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RAIL WELDING

WELDING PROCESSES: • Flashbutt – Fixed and mobile machines • Aluminothermic – Railtech/Boutet, Thermit • Head repair (electric arc)

QUALIFICATION REQUIREMENTS: • AS 1085.20-2012 • Client specifications

COMMON ISSUES & CONCERNS: • Failure to meet qualification requirements • Welding procedures for new rail grades • Qualification of new welding equipment • In-service failures

RESEARCH AND INDUSTRY SUPPORT

Activities:

• Development and qualification of flashbutt welding procedures

• New rail grades • New welding equipment

• Qualification of aluminothermic welding procedures • Development and review of specifications and

standards • Fatigue analysis and testing of welds • In-track instrumentation and remote monitoring of

impact loading at welds • Residual stress measurements • Specialised metallurgical analysis of weld defects

and failures • Welder training

0

20

40

60

80

100

120

140

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-400 -200 0 200 400 600 800

He

igh

t fr

om

Rai

l Fo

ot

(mm

)

Residual Stress (MPa)

Vertical

Longitudinal

THE PERFORMANCE OF PREMIUM RAIL GRADES IN CWR TRACK IS ONLY AS GOOD AS

THAT OF THE RAIL WELDS!

ATW FBWHardness Hardness