed longitudinally in macro this may appear as a lens-shaped feature. 3.11 bright spot localised bright area occurring at the stainless insert/rail interface indicative of a possible martensit
40、ic area (see Annex A) 3.12 lack of bond area within the weld where there is no metal to metal contact (excluding flat spots and bright spots) Note 1 to entry: This may appear as a linear discontinuity at the interfaces when examined in the finished condition or after sectioning. 3.13 welded zone are
41、as of 50 mm on either side of the weld centreline 3.14 throat flare wing entry flare (front) machining or setting of wings to give an entry flare into the throat 3.15 foundry method system to produce casting compliant with the requirements of EN 15689 3.16 workpiece crossing component, insert rail o
42、r rail leg-end extension BS EN 14587-3:2012EN 14587-3:2012 (E) 8 3.17 railway authority (RA) either the railway regulator or the owner of the railway infrastructure or the custodian with a delegated responsibility for a railway infrastructure 3.18 as welded condition rails that have been welded and
43、trimmed only 4 Information to be supplied for approval of procedure 4.1 By the purchaser The following information shall be supplied by the purchaser, agreed upon by the manufacturer, and shall be fully documented: a) the rail profile and crossing geometrical details; b) the rail and crossing grades
44、/materials; c) the profile class of the rail leg-end extension as specified in EN 13674-1, EN 13674-2 or EN 13674-4; d) alignment class/classes of the flash butt welds (see Table 1); e) the type of fatigue tests (if applicable) for approval; f) tolerances at rail ends on the delivered crossing; g) m
45、inimum length of rail leg-end extension; h) rail profile, number and frequency of production bend tests (see 13.7); i) requirements of any track trials. 4.2 By the manufacturer The following information shall be supplied by the manufacturer, agreed upon by the purchaser, and shall be fully documente
46、d: a) a qualified weld procedure; b) traceability system of the welds; c) type and identification number of machine being used. 5 Approval of the manufacturer 5.1 General The manufacturer shall meet the approval requirements as defined in 5.2 to 5.7. The purchaser reserves the right to audit the man
47、ufacturer at any time. 5.2 Welding procedure The manufacturer shall use welding procedures and flash butt welding machines that are approved by the RA. BS EN 14587-3:2012EN 14587-3:2012 (E) 9 5.3 Operators The manufacturer shall maintain a system that ensures the competence of their welding operator
48、s by appropriate training and assessment. 5.4 Supervision The manufacturer shall maintain a management and supervision system of flash butt welding that complies with the requirements of the purchaser. 5.5 Weld Inspection The manufacturer shall maintain a system of weld inspection according to the p
49、urchaser requirements. Instances of non-conformity found during these inspections shall be recorded in the traceability system. 5.6 Equipment Equipment shall comply with the operating manual. Inspection and calibration equipment shall comply with those requirements as agreed between the manufacturer and
