Standard
UPDATE AVAILABLE

AS 1085.20-2012

[Superseded]

Railway track material, Part 20: Welding of steel rail

Sets out performance requirements and tests for welding of steel rail. Gives detailed requirements for flash butt welding, aluminothermic welding and metal arc welding (for repairs). Qualification of the welding procedure is covered, including criteria for requalification when parameters are changed. Test methods are given in appendices.
Published: 29/11/2012
Pages: 85
Table of contents
Cited references
Content history
Table of contents
Header
About this publication
Preface
1 Scope and general
1.1 Scope
1.2 Purpose and context of use
1.2.1 Function
1.2.2 Action
1.3 Referenced documents
1.4 Definitions
1.5 Notation
1.6 Basic requirements
1.7 Qualification of the welding procedure
1.7.1 Qualification
1.7.2 Requalification
1.8 Qualification of welding personnel
1.9 Documentation
1.9.1 Job document
1.9.2 Welding procedure
1.10 Testing
2 Flash butt welding
2.1 General
2.2 Description of the process
2.3 Qualifying the welding procedure
2.4 Job document
2.5 Welding procedure
2.6 Maintenance of equipment
2.7 Inspection and testing of finished welds
2.8 Marking and records
2.8.1 Marking
2.8.2 Records
3 Aluminothermic welding
3.1 General
3.2 Description of the process
3.3 Qualifying the welding procedure
3.4 Job document
3.5 Welding procedure
3.6 Maintenance of equipment
3.7 Inspection and testing of finished welds
3.8 Marking and records
3.8.1 Marking
3.8.2 Records
4 Aluminothermic rail head repair welding
4.1 General
4.2 Description of the process
4.3 Qualifying the welding procedure
4.4 Job document
4.5 Welding procedure
4.6 Maintenance of equipment
4.7 Inspection and testing of finished welds
4.8 Marking and records
4.8.1 Marking
4.8.2 Records
5 Arc rail head repair welding
5.1 General
5.2 Descriptions of welding methods
5.2.1 Manual metal arc welding (MMAW)
5.2.2 Flux-cored arc welding (FCAW)
5.3 Qualifying the welding procedure
5.4 Job document
5.5 Welding procedure
5.6 Maintenance of equipment
5.7 Inspection and testing of finished weld
5.8 Marking and records
5.8.1 Marking
5.8.2 Records
Appendix A
A1 General
A2 Information on methods not covered by this Standard
A3 Aluminothermic welding—Designation of weld types
A4 Aluminothermic welding—Quality control of production of consumables
Appendix B
B1 Flash butt welding
B2 Aluminothermic welding
B3 Electric arc welding
Appendix C
C1 Scope
C2 Statistical sampling
C3 Product certification
C4 Supplier’s quality management system
Appendix D
D1 General
D2 Welders
D3 Qualification testing of welders
Appendix E
E1 Visual inspection
E2 Joint geometry test
E2.1 Surface alignment
E2.2 Surface slope
E2.3 Manufacture of straightedges
E2.4 Calibration of straightedges
E3 Weld collar test
E4 Size of imperfections
Appendix F
F1 Scope
F2 Testing of weld procedure qualifications and finished welds for in service application
F3 Methods of test
F4 Procedure for ultrasonic testing of rail welds
F4.1 Scope
F4.2 Equipment and calibration
F4.3 Qualification of personnel
F4.4 Surface preparation
F4.5 Couplant
F4.6 Sensitivity
F4.6.1 Parent metal
F4.6.2 Weld metal and HAZ
F4.6.3 Reference block
F4.7 Probe selection and methods of scanning
F4.7.1 General
F4.7.2 Parent metal
F4.7.3 Weld metal and HAZ—Head
F4.7.4 Weld metal and HAZ—Head, web and foot below web
F4.7.5 Weld metal and HAZ—Web and foot below web
F4.7.6 Weld metal and HAZ—Foot flange regions
F4.7.7 Discontinuity sizing and evaluation
F5 Record of test and reporting
F6 Product standard
Appendix G
G1 Scope
G2 Weld metal hardness for aluminothermic welding
G2.1 General
G2.2 Report
G3 Hardness traverse for flash butt and aluminothermic welds
G3.1 Principle
G3.2 Procedure
G3.3 Parent rail hardness variation
G3.4 Report
G4 Hardness traverse for arc welds
G4.1 Principle
G4.2 Procedure
G4.3 Report
Appendix H
H1 Scope
H2 Fusion zone—Shape and dimension
H2.1 Procedure
H2.2 Records
H2.3 Report
H3 Visible heat-affected zone—Running surface
H3.1 Procedure
H3.2 Report
Appendix I
I1 Scope
I2 Procedure
I3 Report
Appendix J
J1 Scope
J2 Procedure
J3 Report
Appendix K
K1 Scope
K2 Principle
K3 Apparatus
K4 Procedure
K5 Assessment of fracture faces
K6 Report
Appendix L
L1 Scope
L2 Fatigue test for foot of welded rail section
L2.1 General
L2.2 Principle
L2.3 Apparatus
L2.4 Determination of stress to load relationship
L2.4.1 Test pieces
L2.4.2 Procedure
L2.5 Test pieces for foot fatigue testing
L2.6 Fatigue test procedure
L2.7 Past-the-post test
L2.7.1 Principle
L2.7.2 Fatigue test procedure
L2.8 Staircase fatigue test (Optional, see Paragraph L2.1)
L2.8.1 Principle
L2.8.2 Fatigue strength procedure
L2.8.3 Data analysis
L2.9 Assessment of fracture faces
L2.10 Report
L3 Fatigue test for web of welded section (optional)
L3.1 Principle
L3.2 Testing conditions
L3.3 Apparatus
L3.4 Procedure
L3.5 Report
Appendix M
M1 Scope
M2 General requirement
M3 Testing for qualification and requalification
M3.1 General
M3.2 Qualification for junction and step welds
M3.3 Preparation and allocation of test welds
M3.4 Qualification of flash butt welding procedure
Appendix N
N1 Scope
N2 General requirements
N3 Testing for qualification
N3.1 General
N3.1.1 Joining of rails
N3.1.2 Head repair welds
N3.2 Qualification for group 1 rails (60 kg)
N3.3 Qualification for rails in other groups
N3.4 Qualification for other types of rail
N3.5 Qualification for junction welds
N3.6 Preparation and allocation of test welds
N3.7 Qualification of aluminothermic welding process
N3.7.1 General
N3.7.2 As-cast weld surface
N3.7.3 Ground weld surface
N3.7.4 Chemical analysis of weld metal
N4 Testing for requalification
N4.1 General
N4.2 Parameters
N5 Retest allowance
Appendix O
O1 Scope
O2 General requirements
O3 Qualification of welding process
O3.1 Consumables
O3.2 Qualification tests
O3.3 Qualification of an arc welding procedure
O4 Requalification
Cited references in this standard
Content history
[Superseded]
DR AS 1085.20