oSIST prEN 14587-2:2021
(Main)Railway applications - Infrastructure - Flash butt welding of rails - Part 2: New R200, R220, R260, R260Mn, R320Cr, R350HT, R350LHT, R370CrHT and R400HT grade rails by mobile welding machines at sites other than a fixed plant
Railway applications - Infrastructure - Flash butt welding of rails - Part 2: New R200, R220, R260, R260Mn, R320Cr, R350HT, R350LHT, R370CrHT and R400HT grade rails by mobile welding machines at sites other than a fixed plant
This European Standard specifies requirements for the approval of a welding process by a MFBW machine at sites other than fixed plant, as well as the welding contractor together with the requirements for subsequent welding production. Where a MFBW machine is to be used in a static but temporary situation, the requirements of this part of the standard shall apply.
It applies to new Vignole R200, R220, R260, R260Mn, R320Cr, R350HT, R350LHT, R370CrHT and R400HT grade rails of 46 kg/m and above, as contained in EN 13674-1, welded by a MFBW machine at sites other than a fixed plant and intended for use on railway infrastructures.
This European Standard applies to the welding of rails into welded strings.
Bahnanwendungen - Infrastruktur - Abbrennstumpfschweißen von Schienen - Teil 2: Abbrennstumpfschweißen neuer Schienen der Stahlsorten R200, R220, R260, R260Mn, R320Cr, R350HT, R350LHT, R370CrHT und R400HT durch mobile Schweißmaschinen an Orten außerhalb eines Schweißwerkes
Applications ferroviaires - Infrastructure - Soudage des rails neufs par étincelage - Partie 2 : Rails de nuances R200, R220, R260, R260Mn, R320Cr, R350HT, R350 LHT, R370CrHT et R400HT par des machines à souder mobiles dans des sites autres qu'une installation fixe
Le présent document spécifie des exigences de validation d'un procédé de soudage par une machine à souder mobile, ainsi que les exigences relatives à la production ultérieure des soudures.
Il s'applique aux nouveaux rails Vignole de nuances R200, R220, R260, R260Mn, R320Cr, R350HT, R350LHT, R370CrHT et R400HT de masse supérieure ou égale à 46 kg/m, spécifiés dans l'EN 13674 1, soudés par étincelage au moyen d'une machine à souder mobile et destinés à être utilisés sur des infrastructures ferroviaires.
Le présent document s'applique au soudage des rails en voie.
Železniške naprave - Infrastruktura - Uporovno varjenje tirnic - 2. del: Varjenje novih tirnic kakovosti R200, R220, R260, R260Mn, R320Cr, R350HT, R350LHT, R370CrHT in R400HT s prevoznimi varilnimi stroji zunaj proizvodnega postroja
General Information
Relations
Standards Content (Sample)
SLOVENSKI STANDARD
oSIST prEN 14587-2:2021
01-september-2021
Železniške naprave - Infrastruktura - Uporovno varjenje tirnic - 2. del: Varjenje
novih tirnic kakovosti R200, R220, R260, R260Mn, R320Cr, R350HT, R350LHT,
R370CrHT in R400HT s prevoznimi varilnimi stroji zunaj proizvodnega postroja
Railway applications - Infrastructure - Flash butt welding of rails - Part 2: New R200,
R220, R260, R260Mn, R320Cr, R350HT, R350LHT, R370CrHT and R400HT grade rails
by mobile welding machines at sites other than a fixed plant
Bahnanwendungen - Infrastruktur - Abbrennstumpfschweißen von Schienen - Teil 2:
Abbrennstumpfschweißen neuer Schienen der Stahlsorten R200, R220, R260, R260Mn,
R320Cr, R350HT, R350LHT, R370CrHT und R400HT durch mobile Schweißmaschinen
an Orten außerhalb eines Schweißwerkes
Applications ferroviaires - Infrastructure - Soudage des rails neufs par étincelage - Partie
2 : Rails de nuances R200, R220, R260, R260Mn, R320Cr, R350HT, R350 LHT,
R370CrHT et R400HT par des machines à souder mobiles dans des sites autres qu'une
installation fixe
Ta slovenski standard je istoveten z: prEN 14587-2
ICS:
25.160.10 Varilni postopki in varjenje Welding processes
93.100 Gradnja železnic Construction of railways
oSIST prEN 14587-2:2021 en,fr,de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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oSIST prEN 14587-2:2021
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oSIST prEN 14587-2:2021
DRAFT
EUROPEAN STANDARD
prEN 14587-2
NORME EUROPÉENNE
EUROPÄISCHE NORM
June 2021
ICS 25.160.10; 93.100 Will supersede EN 14587-2:2009
English Version
Railway applications - Infrastructure - Flash butt welding
of rails - Part 2: New R200, R220, R260, R260Mn, R320Cr,
R350HT, R350LHT, R370CrHT and R400HT grade rails by
mobile welding machines at sites other than a fixed plant
Bahnanwendungen - Infrastruktur -
Abbrennstumpfschweißen von Schienen - Teil 2:
Abbrennstumpfschweißen neuer Schienen der
Stahlsorten R200, R220, R260, R260Mn, R320Cr,
R350HT, R350LHT, R370CrHT und R400HT durch
mobile Schweißmaschinen an Orten außerhalb eines
Schweißwerkes
This draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee
CEN/TC 256.
If this draft becomes a European Standard, CEN members are bound to comply with the CEN/CENELEC Internal Regulations
which stipulate the conditions for giving this European Standard the status of a national standard without any alteration.
This draft European Standard was established by CEN 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 same status as the official versions.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway,
Poland, Portugal, Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and
United Kingdom.
Recipients of this draft are invited to submit, with their comments, notification of any relevant patent rights of which they are
aware and to provide supporting documentation.
Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without
notice and shall not be referred to as a European Standard.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels
© 2021 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN 14587-2:2021 E
worldwide for CEN national Members.
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oSIST prEN 14587-2:2021
prEN 14587-2:2021 (E)
Contents
European foreword . 4
Introduction . 5
1 Scope . 6
2 Normative references . 6
3 Terms and definitions . 6
4 Requirements for the welding process . 8
4.1 General . 8
4.2 Rail end preparation and horizontal alignment requirements . 8
4.3 Clamping force . 8
4.4 Pre-heating . 8
4.5 Final flashing . 8
4.6 Upsetting . 8
4.7 Unclamping. 8
4.8 Slippage. 8
4.9 Welding parameters . 9
4.10 Steps across the weld . 9
4.11 Removal of excess upset . 11
4.12 Post-weld thermal treatment . 13
5 Procedure approval. 13
5.1 General . 13
5.2 Information to be supplied by the purchaser . 13
5.3 Sample preparation . 14
5.4 Approval tests . 14
5.4.1 Visual examination . 14
5.4.2 Weld trimming . 14
5.4.3 Weld straightness and flatness . 14
5.4.4 Magnetic particle or dye penetrant testing . 14
5.4.5 Bend test . 14
5.4.6 Macro examination . 15
5.4.7 Micro examination . 16
5.4.8 Hardness test . 16
5.4.9 Fatigue test . 17
5.5 Test report . 17
6 Approval of other rail profiles and grades . 17
6.1 General . 17
6.2 Sample preparation . 17
6.3 Approval tests . 18
6.4 Test report . 18
7 Approval of the contractor. 18
7.1 General . 18
7.2 Welding procedure . 18
7.3 Operators . 18
7.4 Supervision . 18
7.5 Weld testing . 18
7.6 Equipment . 18
7.7 Field approval of the contractor . 18
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8 Weld production following procedure approval . 19
8.1 Weld production . 19
8.2 Information supplied by the purchaser . 19
8.3 Rail end preparation and horizontal rail alignment requirements . 19
8.4 Weld parameter monitoring . 19
8.5 Weld identification . 19
8.6 Visual examination . 20
8.7 Steps across the weld . 20
8.8 Finishing . 20
8.8.1 Correction of vertical and horizontal weld alignment . 20
8.8.2 Profile finishing of the rail head . 20
8.9 Weld straightness and flatness . 20
8.9.1 Alignment requirements . 20
8.9.2 Straightness and flatness measurement . 21
8.10 Bend test . 21
8.10.1 General . 21
8.10.2 Bend test procedure . 22
8.10.3 Interpretation of results . 22
8.10.4 Retesting . 23
8.11 Documentation . 23
Annex A (normative) Bend test requirements . 24
Annex B (normative) Test weld fracture faces – Recording of defects . 26
Annex C (normative) Fatigue test method for flash butt welds . 28
C.1 General . 28
C.2 Test equipment . 28
C.3 Calibration . 30
C.3.1 General . 30
C.3.2 Test piece . 30
C.4 Fatigue test method . 30
C.4.1 General . 30
C.4.2 Staircase test method . 30
C.4.3 Example of the data analysis of a fatigue strength determination by the staircase
method . 33
C.4.4 Past-the-post test method . 33
Annex D (normative) Macro examination and micro examination . 35
D.1 Macro examination . 35
D.2 Micro examination . 35
Annex E (normative) Hardness testing . 37
Annex ZA (informative) Relationship between this European Standard and the Essential
Requirements of EU Directive (EU) 2016/797 aimed to be covered . 39
Bibliography . 41
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prEN 14587-2:2021 (E)
European foreword
This document (prEN 14587-2:2021) has been prepared by Technical Committee CEN/TC 256 “Railway
applications”, the secretariat of which is held by DIN.
This document is currently submitted to the CEN Enquiry.
This document will supersede EN 14587-2:2009.
This document is one of a series of three parts of the EN 14587, Railway applications – Infrastructure –
Flash butt welding of new rails. The list of parts is as follows:
— Part 1: R220, R260, R260Mn, R320Cr, R350HT, R350LHT, R370CrHT and R400HT grade rails in a fixed
plant
— Part 2: R200, R220, R260, R260Mn, R320Cr, R350HT, R350LHT, R370CrHT and R400HT grade rails by
mobile welding machines at sites other than a fixed plant
— Part 3: Welding in association with crossing construction
This document has been prepared under a standardization request addressed to CEN by the European
Commission, and it aims to support essential or other requirements of EU Directive(s) or Regulation(s).
For relationship with EU Directive(s) or Regulation(s), see informative Annex ZA, which is an integral
part of this document.
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prEN 14587-2:2021 (E)
Introduction
This part of EN 14587 has five main topics:
a) requirements of a welding process;
b) procedure approval for a mobile plant;
c) approval of other rail profiles or grades;
d) approval of welding contractor;
e) weld production following approval.
This part of EN 14587 supports a European Directive that will permit the freedom of an open European
market. To enable this, it is essential that 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.
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1 Scope
This document specifies requirements for the approval of a welding process by mobile plant, together
with the requirements for subsequent welding production.
It applies to new Vignole railway rails R200, R220, R260, R260Mn, R320Cr, R350HT, R350LHT,
R370CrHT and R400HT grade rails of 46 kg/m and above, as contained in EN 13674-1, welded by a flash
butt welding process by mobile plant and intended for use on railway infrastructure.
This document applies to the welding of rails into welded strings.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements of this document. For dated references, only the edition cited applies. For
undated references, the latest edition of the referenced document (including any amendments) applies.
EN 13674-1, Railway applications - Track - Rail - Part 1: Vignole railway rails 46 kg/m and above
EN ISO 3452-1, Non-destructive testing - Penetrant testing - Part 1: General principles (ISO 3452-1)
EN ISO 6507-1, Metallic materials - Vickers hardness test - Part 1: Test method (ISO 6507-1)
EN ISO 7500-1:2018, Metallic materials - Calibration and verification of static uniaxial testing machines -
Part 1: Tension/compression testing machines - Calibration and verification of the force-measuring system
(ISO 7500-1:2018)
EN ISO 17638, Non-destructive testing of welds - Magnetic particle testing (ISO 17638)
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
— ISO Online browsing platform: available at https://www.iso.org/obp
— IEC Electropedia: available at http://www.electropedia.org/
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 machinery to execute the production of
flash butt welds by mobile plant. This may include staff and machinery from within the railway authority
3.3
die burn
damage caused by localised overheating (arcing) on the surface of the rail due to poor contact between
the rail and electrode during welding
3.4
dressing
removing trimmed upset by grinding or other similar process
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3.5
finished condition
welded, trimmed and rail head profile finished
3.6
flat spot
process driven discontinuity shown after the slow bend test on the weld fracture face, which has a small
lens like shape. In a vertical longitudinal section (macro) it appears elliptical in shape
3.7
lack of bond
area of incomplete fusion between the rails at the fusion line. This may appear crack like or as a line
discontinuity at the interface either on the surface after removal of the upset or in a weld macro section
3.8
profile finishing
operation by which the rail head or relevant part of the rail head at the weld is restored to rail profile.
The operation can be by grinding, milling, planing or any other suitable means
3.9
purchaser
purchaser of the welds
3.10
railway authority
either the railway regulator or the owner of the railway infrastructure or the custodian with a delegated
responsibility for a railway infrastructure
3.11
trimmed upset
metal remaining around the rail profile following the shearing process
3.12
trimming
removal of upset
3.13
upset
metal extruded around the rail profile as a result of forging
3.14
welded string
long rail comprising of a number of shorter rails welded together
3.15
welding process
part of the sequence from the selection of the rail prior to welding through to the finishing of the welded
string
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4 Requirements for the welding process
4.1 General
All welding shall be carried out on a flash butt mobile welding machine using an automatic, programmed
welding sequence.
4.2 Rail end preparation and horizontal alignment requirements
The rail ends shall always be sawn or disc cut to the tolerances specified by the purchaser. Areas of
electrical contact on the rails and the machine shall be cleaned to bright metal to give a consistent and
good electrical contact at the interface.
The rail shall not be damaged by the cleaning operation or through poor electrical contact.
Rails of the same profile shall be positioned in the welding machine such that the welding interface is
central to the contact electrodes as assessed by visual or mechanical means.
Before welding, rails shall be aligned laterally to the required rail face or edge, i.e. left, or right, or to the
rail centreline.
For reasons of asymmetry rails should be welded with the brand marks on the same side throughout the
welded string.
4.3 Clamping force
Rails shall be secured in the flash butt welding machine by a clamping arrangement. The clamping force
that is exerted on the rails shall not damage in such a way that subsequent cracking in the rail is
generated, see 5.4.1.
4.4 Pre-heating
For the pre-heating, the rail ends shall progress uniformly in a reversible or a continuous process, and
perpendicular to the running surface during the whole welding cycle.
4.5 Final flashing
Once initiated the final flashing shall be continuous.
4.6 Upsetting
Upsetting shall immediately follow final flashing. Sufficient forging pressure shall be applied to ensure
that voids are closed and oxides are expelled such that they are kept to a minimum at the weld interface.
The weld interface shall extend into the upset.
4.7 Unclamping
In order to maintain the alignment, the time between completion of forging and unclamping shall be a
minimum of 4 s.
4.8 Slippage
Clamping force shall be maintained to avoid any movement between the contact dies and rails.
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4.9 Welding parameters
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 pressure;
d) displacement;
e) welding time;
f) limits/range of the main welding parameters;
g) weld identification number.
2) The welding parameters shall be determined during procedural trials and, once approval has been
granted, shall not be changed, with the exception of changes concerning the environments in 4.9 4).
3) The welding parameters shall be monitored and recorded. These records shall be referenced to the
appropriate welds.
4) Due to extreme variations in seasonal temperatures, the contractor may request from the railway
authority the use of an alternative welding program. A bending test according to 5.4.5 shall be carried
out in this case.
5) The weld identification number shall be created and recorded by the machine in a chronological order
for all welds produced during approval and production processes.
4.10 Steps across the weld
— Any step between the rails across the weld in the trimmed but not dressed condition shall not exceed
those dimensions shown in Table 1.
— 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 Figure 1. An alternative step measurement gauge
may be used as shown in Figure 2.
Table 1 — Maximum permitted steps
Maximum
permitted
Position of step on the rail
step (in
mm)
Vertically on the longitudinal centreline of the running
0,5
surface
Horizontally on the aligned face or edge 14 ± 1 mm
0,5
below the running surface
Horizontally on the edge of the rail foot 2,0
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Where the step arises from the rail dimensions the rail foot tips may be dressed locally to achieve this
requirement.
Dimensions in millimetres
Key
A running surface
B nibbed straight edge
C weld upset centreline
Z detail view of the step
NOTE Step = [x-y] mm
Figure 1 — Measurement of the step with nibbed straight edge
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prEN 14587-2:2021 (E)
Dimensions in millimetres
Figure 2 — Gauge for measuring the step
4.11 Removal of excess upset
a) Excess upset should be automatically trimmed. If not possible, the upset shall be removed by
grinding.
b) Removal of the excess upset shall not cause any mechanical or thermal damage to the rails.
c) The surface of the trimmed area shall be free from visible transverse cracking.
d) Removal of the excess upset shall be completed in such a manner to keep the joint in compression.
e) Any dressing of the weld following the removal of upset shall not cause damage to the rail or weld
nor reduce either to a dimension below the original rail profile.
f) The maximum thickness of the trimmed upset shall be as set out in Table 2 below and shown in
Figure 3. A suggested measurement gauge is shown in Figure 4.
Table 2 — Maximum permitted trimmed upset
Maximum
Zone Position of trimmed upset about the weld permitted upset
(in mm)
Full head profile from the lower corner on the gauge face to
A 2,5
the lower corner on the opposite face
B The fishing surface on the underside of the head 3,0
The web, including the top fillet radius and extending down
C 2,5
to the start of the bottom fillet radius
The foot, including the start of the bottom fillet radii in the
D web and extending to the foot tips and completely across the 2,0
underside of the rail foot
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Where there is a differ
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