1、BS EN 15689:2009ICS 93.100NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAWBRITISH STANDARDRailway applications Track Switches andcrossings Crossingcomponents madeof cast austeniticmanganese steelThis British Standardwas published under theauthority of the StandardsPolicy and St
2、rategyCommittee on 31 January2010 BSI 2010ISBN 978 0 580 58897 6Amendments/corrigenda issued since publicationDate CommentsBS EN 15689:2009National forewordThis British Standard is the UK implementation of EN 15689:2009.The UK participation in its preparation was entrusted to TechnicalCommittee RAE/
3、2, Railway track components.A list of organizations represented on this committee can be obtained onrequest to its secretary.This publication does not purport to include all the necessary provisionsof a contract. Users are responsible for its correct application.Compliance with a British Standard ca
4、nnot confer immunityfrom legal obligations.BS EN 15689:2009EUROPEAN STANDARD NORME EUROPENNE EUROPISCHE NORM EN 15689 November 2009 ICS 93.100 English Version Railway applications - Track - Switches and crossings - Crossing components made of cast austenitic manganese steel Applications ferroviaires
5、 - Voie - Appareils de voie - Coeurs ou composants de coeur en acier moul au manganse Bahnanwendungen - Oberbau - Weichen und Kreuzungen -Gegossener austenitischer Manganstahl fr Herzstckbauteile This European Standard was approved by CEN on 10 October 2009. CEN members are bound to comply with the
6、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 Centre o
7、r 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 official ve
8、rsions. 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, Slovenia,
9、 Spain, Sweden, Switzerland and United Kingdom. EUROPEAN COMMITTEE FOR STANDARDIZATION COMIT EUROPEN DE NORMALISATION EUROPISCHES KOMITEE FR NORMUNG Management Centre: Avenue Marnix 17, B-1000 Brussels 2009 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN nation
10、al Members. Ref. No. EN 15689:2009: EBS EN 15689:2009EN 15689:2009 (E) 2 Contents Page Foreword 31 Scope 42 Normative references 43 Terms and definitions .54 Quality systems .55 Sample approval 56 General requirements 66.1 Materials (liquid chemistry) 66.2 Microstructure 66.3 Surface conditions.66.3
11、.1 Un-machined and heat treated surfaces .66.3.2 Definition of surface zones .76.3.3 Machined surfaces.76.3.4 Tolerances 76.4 Internal soundness 86.4.1 General 86.4.2 Definition of zones and acceptance levels .86.4.3 Frequency for radiographic examination . 126.5 Foundry practice . 127 Acceptance te
12、sts 137.1 Chemical analysis . 137.2 Impact bend . 137.3 Metallographic examination 137.4 Visual inspection 137.5 Dye penetrant testing . 137.6 Radiography 147.6.1 General . 147.6.2 Method of radiography . 148 Additional requirements for pre-hardened crossings 148.1 Qualification 148.1.1 Generally 14
13、8.1.2 Dye penetration test . 148.1.3 Hardness requirements 148.2 Production tests 168.3 Monitoring of pre-hardening process . 169 Weld rectification of surface discontinuities . 169.1 Qualification of the weld procedure and the welder . 169.2 Definition of rectification zones, max. dimensions of exc
14、avations . 169.3 Testing of weld rectification 179.4 Welding records 1710 Identification and marking . 1711 Documentation 1812 Non-common cast manganese crossings . 18Bibliography . 19BS EN 15689:2009EN 15689:2009 (E) 3 Foreword This document (EN 15689:2009) has been prepared by Technical Committee
15、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 2010, and conflicting national standards shall be withdrawn at the l
16、atest by May 2010. 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 European Standard is complementary to the series of standards
17、EN 13232 “Railway applications Track Switches and crossings”, which covers the design and quality of switches and crossings in flat bottomed rail. According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European S
18、tandard: 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, Slovenia, Spain, Sweden, Switzerland and the United Kingd
19、om. BS EN 15689:2009EN 15689:2009 (E) 4 1 Scope The scope of this European Standard is: to establish material requirements for cast austenitic manganese steel for fixed crossings and cradles for crossings with moveable parts designed to be welded or bolted to rails; to formulate codes of practice fo
20、r inspection, testing of un-machined and machined heat-treated castings; to list the methods by which crossings should be identified and traced; to define limits of weld rectification by the supplier; special requirements for pre-hardened crossings. Geometrical aspects, as machining tolerances and i
21、nspection of finished crossings are covered in EN 13232-6 and EN 13232-7 and therefore not in this European Standard. This European Standard specifies the minimum requirements for cast manganese crossing components. Special applications (for instance tram systems) can require different demands in ce
22、rtain paragraphs and need to be agreed between customer and supplier. 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 d
23、ocument (including any amendments) applies. EN 444:1994, Non-destructive testing General principles for the radiographic examination of metallic materials using X- and gamma-rays EN 462-3:1996, Non-destructive testing Image quality of radiographs Part 3: Image quality classes for ferrous metals EN 4
24、73:2008, Non destructive testing Qualification and certification of NDT personnel General principles EN 571-1, Non destructive testing Penetrant testing Part 1: General principles EN 1370, Founding Surface roughness inspection by visual/tactile comparators EN 1371-1, Founding Liquid penetrant inspec
25、tion Part 1: Sand, gravity die and low pressure die castings EN 10204, Metallic products Types of inspection documents EN 13232-1:2003, Railway applications Track Switches and crossings Part 1: Definitions EN 13232-6:2005, Railway applications Track Switches and crossings Part 6: Fixed common and ob
26、tuse crossings EN 13232-7:2006, Railway applications Track Switches and crossings Part 7: Crossings with moveable parts EN ISO 11970, Specification and approval of welding procedures for production welding of steel castings (ISO 11970:2001) BS EN 15689:2009EN 15689:2009 (E) 5 ISO 8062, Castings Syst
27、em of dimensional tolerances and machining allowances 3 Terms and definitions For the purposes of this document, the terms and definitions given in 7.4 and 7.5 of EN 13232-1:2003, 3.1 of EN 13232-6:2005, Clause 4 of EN 13232-7:2006 and the following apply. 3.1 weldable crossing crossing with rail en
28、ds suitable for welding into track 3.2 fishplated crossing crossing with rail ends suitable for mechanical joints 3.3 pre hardened contact area and running table which is intentionally hardened prior to installation in track 3.4 chaplet metallic core support that remains in finished part 3.5 custome
29、r operator or user of the equipment, or the purchaser of the equipment on the users behalf 3.6 supplier body responsible for the use of the EN in response to the customers requirements 4 Quality systems The supplier responsible for the manufacture of the crossing shall be certified by an accredited
30、third party and have an audited quality system or shall have a quality system approved by the customer. 5 Sample approval The suitability of the pattern design, mould preparation procedures, casting conditions and heat treatment procedures shall be demonstrated by producing prototype casting for eve
31、ry new pattern. Sample approval by the supplier is necessary for every new pattern. Any subsequent modifications in the manufacturing process, which may influence the quality of the components, shall be the responsibility of the cast foundry to test and record. The customer shall have the right to h
32、ave access to these records. All tests according to Clause 7 shall be performed for sample approval. However, radiography may be dispensed with by the customer, in which case this shall be specified in the tender documents. BS EN 15689:2009EN 15689:2009 (E) 6 6 General requirements 6.1 Materials (li
33、quid chemistry) Table 1 Materials (liquid chemistry) Element Percentage weight components Weight % Carbon 0,95 to 1,3 aSilicon 0,65 max.Manganese 11,5 to 14,0 aPhosphorus 0,050 max.Sulphur 0,03 max.Nickel 1,75 max.Molybdenum 0,75 max. Chromium 0,50 max.Copper 0,30 max.Aluminium 0,045 max.aManganese
34、shall not be less than 10 times the carbon content. Other alloying elements shall not be added. 6.2 Microstructure Crossing shall have an austenitic microstructure and be free of detrimental carbide precipitation. To prove the as-cast carbidic structure has changed to an acceptable austenitic struct
35、ure this shall be demonstrated by metallographic examination or mechanical testing (see Clause 7). 6.3 Surface conditions 6.3.1 Un-machined and heat treated surfaces The minimum level of surface finish shall be as specified in Table 2 with the relevant SCRATA comparators (refer to EN 1370). Table 2
36、Inspection zones Inspection zone Ai Aii Aiii Bi Bii Biii Surface finish A2 A2 A3 A2 A2 A4 Surface inclusions B2 B2 B4 B2 B2 B5 Gas porosity C2 C2 C3 C2 C1 C4 Laps and cold shuts D1 D1 D2 D2 D1 D5 Scabs E3 E3 E5 E3 E3 E5 Welds J1 J1 J1 J1 J1 J1 BS EN 15689:2009EN 15689:2009 (E) 7 6.3.2 Definition of
37、surface zones The definition of surface zones is as shown in Figure 1. Dimensions in millimetres Figure 1 Definition of surface zones 6.3.3 Machined surfaces The maximum levels of arithmetical roughness are: wheel contact area: Ra 6,3 m; surfaces without wheel contact: Ra 12,5 m; fishplate areas: Ra
38、 6,3 m. 6.3.4 Tolerances Dimensions of non-machined areas of the casting areas shall comply with tolerances given by ISO 8062 CT11 unless otherwise agreed between the customer and supplier. Dimensional tolerances for machined castings shall be referenced on detail drawings for the crossing component
39、. Basic dimensional requirements are given in EN 13232-6 and EN 13232-7. BS EN 15689:2009EN 15689:2009 (E) 8 6.4 Internal soundness 6.4.1 General Check all zones on sample castings over the full length, using radiography according to 7.6.1. 6.4.2 Definition of zones and acceptance levels If the cust
40、omer requires different quality levels than those stated in the table below, they shall be agreed at the time of tender. In areas with greater width additional radiographs may be taken to determine the location of indications where possible. Acceptance levels according to ASTM E446, ASTM E280 and AS
41、TM E186 for the zones of test are illustrated in Figures 2 to 6 and Table 3. Table 3 Inspection zone Zone Location Acceptance level See Figure Zone 1 running surface and rail weldable endpieces A1 B1 C1 2, 3, 4, 6 Zone 2 under running surface on the nose up to 60 mm nose width A3 B3 C3 2, 3 Zone 3 b
42、elow Zone 1; wing rail limited by a distance of 400 mm from theoretical point towards wing front rearwards up to the end of the running surface A3 B3 C3 3 Zone 4 changes of section (below Zone 1) A3 B3 C3 2, 5 Zone 5 web of the leg ends of fishplated crossings for the whole length of the fishplate A
43、3 B3 C3 6 Rest all other zones of the crossing A3 B3 C4 All A = Gas porosity B = Inclusions (sand and slag) C = Shrinkage The minimum depths of the different zones are post machining. BS EN 15689:2009EN 15689:2009 (E) 9 Dimensions in millimetres Key 1 theoretical point rearwards 5 zone 4 2 theoretic
44、al point toward wing front 6 zone 2 under zone 1 3 wheel transfer area 7 thickness of vee measured at 14 mm below running surface 4 end of running table Figure 2 Crossing NOTE 1 For section A-A and B-B, see Figure 3. NOTE 2 For section C-C, see Figure 4. NOTE 3 For view on D, see Figure 6. BS EN 156
45、89:2009EN 15689:2009 (E) 10 Dimensions in millimetres Figure 3 Wheel transfer area Dimensions in millimetres Figure 4 Remaining length of crossing BS EN 15689:2009EN 15689:2009 (E) 11 Dimensions in millimetres Key 1 change of section from rail profile to main body 2 minimum 280 Figure 5 Changes of s
46、ection BS EN 15689:2009EN 15689:2009 (E) 12 Dimensions in millimetres Key 1 crossing endpiece to be welded 2 leg end of fishplated crossing Figure 6 View D 6.4.3 Frequency for radiographic examination One in every 50 crossings of each pattern type shall be checked by radiography in the following loc
47、ations: a) the nose zones 1 and 2 up to where nose width equals 60 mm; b) the wheel transfer area zones 1 and 3; c) leg ends 50 mm back from as-cast end face; d) changes of sections minimum coverage to be 280 mm centred on the change of section. If the levels are not met, the customer shall be infor
48、med; the production shall be stopped and the process shall be reviewed. Failure to meet the above minimum radiographic acceptance levels will render the examined crossing scrap, unless a concession is granted by the customer for the affected crossing. 6.5 Foundry practice The use of chaplets is not
49、permitted unless agreed with the customer at the tender stage. BS EN 15689:2009EN 15689:2009 (E) 13 7 Acceptance tests 7.1 Chemical analysis The chemical composition according to 6.1 shall be checked from each cast or batch of liquid steel. 7.2 Impact bend The efficiency of the heat treatment shall be checked by an impact test. This test shall be done for each melt and
