SIST EN 14587-3:2012

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Železniške naprave - Zgornji ustroj - Elektro uporovno varjenje tirnic - 3. del: Varjenje pri izdelavi kretnicBahnanwendungen - Oberbau - Abbrennstumpfschweißen von Schienen - Teil 3: Schweißen im Zusammenhang mit WeichenkonstruktionenApplications ferroviaires - Voie - Soudage des rails par étincelage - Partie 3 : Soudure associée à la fabrication des appareils de voieRailway applications - Track - Flash butt welding of rails - Part 3: Welding in association with crossing construction93.100Gradnja železnicConstruction of railways25.160.10Varilni postopki in varjenjeWelding processesICS:Ta slovenski standard je istoveten z:EN 14587-3:2012SIST EN 14587-3:2012en,fr01-november-2012SIST EN 14587-3:2012SLOVENSKI
STANDARD
EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM
EN 14587-3
September 2012 ICS 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 étincelage - Partie 3: Soudure associée à la fabrication des coeurs de voie
Bahnanwendungen - Oberbau - Abbrennstumpfschweißen von Schienen - Teil 3: Schweißen im Zusammenhang mit Herzstückkonstruktionen 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 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-CENELEC 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 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, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and United Kingdom.
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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 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 analysis 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 testing non-austenitic materials . 40G.1 Reference line (DAC) generation – Reference block . 40G.2 Reference line (DAC) generation and acceptance criteria . 40Bibliography . 42 SIST EN 14587-3:2012

Key 1 elevation 2 plan Figure 1 — Tolerances for rail end squareness 6.3 Clamping force Workpieces shall be secured in the flash butt welding machine by clamps of such a surface shape or contour, that when a clamping force is exerted on the workpieces, it shall not damage the workpiece. The clamping force shall be sufficient such that slippage does not occur. 6.4 Initial burn-off The workpieces should undergo initial flashing to ensure full rail end contact during the subsequent preheating cycles. 6.5 Preheating The fronts of the heating area shall progress such that at completion of preheating an even heat band is present in both workpieces. On completion of welding there shall be no evidence of localised melting on the ends of the workpieces. 6.6 Final flashing Once initiated, final flashing shall be continuous. 6.7 Upsetting Upsetting shall immediately follow 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. The time between completion of upsetting and unclamping shall be sufficient to ensure required weld integrity. During this time, sufficient longitudinal force shall remain present to prevent damage to the weld. SIST EN 14587-3:2012

The post-weld heat treatment parameters shall be monitored, checked against approval limits and recorded. These records shall be referenced to the appropriate welds. 6.10 Removal of upset and correction of weld alignment The upset material shall be removed by the method carried out during the approval process and once agreed shall not be changed without prior purchaser approval. In exceptions where upset material cannot be removed, finish and dimensions shall be agreed between the purchaser and the manufacturer. Removal of the upset shall not cause any mechanical or thermal damage to the crossing or rail. Any surface where upset has been removed shall be free from visible cracking. The correction of the weld alignment shall be carried out by pressing. 7 Profile finishing of the weld The surface finishing shall be carried out in the longitudinal direction using machining/grinding. The roughness limit within the welded zone shall be: SIST EN 14587-3:2012

Class 1 Class 2 Class 3 Class 4 Maximum grinding length Horizontal 0/+0,3 0/+0,5 +/-0,4
900 mm Vertical 0/+0,3 -0,1/+0,2 -0,3/0 +0,1/+0,3 900 mm Flatness ≤ 0,1 ≤ 0,2
NOTE 1 For horizontal alignment, positive tolerances will widen gauge. NOTE 2 The purchaser may select different classes for vertical and horizontal alignment and flatness from the above. The vertical and horizontal alignment can be mixed between classes. Horizontal and vertical alignment should be checked by use of a 1 m straightedge. Flatness should be checked by use of a 1 m straightedge in the grinding zone to be in accordance with EN 14587-1 and EN 14587-2. NOTE 3 Horizontal tolerances do not apply to crossings with built-in curvatures or where the weld is within the throat flare area. Where crossings are manufactured with built-in curves, an agreement concerning the tolerances is necessary between the manufacturer and the purchaser. NOTE 4 Maximum grinding length is not necessarily symmetrical about the weld but no more than 450 m either side of the weld.
8.2 Alignment and flatness across the weld Alignment and flatness across the weld shall be measured as follows: a) The vertical alignment across the running surface shall be measured along the longitudinal centre line of the rail with the weld centrally between and referenced to datum points on the rail 500 mm either side of the weld. b) The horizontal alignment of the weld across the rail head shall be measured on the running edge at a point 14 mm below the running surface and referenced to datum points on the rail 500 mm either side of the weld. c) The running surface flatness at the level of the weld shall be measured by means of a 200 mm straightedge positioned on the ground area. The maximum gap between the straightedge and the profiled running table of the rail shall be in one of the classes in Table 1. SIST EN 14587-3:2012

b) At 14 mm from the foot tip, a tolerance of 15 % maximum thickness reduction from the minimum rail foot thickness may be permitted subject to agreement between the manufacture and the purchaser. 9 Weld identification Weld identification shall permit traceability to production records. 10 Procedure approval 10.1 General Flash butt welding machines used in this work shall be individually approved by the RA; type approval is not permitted. Approval is granted for welding procedures specified to selected materials. Approval for rail profiles within the same grade can be considered in groups (see Table 2). At least one profile in a group shall undergo testing in accordance with 10.4; the remaining rail profiles within that group shall undergo a minimum of five bend tests in accordance with 10.4.7. Table 2 — Rail groups Cross sectional area (cm²) Examples 40 < 46 33E1(42,6) 46 < 52 39E1(50,6) 52 < 58 43E1 (55,8) 58 < 64 49E1(62,9) 64 < 71 52E1 (66,4) 71 < 78 60E2 (76,5) 78 < 85 49E1 A3 (80,5) 85 < 92 60E1 A4 (88,9) 92 ≤ 99 60E1 T2 (94,6) 60E1 and 60E2 may be considered as the same profile. The approval tests for rail grade/material combinations and extensions of these approvals are given in 10.4 and Clause 11. The grades and materials shall be specified using the respective European Standard or by their mechanical and chemical characteristics in the absence of a European Standard. Procedure approval shall be carried out by testing weld samples produced in accordance with this standard; the samples shall be representative of those carried out in production. Procedure approval testing shall be carried out on the rail/crossing profile and material grade specified by the purchaser. The intermediate buffer material used for the approval tests shall be the same as that used in production. All test results and weld fracture faces shall be made available for inspection. SIST EN 14587-3:2012

On completion of visual inspection, the welded zone to be tested by non-destructive testing is limited to 20 mm either side of the weld(s) including the whole of the insert. The following tests are required on welds in the finished condition:  welds with austenitic component(s): liquid penetrant testing shall be carried out in accordance with EN 571-1, acceptance shall be in accordance with EN 1371-1: severity level SP1. No linear indications shall be permitted.  welds without austenitic component(s): magnetic particle testing shall be carried out in accordance with EN ISO 17638. No cracks or lack of bond shall be permitted. Liquid penetrant testing may be carried out on welds without austenitic component(s) in place of magnetic particle testing. In these cases, the acceptance level shall be agreed upon with the purchaser. SIST EN 14587-3:2012

The methods and acceptance criteria are described in Annex G. 10.4.7 Bend testing 10.4.7.1 General The five specimens having met the requirements of 10.4.2 to 10.4.6 shall be subject to bend testing in accordance with Annex B. Each bend test shall be continued until the specimen reaches fracture or the maximum deflection capability of the machine is achieved. Photographs shall be taken of the fracture faces (one per sample) of all broken test welds. 10.4.7.2 Acceptance criteria for bend tests a) For welds with austenitic component(s): 1) Bend test requirements are specified in Table B.1. 2) Deflection values shall be recorded during the approval bend tests. 3) The deflection requirements of the approval bend test shall be agreed between the purchaser and the supplier. These requirements shall recognise the material composition and the insert thickness. b) For welds with non austenitic component(s): 1) Bend test requirements and deflection values are specified in Table B.2 and actual values shall be recorded. 2) The specimens shall be in the as-welded and wire-brushed condition, they shall meet the requirements 10.4.3, 10.4.5 and 10.4.6 and shall be subject to bend testing in accordance with Annex B. If full section fracture occurs about the weld line, the fracture surfaces shall be inspected. The details of any weld imperfection shall be recorded in accordance with Annex C. Lack of bond shall not be permitted. If fracture occurs remote from the weld, the fracture surfaces shall be checked for the presence of die burn, which if detected shall cause the process to fail approval. If fracture occurs within the non-austenitic rail for reasons other than die burn then another test weld specimen shall be substituted for testing.
10.4.8 Fatigue testing If fatigue testing is required by the approving RA, it shall be carried out in accordance with 4.1 e) and Annex D of this European Standard. Depending on the type of fatigue test specified by the RA, ten welds in the finished condition (see 3.9) shall be taken for the staircase test method, or three welds in the finished condition (see 3.9) shall be taken for the past-the-post test method. 10.4.9 Macro-examination Four welds in the finished condition shall be sectioned for macro-examination in accordance with Annex E, E.1 when welding austenitic component(s) and shall conform to the following requirements: SIST EN 14587-3:2012

10.4.10.2 Welds without austenitic component(s) For welds without austenitic component(s), the requirements of Annex D of EN 14587-1:2007 shall apply. In addition, for quenched and tempered steels and bainitic steels, no martensite shall be present with hardness greater than 500 HV. 10.4.11 Hardness testing 10.4.11.1 General The remaining two of the four full rail depth longitudinal vertical sections taken for macro- and micro-examination shall be subjected to hardness testing which shall be carried out in accordance with Annex F. 10.4.11.2 Grades R220, R260 and R260Mn
For the grades R220, R260 and R260Mn, the minimum and maximum hardness values obtained in the rail steel shall conform to the following requirements: a) minimum hardness in the rail steel shall not be less than P - 30 HV30
b) maximum hardness in the rail steel shall not exceed P + 60 HV30 where P is the average hardness in the rail steel of the parent rail as specified in EN 13674-1. An isolated hardness value falling outside of the stated minimum and maximum values above shall be permitted when such a hardness value falls between the two adjacent values that conform to the requirements. 10.4.11.3 Grades with hardness values higher than R260Mn Each hardness > P + 60 HV30 in the rail steel shall be investigated to determine the reason for this hardness level. In the case of martensite being present, further investigation shall be undertaken with the agreement of the RA. An isolated hardness value falling outside of the stated minimum and maximum values above shall be permitted when such a hardness value falls between the two adjacent values that conform to the requirements. SIST EN 14587-3:
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