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Aluminothermic Welding Process

Improvement

Frédéric DELCROIX – Krakow, 15-17 maj 2013 r

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RAILWAYS

INCREASED NEEDS (axle load, traffic volume, speed, etc.)

Heavy Haul, High Speed Lines, Classical Lines, etc.

Availability

Reliability

Safety

Profit earning

Etc.

Costs

Maintenance

Etc.

Ballast track

Slab track

Rail grades

Trackwork

Rail joints

Rail grinding

Rail profile

Friction

Welding

Etc.

Concrete ties (sleepers)

Fastenings

Inspection

Maintenance

Track geometry

FEEDBACK

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POROSITY Moisture

DEFECTS

INCLUSIONS (Slag, Sand…)

Preheating, mold, crucible,

tapping time…

"Classical" "Settings"

DEFECTS

LACK OF

FUSION

Preheating,

Rails Adjustment… CRACK Preheating…

"Classical" "Settings"

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DEFECTS

THERMAL

CONTRACTION Rails movement during

solidification LEAK

Luting, Molds

Adjustment, Early

unmoulding…

"Classical" "Settings"

DEFECTS REX

DIPPING – METAL FLOW

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DEFECTS REX

Rails

Standard

High Strength

OCP

UHC

R400HT

Bainitic

…

GRINDING

DIPPING – METAL FLOW

SQUAT

DEFECTS REX

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Rolling Contact Fatigue – Head Check – Squat – etc. Grinding

10th international Heavy Haul association conference 2013

Preventive Grinding on Estrada de Ferro Carajás, Brazil Peter Sroba, Fernando Sgavioli, Richard Joy, Jose Ribamar Santos, Antonio C. A. Pina & Robert Caldwell

Railway Consultant, Newcastle, Australia, Vale, Estrada de Ferro Carajas, Brazil Transportation Technology Center Inc, Pueblo

Colorado, USA, 4NRC Surface Transportation, Ottawa, Canada

Brésil VALE : Projection : 2012=210MGT / 2016=460MGT : solution = meulage préventif

Rail Grinding on the South Central Railway Region of Indian Railways Peter Sroba, Pradeep Kumar Garg & Robert Caldwell

Railway Consultant, Newcastle, Australia, Indian Railways Institute of Civil Engineering, Pune, India 3NRC Surface

Transportation, Ottawa, Canada

Inde : Meulage préventif = réduction RCF et taux rupture rails + soudures

"Man vs. Machine": Testing Automated Rail Grinding Pre-Inspection vs. Manual Methods J. F. Holt, D. H. Isdahl, R. C. Harris, B. J. Koch, D. M. Daftari, C. P. Rudeen & J. M. Carlin

Loram Maintenance of Way, Inc., Hamel, MN USA

Publicité LORAM : UK, Inde réseau + métro Delhi, Brésil

DEFECTS REX

FATIGUE WEB / HEAD

DEFECTS REX

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FATIGUE FOOT

DEFECTS REX

HORIZONTAL FRACTURE

DEFECTS REX

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SOLUTIONS

Before Railtech studies

Minimum weld life = 3 months

After Railtech solutions

56 months without rupture (september 2007 to may 2012)

326Mt – (191 000t/day)

Re-Railing

Exa

mp

le :

1 c

urv

e in

1 R

ailw

ay

SOLUTIONS

No rupture in the weld

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HYBRID MOLDS

Head Wash Repear

Ignitor : Startwel

INFORMATIONS

FLASHING

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Cold laps

3.8 million cycles @ 230MPa

1.2 million cycles @ 230MPa

FOOT FATIGUE FAILURE CHARACTERISTICS

All failures along fusion boundary

BREAKING… Rails misalignment

Molds misalignment

Wear

…

FLASHING

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HYBRID MOLDS

CLASSICAL HYBRID

HYBRID MOLDS

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HY Type B

4 to 15 mm

Wear difference between 2 rails

(Δ Wear) 4 mm ≤ Wear ≤ 7 mm

0 to 15 mm

Wear difference between 2 rails

(Δ Wear) ≤ 3 mm

Molds Wear

HY Type C

HYBRID MOLDS

HY Type B

New rail / Worn rail

4mm mini Worn rails : 7mm max Worn Rails : 11-8mm / 15mm

HYBRID MOLDS

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New rails Worn rails : 15mm max Wear difference : 3mm max

HYBRID MOLDS

HY Type C

Wear = 15mm Max

4mm ≤ Δ Wear ≤ 7mm

15 m

m

4 m

m

4 m

m

HYBRID MOLDS

HY Type B

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15 m

m

HYBRID MOLDS

HY Type C

Wear = 15mm Max

Δ Wear ≤ 3mm

CL

AS

SIC

AL

F

LA

SH

ING

HYBRID MOLDS

HY

BR

ID

WIT

HO

UT

FL

AS

HIN

G

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0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

0 HYB

1 HYB HYB

2 HYB HYB HYB

3 HYB HYB HYB HYB

4 HYC HYB HYB HYB HYB

5 HYC HYC HYB HYB HYB HYB

6 HYC HYC HYC HYB HYB HYB HYB

7 HYB HYB HYB HYB HYC HYC HYC HYC HYC HYC HYC HYB HYB HYB HYB

8 HYB HYB HYB HYB HYC HYC HYC HYC HYC HYC HYC HYB HYB HYB HYB

9 HYB HYB HYB HYB HYC HYC HYC HYC HYC HYC HYC HYB HYB HYB

10 HYB HYB HYB HYB HYC HYC HYC HYC HYC HYC HYC HYB HYB

11 HYB HYB HYB HYB HYC HYC HYC HYC HYC HYC HYC HYB

12 HYB HYB HYB HYB HYC HYC HYC HYC HYC HYC HYC

13 HYB HYB HYB HYB HYC HYC HYC HYC HYC HYC

14 HYB HYB HYB HYB HYC HYC HYC HYC HYC

15 HYB HYB HYB HYB HYC HYC HYC HYC

RAILTECH QP MOULD SELECTION MATRIX

HYBRID FELT MOULDS FOR MAINTENANCE

See Note WEAR ON THE FIRST RAILW

EA

R O

N T

HE

SE

CO

ND

RA

IL

QPQP QP QP

QPQP QP QP

QPQP QP QP

QP QP QP

QP

QP

QP

QP

QP

QP

QPQP QP

QP

QP

QP

QP

QP

QP

QP

QP

QP

QP

QP

QP

QP

QP

QP

QP

QP QP

QP

QP

QP QP

QP QPQP

HYBRID MOLDS

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

0 HYB

1 HYB HYB

2 HYB HYB HYB

3 HYB HYB HYB HYB

4 HYC HYB HYB HYB HYB

5 HYC HYC HYB HYB HYB HYB

6 HYC HYC HYC HYB HYB HYB HYB

7 HYB HYB HYB HYB HYC HYC HYC HYC HYC HYC HYC HYB HYB HYB HYB

8 HYB HYB HYB HYB HYC HYC HYC HYC HYC HYC HYC HYB HYB HYB HYB

9 HYB HYB HYB HYB HYC HYC HYC HYC HYC HYC HYC HYB HYB HYB

10 HYB HYB HYB HYB HYC HYC HYC HYC HYC HYC HYC HYB HYB

11 HYB HYB HYB HYB HYC HYC HYC HYC HYC HYC HYC HYB

12 HYB HYB HYB HYB HYC HYC HYC HYC HYC HYC HYC

13 HYB HYB HYB HYB HYC HYC HYC HYC HYC HYC

14 HYB HYB HYB HYB HYC HYC HYC HYC HYC

15 HYB HYB HYB HYB HYC HYC HYC HYC

RAILTECH QP MOULD SELECTION MATRIX

HYBRID FELT MOULDS FOR MAINTENANCE

See Note WEAR ON THE FIRST RAIL

WE

AR

ON

TH

E S

EC

ON

D R

AIL

QPQP QP QP

QPQP QP QP

QPQP QP QP

QP QP QP

QP

QP

QP

QP

QP

QP

QPQP QP

QP

QP

QP

QP

QP

QP

QP

QP

QP

QP

QP

QP

QP

QP

QP

QP

QP QP

QP

QP

QP QP

QP QPQP

HYBRID MOLDS

First rail worn 8mm

Example 1 Step = 3 mm = Mould type HYC

Second rail worn 11 mm

First rail worn 7 mm

Example 2 Step = 5 mm = Mould type HYB

Second rail worn 12 mm

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Easy to use for the welder

Just grind the running surface

Quick setting

Same collar shape (top of the foot)

Good verticality molds adjustment (felt)

Avoid flashing (under the head, web and the foot)

HYBRID MOLDS

Head Wash Repear

15 m

m

No rail plug to introduce on track

Quick to establish

(no rail cut, no rail, no gap to achieve)

No destressing welding to perform

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Hydraulic grinder Electric grinder Flame cuting

Head Wash Repear

Grinding : 50mm

Head Wash Repear

Contact mold / foot

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Slow bending test : 36mm –1590 KN - No rupture

Head Wash Repear

STARTWEL ®

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STARTWEL® STARTER

STARTWEL ®

STARTWEL®

Ignition

38

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Liquid slag

Liquid steel

STARTWEL®

Reaction

39

STARTWEL ®

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THANK YOU

FOR YOUR ATTENTION