iv welding technical konferenz railtech welding &...
TRANSCRIPT
Warsaw, May,11-13 2016
IV WELDING TECHNICAL KONFERENZ
RAILTECH WELDING & EQUIPMENT
Audrey DURAND
AREA SALES MANAGER
1902: Clarence Léon Delachaux started an industrial company dedicated to the cable
car, the revolutionary mode of transportation of that time.
1917: built its first industrial operation in its historical site of Gennevilliers (Paris-
France).
1920’s: Clarence Leon Delachaux took part in the electrification of the Shanghai Metro project.wit
international vision of its growth
By 1954 …h an
After 110 years of continuous growth, these values and principles drive daily our multi-cultural teams.
The world leader in rail fastening systems and ballast-less
tracks. • World leader in rail fastening systems and ballast-less
tracks
• Electrification Systems – rigid catenary, 3rd rail, trolley bus
• Rosenqvist : handling and clipping
R A I L T E C H INTERNATIONAL
24 SUBSIDIARIES around the world
RAILTECH ALGERIE
100%
RAILTECH BOUTET
RAILTECH ALU SINGEN 51%
65%
RAILTECH ZHUQIAO
RAILTECH PLÖTZ
FLORIANER BAHN
RAILTECH PLÖTZ POLSKA
RAILTECH PLÖTZ HUNGARY
100%
100%
100%
100%
24 SUBSIDIARIES AROUND THE WORLD
• Expertise, technical solutions and R&D, quality, services provided to customers
• Two Brands : RAILTECH and RAILTECH-DEUTSCHLAND.
• Track Equipment : a complete range of thermal, electric and hydraulic machines and tools.
• Our R&D have filed several patents such as:
o the One-Shot Crucible (CJ),
o Sand moulds with Felt Joints (JS),
o Hybrid moulds for worn rails (HYB),
o the high-secured Ignition System (STARTWEL),
• RAILTECH SYSTEMS & SERVICES (RSS): fixed or itinerant workshops for Flash-Butt rail-welding
• ISSTAF, welding school:
o In track-Weld or out-track Training/Execution/Supervision,
o Non-Destructive Inspections,
o ultrasonic inspections etc.
ACTIVITIES OF RAILTECH
WELDING KIT COMPOSITION PLA (France)
1 mould – gap 25 – 68mm
1 base plate
1 plug
1 aluminothermic portion
One-shot crucible
with filter or not
Luting mould Self sealing mould Hybrid mould
MOULD TYPES - PLA
For worn rails, between 0 to 6 mm wear New rails, between 0 to 3 mm wear Moulds for worn rails
WELDING KITS LP – RAILTECH-DEUTSCHLAND
• One-shot crucible available in version cardboard and
metal can
• The portion is already filled in the crucible
• Preheating time : between 4-6 min depending on the
rail
• Gap : 25 -50- 70 mm
Ex of EU where the PLA of RAILTECH’s are homologated :
• Belgium
• Denmark
• France
• Netherlands
• Sweden
• Swizterland
• United Kingdom
• …..
Ex of EU countries where the LP of RAILTECH-
DEUTSCHLAND are homologated :
• Austria
• Czech Republic
• Denmark
• Germany
• Hungary
• Italy
• Poland
• ….
HOMOLOGATIONS WELDINGS- EN 14730-1
TRACK EQUIPMENT
A complete range of machines and devices for track laying and track maintenance:
Different models with various power sources:
• Petrol engines • Electric engines • Hydraulic generators
TRACK EQUIPMENT
Lorry
Rail Stressor
TRACK EQUIPMENT - A complete range of machines and devices for
track laying and track maintenance
Rail Cutting machine
Alignement of the rail
Shearing machine
Rail Stressor
TRACK EQUIPMENT
Grinder
Gas cylinder heater
Rail Cleaner
Straight edge
Tent
Welding training in the school or out of track
Approval for welding teams Training with delivrance of welder / welds supervisor / welds inspector
certicate
Technical assistance
ISSTAF -WELDING TRAINING and TRACK WORKS
ISSTAF - ULTRASONIC TESTING of RAILS
Type of defect to be detected: Cracks, Schelling with defibration, head checking, squat, bolt hole cracks, fatigue spots, rail wear and corrosion, Redaction of a report
Spot checking with an inspection walking-stick Long rail inspection
ISSTAF - ULTRASONIC TESTING of WELDS
With redaction of a report
ACCEPTANCE INSPECTION OF ALUMINOTHERMIC WELDS
Visual inspection and geometrical inspection of collars
GEOMETRIC INSPECTION OF THE TRACK
Mesure of the gauge
Mesure of the wear waves
STARTWEL NEW DEVELOPMENT
STARTWEL – IGNITER CLASSIFICATION
STARTWEL – SO EASY TO USE
NEW DEVELOPMENTS – HEAD WASH REPAIR WELD
NEW DEVELOPMENTS – HEAD WASH REPAIR WELD
HWR process offers new capabilities to network maintenance. It provides a fast and cost
effective solution to remove a defect up to 25mm deep depending on the rail profile, both in
the rail and FWB welds
-No rail replacement needed
-No need to cut the rails, no rail disturbance
1 plug
2 ATW (3-4h)
HWR – can even repair defects on flashbutt welds
NEW DEVELOPMENTS – HEAD WASH REPAIR WELD
Defects noticed on different European Networks are :
Defects on running surface (60%)
Fatigue defects (20%)
Wheel burn (20%)
HWR
USA – Canada
EVOLUTION OF HWR WELDING PROCESS
First tests
France
2013 2010
First tests
United Kingdom
First tests in TTCI
HWR with Felt
Both FBW & rail
End of 2014
First tests in track
2008
France
UK
Certificate of
acceptance
2012
France
Certificate of
acceptance
HWR – WELDING
2 filling slots - 3 modalities
GRINDER hydraulic powered GRINDER electric powered Oxy-propane cutting set
HWR – WELDING
HEAD WASH REPAIR WELD PROCESS
Mould grinding
Grinding the 3 steps to adjust the HWR mould on new rail
Adjustement of moulds according to dedicated rail’s wear
HWR – WELDING
HEAD WASH REPAIR WELD PROCESS
60 E1 NEW RAIL
HWR MOULD SHOES
HWR Mould Mould perfectly adjusted to the two rails
Mould Fitting on the rail foot
HEAD WASH REPAIR WELD PROCESS
Adjustement of moulds according to dedicated rail’s wear
to avoid having FLASHING underneath
HEAD WASH REPAIR WELD PROCESS
PERFECT ADJUSTEMENT
UNDER THE HEAD
Adjustement of moulds according to dedicated rail’s wear
HWR – WELDING
DO NOT FORGET THAT
Weldings on High Speed Track
The highest speed on track, the most countries and most different rails grades.
