Professional Documents
Culture Documents
Weld Technics
Weld Technics
Technique
INTRODUCTION
By : R.K. Kathal
Associate Professor Track 2
IRICEN , Pune
CODES & MANUALS
MANUAL FOR FUSION WELDING OF
RAILS BY ALUMINO THERMIC PROCESS
Revised (2022)
INDIAN RAILWAY STANDARD
SPECIFICATION FOR FUSION WELDING
OF RAILS BY ALUMINO THERMIC
PROCESS (IRS-T-19-2021)
MANUAL FOR FUSION WELDING OF RAILS
BY ALUMINO THERMIC PROCESS (2022)
SCOPE –
Method of welding- covers only SKV AT welding technique
with short pre-heating process.
Precautions & steps to be taken before, during & after
welding by short pre-heating process for achieving
satisfactory weld.
Tolerances of finished weld & acceptance tests.
List of equipments
Record maintenance of A.T. welding
Training & certification of welders
INDIAN RAILWAY STANDARD SPECIFICATION
FOR FUSION WELDING OF RAILS BY ALUMINO
THERMIC PROCESS (IRS-T-19-2021)
SCOPE –
Technical requirements for thermit portions and welded
joints including various acceptance tests.
Procedure for approval of Alumino-Thermic “portion
manufacturers”
Procedure for approval of A.T. welding Supervisors,
welders & contracting firms.
Acceptance tests for in-situ & cess A.T. joints.
Procedure for approval of alumino thermic portion
manufacturers with upgraded alumino thermic welding
technology.
INTRODUCTION
THE SOUNDNESS OF THE WELDS
PRODUCED BY ALUMINO THERMIC
PROCESS DEPENDS ON THE QUALITY OF
(A) ALUMINO THERMIC MIXTURE
HEREINAFTER REFERRED TO AS THE
MIXTURE AND THE TECHNICAL CONTROL
EXERCISED DURING THE PREPARATION
FOR AND THE EXECUTION OF THE
WELDING BY THIS PROCESS
INTRODUCTION
THE QUANTITY OF THE MIXTURE
REQUIRED FOR WELDING ONE RAIL
JOINT SHALL BE CALLED A PORTION
PORTION MANUFACTURED BY
o Mill scales
o Aluminum
o Ferro-manganese
o Steel chips
o Silicon carbide
o Ferro vanadium
o Flour spar
Shelf life ?
(a) One random sample per batch of 600 or part there-of may be drawn
from the portions available in stores.
(b) The sample shall be tested for reaction test. If the reaction is normal,
the batch represented by the sample can be used without further tests.
(c) In case the reaction is found to be quiet or boiling, a test joint should
be made from one more sample selected from the batch.
WELDING PORTION
If fish bolt holes are not present, the ends should preferably
be cropped for a minimum of distance 150mm.
For perfect vertical cut abrasive rail cutter should be used for rail.
Abrasive cutting blade
Dia of blade – 400+5 mm
-3
Thickness of blade -4+.25 mm
-.25 mm
Bore – 22.23 mm
Size -400*4*22.23 mm
PREPARATORY WORK
Pre-heating equipment
Pre-heating pressure
Minimum pre-heating time
Pre-heating
The runner and riser must not be removed until cold, and
that too only by knocking towards the rail.
WELDING PROCESS
No welding shall be carried out if it is raining. In case, the
rains start while the joint is under execution, immediate
arrangement to adequately cover the site shall be made.
DIMENSIONAL CHECK
USFD
Tolerance of Finished Weld
Tolerances after Welding
SAMPLE TEST JOINT
The test shall be done on the top surface of the head of the
test weld with a ball of 10 mm dia and a test load of 3000
kg maintained for 10 secs.
For R 260 RAILS HARDNESS -260-300
FOR HEAD HARDENED RAIL -340-390
FOR 1175 HT GRADE RAIL 350-390
Hardness Test
For 25mm gap SKV welding & for any preheating device
used. (Air-petrol/ Compressed Air Petrol/ Oxy-LPG)
X = 40 mm Y = 100 mm
107
108
109
Transverse Load Breaking Test
The test weld shall be supported on cylindrical or semi-
cylindrical supports having a distance of one metre between
them from center to center.
116
Macro Examination
117
FUSION ZONE-SHAPE AND
DIMENSION
After macro examination, measurements of
the fusion zone shall be made on the cuts
illustrated in Fig. 2 the minimum distance X
(Fig. 2) between the parent rail ends before
welding and the fusion line shall be equal to or
greater than 3mm. The measurement of X
shall be made using datum marks to locate
the original position of the rail ends
FUSION ZONE-SHAPE AND
DIMENSION
Key
* Datum marks
1. Fusion line
2. Rail ends before welding
3. Rail head
4. Rail foot
FUSION ZONE-SHAPE AND
DIMENSION
FUSION ZONE-SHAPE AND
DIMENSION
1-FUSION LINE
2-RAIL ENDS BEFORE WORKING
3 –RAIL HEAD
4-RAIL FOOT
FUSION WELD SHAPE
following
The firm shall define the mean value for each element
with a working range in Table
above. Actual values shall not vary by more than the
working range and this range shall
fit within the permitted range
* Either Vanadium or Molibdenum may be used as
grain refiner.
+In case single shot crucible is used, the maximum
limit of Si% may be taken as
1.20 % for 90 UTS /R260/1080 Head Hardened rail,
PRECAUTIONS
TRAINED WELDING SUPERVISER
TRAINED WELDER
SUPERVISE NOT MORE THAN TWO WELDING
TEAM (WITH IN 50 m)
PORTION MATCHING TYPE & CHEMISTRY
END SQUARENESS & VERTICALITY
PERFECT ALIGNMENT
PERFECT CLEANING OF ENDS
PRECAUTIONS (contd..)
STOP WATCH
PRESSURE IN THE TANKS
CORRECT GAP AT HEAD,WEB & FOOT
CORRECT PREHEATING TIME
CLEANING OF NOZZLES OF BURNER
CORRECT TAPPING & MOLD WAITING TIME
GLOVES & COLORED GLASSES
PRECAUTIONS (contd..)
LATERAL WEAR >6mm
NO WELD SHOULD LIE WITHIN 4 m OF ANY
OTHER WELD/FISHPLATED JOINT
NO WELDING IF IT IS RAINING
FIRMS BY RDSO
COMPETENCY TRAINING(Ref: Rly Bd’s
Lr No. E(MPP)99/19/1/Vol.III dtd.21.03.06)
Category Course Syllabi Periodicity Duration Agency
60 Kg 90 UTS/52 Kg 90 UTS
APPROVED FOR M/s ITC
APPROVAL FOR M/s
HTI/RAIPUR UNDER
DEVELOPMENT
50mm
WIDE GAP WELDING
ONE SHOT CRUCIBLE
FATIGUE TEST ARRANGEMNENT
FOR AT WELDS
The inner span (W) shall be a minimum 150
mm plus weld collar width under the foot.
The outer span (L) shall exceed the inner span
by at least twice the rail height (H) and
shall be symmetrical about the inner span
LW+2H
The inner and outer spans shall be measured
and recorded. The distances from the centre
line of the actuator to the loading points shall
be measured and recorded. Corresponding
dimensions on either side of the actuator
centre line should not differ by more than 3
mm.
FATIGUE TEST ARRANGEMNENT
FOR AT WELDS
The radius of curvature of the loading
points shall not be less than 40 mm. The
loading
point contact surfaces shall be free to
translate or rotate so that friction
between the loading
points and the specimen is minimized.
Fatigue testing of thermit welding technique
shall be arranged by the firm at his own
expense. Following principle shall be followed:
i) For 90UTS metallurgy Anyone section out of
52kg / 60kg (when both the sections have
been developed the lighter section should be
selected for fatigue testing).
ii) For R260 metallurgy Anyone section out of
60Kg / 60E1
iii) For 1175 HT metallurgy Anyone section
out of 60Kg / 60E1
FATIGUE TEST
DEVELOPMENT OF ANY OTHER AT WELDING
TECHNOLOGY SUCH AS WIDER GAP,1080
HEAD HARDENED RAILS SHALL ALSO BE GOT
SEPARATELY FATIGUE TESTED BEFORE
STANDARDISATION. HOWEVER, ONE
SECTION FOR ONE TECHNIQUE SHALL BE
REQUIRED TO BE FATIGUE TESTED.
THE WELD SAMPLES SHALL BE TESTED IN A
RECOGNIZED /TEST CENTRE
FATIGUE TEST
THREE WELD SAMPLES SHALL BE MADE IN
PRESENCE OF RDSO REPRESENTATIVES.
THE WELD SAMPLE SHALL BE MADE WITH
ONE METER LONG NEW RAIL PIECES TO
HAVE AN OVERALL LENGTHN OF 2.00 M .THE
RAIL AND JOINT SHALL BE ULTRASONICALLY
TESTED.
TESTING SHALL BE DONE FOR STRESS
RANGE OF TENSILE 20KG/MM TO
COMPRESSIVE 4KG/MM (THESE ARE THE
BOTTOM SURFACE OF THE RAIL FOOT)
FATIGUE TEST
THE TEST FREQUENCY SHALL BE ANYONE
FREQUENCY BETWEEN 8.33 TO 12.00 HZ
A JOINT SHALL BE DEEMED TO HAVE PASSED
IF IT IS WITHSTAND A MINIMUM OF 2
MILLION CYCLES EXCEPT FOR JOINTS OF
1175 HT GRADE RAILS A JOINT SHALL BE
DEEMED TO HAVE PASSED IF IT WITHSTAND
A MINIMUM OF 5 MILLION CYCLES.
THE TECHNIQUE SHALL BE DEEMED TO HAVE
CLEARED FATIGUE TEST IF ALL THE THREE
SAMPLES PASS THE ABOVE TEST.
SELF TAPPING THIMBLE
Marking of Joints
Surface preparation
Remove dust, loose rust and mill scale by wire
brushing.
Surface preparation
Remove dust, dirt and flaked paint from the welded
joint by wire brushing.
Degrease the surface by petroleum hydrocarbon or any
other suitable solvent, if oil or grease is present.
Allow it to dry.
NORMAL CORROSION
Painting procedure
Apply one coat of ready mixed paint, brushing
bituminous black, lead free, acid , alkali and chlorine
resistant to IS:9862-1981 or bituminous emulsion to
IRS: P-30-1996 on welded area and 10 cm on either
side.
Surface preparation
Remove dust, loose rust and mill scale by wire
brushing
Scrub welded area with water to make it free
from slag and other water soluble compounds.
Make it dry.
SEVERE CORROSION
Painting procedure
Apply one coat of high build epoxy paint (two pack)
conforming to RDSO specification No. M&C/PCN-
111/88 on the welded area up to 10 cm on either
side.
SEVERE CORROSION
MAINTENANCE PAINTING(FOR OLD
PAINTED JOINTS)
Surface preparation:
Remove dust, dirt and flaked paint from the welded
joint by wire brushing.
Degrease the surface by petroleum hydrocarbon or
any other suitable solvent, if oil or grease is present.
Allow it to dry
SEVERE CORROSION
Painting procedure
Apply one coat of high build epoxy paint (two
pack) conforming to RDSO specification no.
M&C/PCN-111/88 on the welded area up to 10
cm on either side.
YIELD STRENGTH
S. TYPE OF YIELD UTS
N RAIL STRENGTH (MPA)
o (MPA)
RAIL WELD RAIL WELD
LACK OF FUSION
CUPPING
SAND INCLUSION
CRACKING OF WELD AFTER COOLING
MAJOR DEFECTS IN AT
WELDS
POROSITY
SLAG
INCLUSION
MAJOR DEFECTS IN A.T. WELDING
BECAUSE OF IMROPER WELD
EXECUTION
Storage of A.T. Portion
Stores should be dry, well ventilated, and where required
light, power and running water should be available.
Once the two ends are cut, a gap required for wide gap
welding will be created by using rail tensors and joint welded
by wide gap AT welding technique
Permanent Repair of Weld Fracture
In case rail closure with required welding gap temporary
repairs, one joint of the closure rail shall be welded without
rail tensor after setting correct gap for welding.
Joggled fish plate with clamps or two far end bolts on good
AT welds shall be provided on banks having height 5 m or
more.
Joggled fish plates with far end tight bolt shall be provided
on AT welds which have undertaken traffic equal to or
more than 50% of stipulated fatigue life (GMT) of the rail.
Joggling of AT Weld for Bridge
Joggled fish plate with clamps or two far end bolts on good
AT welds shall be provided on bridges having length of
water way as 100 m or more and on approaches upto 100
m length.
For all important and major bridge with approach upto 100
m length , joggled fish plate with clamps or two far end
bolt on good AT weld should be provided.
Joggling of AT Weld for Curve
All defective joints shall be broken with the help of jim crow in
presence of firm’s representative and a joint report be
prepared. Defects observed on fractured faces shall be
recorded in form of photograph/ sketch.
Defective Fractured Joints
Sectional DEN/Sr. DEN shall carry out
investigation/analysis for all in track fractured joints
and joints broken as per above point. Information
shall be compiled in the format indicated below
Defective Fractured Joints
Any Suggestions?
Contact At : kathal@iricen.gov.in