recommended practices for the welding of rails and · pdf file(smaw), gas metal arc welding...

6
Recommended Practices for the Welding of Rails and Related Rail Components for Use by Rail Vehicles AWS D15.2:2003 An American National Standard

Upload: ngodung

Post on 31-Jan-2018

231 views

Category:

Documents


5 download

TRANSCRIPT

Page 1: Recommended Practices for the Welding of Rails and · PDF file(SMAW), gas metal arc welding (GMAW), flux cored arc welding (FCAW), flash welding (FW), thermite welding ... Recommended

RecommendedPractices forthe Welding ofRails and RelatedRail Componentsfor Use by RailVehicles

AWS D15.2:2003An American National Standard

Page 2: Recommended Practices for the Welding of Rails and · PDF file(SMAW), gas metal arc welding (GMAW), flux cored arc welding (FCAW), flash welding (FW), thermite welding ... Recommended

550 N.W. LeJeune Road, Miami, Florida 33126

AWS D15.2:2003An American National Standard

Approved byAmerican National Standards Institute

October 7, 2003

Recommended Practices

for the Welding of Rails

and Related Rail Components

for Use by Rail Vehicles

Supersedes ANSI/AWS D15.2-94

Prepared byAWS D15 Committee on Railroad Welding

Under the Direction ofAWS Technical Activities Committee

Approved byAWS Board of Directors

AbstractThis document recommends minimum standards for the maintenance welding of rails and related rail components usedby rail vehicles. Repair procedures for rails and austenitic manganese steel components are covered. Thermite weldingand electric flash welding guidelines are discussed. Procedure qualification, welder qualification, and general weldingsafety procedures are addressed.

Key Words—Arc welding processes, crossings, wheel burns, flash welding, frogs, oxyfuel welding, procedure qualification, railroad safety, railroad welding, rails, switch points, thermite welding, track, welder qualification

Page 3: Recommended Practices for the Welding of Rails and · PDF file(SMAW), gas metal arc welding (GMAW), flux cored arc welding (FCAW), flash welding (FW), thermite welding ... Recommended

vii

Table of Contents

Page No.

Personnel .................................................................................................................................................................... iiiForeword ......................................................................................................................................................................vList of Tables ...............................................................................................................................................................ixList of Figures..............................................................................................................................................................ixList of Forms................................................................................................................................................................ix

1. Scope .....................................................................................................................................................................1

2. Referenced Documents .........................................................................................................................................1

3. Rail, Rail Components Manufactured from Rail, and Their Repair .....................................................................23.1 Specific Items ..............................................................................................................................................23.2 Welding Processes .......................................................................................................................................23.3 Railroad Rail Welding .................................................................................................................................23.4 Repair of Battered Rail Ends and Wheel Burns (Carbon Steel or Premium Steel Rail) .............................23.5 Repair of Rail-Type Switch Points and Switch Point Protectors ................................................................33.6 Frogs, Crossings, and Other Components Made From Rail Steel...............................................................43.7 Miscellaneous Carbon Steel and Low Alloy Steel Components .................................................................4

4. Repair or Fabrication of Components Manufactured from Austenitic Manganese Steel .....................................44.1 Metallurgical Background ...........................................................................................................................44.2 Components .................................................................................................................................................44.3 Welding Processes .......................................................................................................................................44.4 Filler Metals.................................................................................................................................................44.5 Preparation for Welding ..............................................................................................................................44.6 Welding Recommendations—General ........................................................................................................54.7 Welding Recommendations—Frogs and Crossings in Track......................................................................6

5. Recommended Practices for Joining of Rails by Thermite Welding (TW) ..........................................................65.1 General Description .....................................................................................................................................65.2 Application ..................................................................................................................................................65.3 Preparation of Final Gap for Welding .........................................................................................................65.4 Welding Procedure ......................................................................................................................................65.5 Care of Thermite Materials..........................................................................................................................75.6 Procedure Qualification ...............................................................................................................................85.7 Welder Qualification ...................................................................................................................................85.8 Thermite Welding Safety Precautions .........................................................................................................8

6. Flash Welding (FW) of Rail..................................................................................................................................86.1 General Process Description........................................................................................................................86.2 Rail Preparation ...........................................................................................................................................86.3 Rail Welding................................................................................................................................................96.4 Finishing Operations....................................................................................................................................96.5 Continuous Welded Rail Storage.................................................................................................................9

7. Procedure Qualification—Arc Welding Processes ...............................................................................................97.1 Prequalified Procedures ...............................................................................................................................97.2 Welding Procedures.....................................................................................................................................9

AWS D15.2:2003

Page 4: Recommended Practices for the Welding of Rails and · PDF file(SMAW), gas metal arc welding (GMAW), flux cored arc welding (FCAW), flash welding (FW), thermite welding ... Recommended

viii

Page No.

8. Track Welder Qualification—Arc Welding Processes .........................................................................................98.1 Procedure Qualification ...............................................................................................................................98.2 Workmanship Samples ..............................................................................................................................138.3 Results of the Workmanship Samples .......................................................................................................13

9. Nondestructive Testing .......................................................................................................................................139.1 Geometry Inspection (Rail Weld Alignment)............................................................................................139.2 Magnetic Particle Inspection .....................................................................................................................139.3 Ultrasonic Inspection .................................................................................................................................139.4 Radiography...............................................................................................................................................139.5 Dye Penetrant Inspection...........................................................................................................................13

Nonmandatory Annexes..............................................................................................................................................15Annex A—Welding Processes.....................................................................................................................................15Annex B—Welding of Austenitic Manganese Steel ....................................................................................................21Annex C—Flash Welding Guidance ...........................................................................................................................25Annex D—AREMA Tests for Continuous Welded Rail...............................................................................................27Annex E—Safe Practices ............................................................................................................................................31Annex F—Guidelines for Preparation of Technical Inquiries for AWS Technical Committees ................................35

List of AWS Documents on Railroad Welding............................................................................................................37

AWS D15.2:2003

Page 5: Recommended Practices for the Welding of Rails and · PDF file(SMAW), gas metal arc welding (GMAW), flux cored arc welding (FCAW), flash welding (FW), thermite welding ... Recommended

ix

List of Tables

Table Page No.

D1 Processes for Carbon and Alloy Steel Rail Components ...............................................................................2D2 Minimum Performance Specifications for New Flash and Thermite Welded Rail .......................................7D1 Wheel Loads for Rolling Load Test.............................................................................................................27

List of Figures

Figure Page No.

A1 Typical Weld Pattern for Rail End Repair .....................................................................................................3A2 Typical Skip Welding Repair.........................................................................................................................5A3 Layout of Hardness Survey on Rail Head....................................................................................................10A4 Layout of Transverse Hardness Survey .......................................................................................................11A1 Shielded Metal Arc Welding (SMAW) .......................................................................................................16A2 Gas Metal Arc Welding (GMAW)...............................................................................................................16A3 Flux Cored Arc Welding (FCAW)...............................................................................................................17A4 Section Through a Thermite Mold and Crucible .........................................................................................18A5 Automatic Hydraulically Operated Flash Welding Machine with Horizontal Clamping............................18A6 Rail Welding Production Line .....................................................................................................................19A7 Oxyfuel Gas Welding (OFW) ......................................................................................................................19D1 Loading Arrangement for the 12 in. Stroke Rolling Load Machine ............................................................28D2 Load Arrangement for the Slow Bend Test and Formula for Deriving the Modulus of Rupture................29

List of Forms

Form Page No.

1 Typical Welding Procedure Qualification Test Record...............................................................................122 Typical Welder Qualification Test Record ..................................................................................................14

AWS D15.2:2003

Page 6: Recommended Practices for the Welding of Rails and · PDF file(SMAW), gas metal arc welding (GMAW), flux cored arc welding (FCAW), flash welding (FW), thermite welding ... Recommended

AWS D15.2:2003

1

1. ScopeThis document recommends standards for the joining,

repair, maintenance, inspection of rail welds, and relatedrail components. For the purposes of this document,rails include railroad rails, crane rails, guard rails, electri-cal contact rails, girder rails, and retarder rails. Classifica-tion of rails is based on the American Railway Engineeringand Maintenance of Way Association (AREMA) specifi-cations governing the manufacture of rails.

Related rail components include rail crossings andturnouts which further include switch points, stock rails,switch point guards, spacer blocks, connecting rods,switch rods, plates, frogs, and frog components.

The use of track components reconditioned bywelding is a decision of the rail owner outside the scopeof this document. This document does not include roadbed maintenance except where it affects the expected lifeof the repair. Safety precautions shall conform to Code ofFederal Regulations (CFR), Title 49, Part 214, RailroadWorkplace Safety. Safety and health issues and concernsare beyond the scope of this standard, and therefore arenot fully addressed herein. Safety and health informationis available from other sources, including, but not limitedto, ANSI Z49.1, Safety in Welding, Cutting, and AlliedProcesses, and applicable federal and state regulations(see also Annex E, Safe Practices).

Welding processes include shielded metal arc welding(SMAW), gas metal arc welding (GMAW), flux cored arcwelding (FCAW), flash welding (FW), thermite welding(TW), and oxyfuel gas welding (OFW). See Annex A andVolume 2, Eighth Edition, Welding Handbook for details.

This standard makes use of the U.S. Customary Units.Approximate mathematical equivalents in the InternationalSystem of Units (SI) are provided for comparison in paren-theses ( ) or in appropriate columns in tables and figures.

2. Referenced DocumentsThe following standards contain provisions which,

through reference in this text, constitute provisions of

this AWS standard. For dated references, subsequentamendments to, or revisions of, any of these publicationsdo not apply. However, parties to agreements based onthis AWS standard are encouraged to investigate the pos-sibility of applying the most recent editions of the docu-ments shown below. For undated references, the latestedition of the standard referred to applies.

(1) ANSI Z49.1, Safety in Welding, Cutting, and AlliedProcesses, Volume 2, Eighth Edition, Welding Handbook1

(2) AREMA Chapter 4, Rail2

(3) ASTM E 140, Hardness Conversion Tables forMetals (Relationship Among Brinell Hardness, VickersHardness, Rockwell Hardness, Rockwell SuperficialHardness, Knoop Hardness, and ScleroscopeHardness)3

(4) ASTM E 164-97, Standard Practice for Ultra-sonic Contact Examination of Weldments

(5) ASTM E 1417-99, Standard Practice for LiquidPenetrant Examination

(6) ASTM E 709-01, Standard Guide for MagneticParticle Examination

(7) AWS A5.13, Specification for Surfacing Elec-trodes for Shielded Metal Arc Welding2

(8) AWS A5.21, Specification for Composite Surfac-ing Welding Rods and Electrodes

(9) Code of Federal Regulation, Title 49, Volume 4,Parts 200–299, revised October 1, 2000.4

1. ANSI Z49.1 and AWS documents are published by theAmerican Welding Society, 550 N.W. LeJeune Road, Miami,FL 33126.2. AREMA documents are published by the American RailwayEngineering and Maintenance of Way Association, 8201Corporate Drive, Suite 1125, Landover, MD 20785-2230.3. ASTM documents are published by the American Society forTesting and Materials, 100 Barr Harbor Drive, West Consho-hocken, PA 19428-2959.4. Federal regulations are published by the U.S. GovernmentBookstore, Wells Fargo Building, 201 West 8th, Pueblo, CO81003, or http://www.gpo.gov/.

Recommended Practices for the Welding of Rails andRelated Rail Components for Use by Rail Vehicles