1、BS EN 16771:2016Railway applications Infrastructure Aluminothermic welding ofgrooved railsBSI Standards PublicationWB11885_BSI_StandardCovs_2013_AW.indd 1 15/05/2013 15:06BS EN 16771:2016 BRITISH STANDARDNational forewordThis British Standard is the UK implementation of EN 16771:2016. The UK partici
2、pation in its preparation was entrusted to TechnicalCommittee RAE/2, Railway Applications - Track.A list 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 respo
3、nsible for its correct application. The British Standards Institution 2016.Published by BSI Standards Limited 2016ISBN 978 0 580 83485 1 ICS 25.160.10; 93.100 Compliance with a British Standard cannot confer immunity from legal obligations.This British Standard was published under the authority of t
4、he Standards Policy and Strategy Committee on 30 November 2016.Amendments/corrigenda issued since publicationDate T e x t a f f e c t e dBS EN 16771:2016EUROPEAN STANDARD NORME EUROPENNE EUROPISCHE NORM EN 16771 November 2016 ICS 25.160.10; 93.100 English Version Railway applications - Infrastructur
5、e - Aluminothermic welding of grooved rails Applications ferroviaires - Infrastructures - Soudage par aluminothermie des rails gorge Bahnanwendungen - Infrastruktur - Aluminothermisches Schweien von Rillenschienen This European Standard was approved by CEN on 15 July 2016. CEN members are bound to c
6、omply 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 standards may be obtained on application to the CEN-CENE
7、LEC 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 and notified to the CEN-CENELEC Management Centre has the
8、 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, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembo
9、urg, 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-CENELEC Management Centre: Avenue Marnix 17, B-1000 Brussels
10、 2016 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members. Ref. No. EN 16771:2016 EBS EN 16771:2016EN 16771:2016 (E) 2 Contents Page European foreword. 4 Introduction 5 1 Scope 6 2 Normative references 6 3 Terms and definitions . 6 4 Information to
11、 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 compliance testing 11 5.7 Preparation a
12、nd 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 Internal examination 17 7.4.1 Weld soundn
13、ess 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 (informative) Procedure for FRY etching 2
14、5 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 aluminothermic welds to be sectioned . 30
15、 G.1 Principle 30 G.2 Apparatus 30 G.3 Preparation of samples 30 G.4 Calibration 30 BS EN 16771:2016EN 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 zone of welds . 32 Annex I (normative) Proc
16、edure for measurement of the heat softened zone width 33 I.1 Measurement of hardness . 33 I.2 Evaluation of hardness data . 34 Bibliography . 36 BS EN 16771:2016EN 16771:2016 (E) 4 European foreword This document (EN 16771:2016) has been prepared by Technical Committee CEN/TC 256 “Railway applicatio
17、ns”, 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 withdrawn at the latest by May 2017. Attention i
18、s 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 standards organisations of the following countri
19、es 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, Lithuania, Luxembourg, Malta, Netherlands, Norway, Polan
20、d, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom. BS EN 16771:2016EN 16771:2016 (E) 5 Introduction This standard defines the approval procedure for aluminothermic welding processes for grooved rail welding through laboratory tests of welds produced
21、in a workshop. This laboratory approval will provide the railway authority with sufficient information for tests in the track if required. BS EN 16771:2016EN 16771:2016 (E) 6 1 Scope This standard defines the laboratory tests and requirements for approval of an aluminothermic welding process using w
22、elds 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. Compliance with the requirements of this standard does not in i
23、tself 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 requirements, this standard also requires the items detailed in C
24、lause 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 referenced in this document and are indispensable for its app
25、lication. 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 associated construction EN ISO 6506-1, Metallic materials -
26、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 9712) 3 Terms and definitions For the purposes of this do
27、cument, 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 fusion zone within the rail steel microstructure has been
28、 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 adjacent to the weld collar caused by gaps between the m
29、ould and the rail BS EN 16771:2016EN 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 following bend testing that has not already been identified as a surfa
30、ce 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 welding process in accordance with this standard 4 Information to
31、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 documented items shall be satisfied: a) which of the width levels o
32、f 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 informative Annex A. 5.2 Process identification The approval shall
33、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 process manual in accordance with 5.4.1. 5.3 General requirements T
34、he 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; BS EN 16771:2016EN 16771:2016 (E) 8 b) the aluminothermic welding portion shall be packed to avoid the risk of moisture contamination in prescribed storage
35、 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 automatically (automatic tapping) and shall have a device to limit spattering
36、; 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 submitted: 5.4.1 The process manual. The supplier shall produce a manual
37、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 operations. The manual shall specify the critical parameters of the weldi
38、ng 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) nominal gap shall have a tolerance of 2 mm for a 30 mm gap and 3
39、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 Drawing with the required measurements. A drawing, as illustrated
40、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 depth of collar at section B-B (d1 and d2); d) riser cross section at
41、 foot; BS EN 16771:2016EN 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 taken from the drawing of the pattern used to produce the moulds. Key 1 fig
42、ure 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 taken from mould pattern 5.4.3 Chemical analysis ranges and tolerances. The
43、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. BS EN 16771:2016EN 16771:2016 (E) 10 Table 1 Rail profile groups 1 New names Former names
44、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 Former names 46G1 60 G 51R1 Ri 52-R13, Ri 52 52R1 Ri Ir 53R1 Ri 53-R13, Ri 53
45、 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 R260 grade. Results are valid for the three grades of all rail profiles in ei
46、ther 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 test specimen can be used for several different tests. BS EN 16771:2016EN 167
47、71:2016 (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 Annex G 7.4.1.1 2 Nil E Weld soundness 7.4.1 7.3 2 (2) Nil F Fusion Zone Shape and
48、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
49、 conducted using not heat treated grade on one rail profile from group 1 or 2 (Table 1 or 2). bCategory 2 Tests required extending approval for heat treated grades. Tests on one rail profile cover all profile groups approved in categories 1 and 2. 5.6 Extension of initial compliance testing Initial compliance can be extended as follows: The relevant railway authority requirements defined in Clause 4 shall be met for each of the items below: a) to other group of rail profiles listed in Table 1 or 2 5.5, a), by doing the tests given in Table
