AS 1085.20-2006

1 - AS 1085.20-2006 RAILWAY TRACK MATERIAL - WELDING OF STEEL RAIL
4 - PREFACE
5 - CONTENTS
7 - SECTION 1 SCOPE AND GENERAL
7 - 1.1 SCOPE
7 - 1.2 PURPOSE AND CONTEXT OF USE
7 - 1.2.1 Function
7 - 1.2.2 Action
8 - 1.3 REFERENCED DOCUMENTS
8 - 1.4 BASIC REQUIREMENTS
9 - 1.5 QUALIFICATION OF THE WELDING PROCESS
9 - 1.5.1 Qualification
9 - 1.5.2 Requalification
9 - 1.6 QUALIFICATION OF WELDING PERSONNEL
9 - 1.7 DOCUMENTATION
9 - 1.7.1 Job document
9 - 1.7.2 Welding procedure
9 - 1.8 TESTING
10 - 1.9 DEFINITIONS
10 - 1.9.1 Aluminothermic welding
10 - 1.9.2 Bond line
10 - 1.9.3 Closing portion
10 - 1.9.4 Closure
10 - 1.9.5 Cold shut
10 - 1.9.6 Consumables
10 - 1.9.7 Crucibles
10 - 1.9.8 Flashing
10 - 1.9.9 Fusion zone
10 - 1.9.10 Heat-affected zone
11 - 1.9.11 Heat-affected zone, visible
11 - 1.9.12 Heat-softened zone
11 - 1.9.13 Hot tear
11 - 1.9.14 Igniter
11 - 1.9.15 Inclusions
11 - 1.9.16 Job document
11 - 1.9.17 Junction weld
11 - 1.9.18 Luting material
11 - 1.9.19 Mould unit
11 - 1.9.20 Porosity
11 - 1.9.21 Portion
11 - 1.9.22 Pouring mode
11 - 1.9.23 Short head
11 - 1.9.24 Shrinkage crack
11 - 1.9.25 Step weld
12 - 1.9.26 Thimble
12 - 1.9.27 Upset
12 - 1.9.28 Welding procedure
12 - 1.9.29 Welding process
12 - 1.9.30 Weld gap
12 - 1.9.31 Weld metal head
12 - 1.9.32 Weld reinforcement
12 - 1.10 NOTATION
14 - SECTION 2 FLASH BUTT WELDING
14 - 2.1 GENERAL
14 - 2.2 DESCRIPTION OF THE PROCESS
14 - 2.3 QUALIFYING THE WELDING PROCEDURE
15 - 2.4 JOB DOCUMENT
15 - 2.5 WELDING PROCEDURE
16 - 2.6 MAINTENANCE OF EQUIPMENT
16 - 2.7 INSPECTION AND TESTING OF FINISHED WELDS
17 - 2.8 MARKING AND RECORDS
17 - 2.8.1 Marking
17 - 2.8.2 Records
18 - SECTION 3 ALUMINOTHERMIC WELDING
18 - 3.1 GENERAL
18 - 3.2 DESCRIPTION OF THE PROCESS
18 - 3.3 QUALIFYING THE WELDING PROCEDURE
18 - 3.4 JOB DOCUMENT
19 - 3.5 WELDING PROCEDURE
20 - 3.6 MAINTENANCE OF EQUIPMENT
20 - 3.7 INSPECTION AND TESTING OF FINISHED WELDS
20 - 3.8 MARKING AND RECORDS
20 - 3.8.1 Marking
21 - 3.8.2 Records
22 - SECTION 4 ARC WELDING
22 - 4.1 GENERAL
22 - 4.2 DESCRIPTIONS OF WELDING METHODS
22 - 4.2.1 Manual metal arc welding (MMAW)
22 - 4.2.2 Flux-cored arc welding (FCAW)
22 - 4.2.3 Gas metal arc welding (GMAW)
22 - 4.3 QUALIFYING THE WELDING PROCEDURE
23 - 4.4 JOB DOCUMENT
23 - 4.5 WELDING PROCEDURE
24 - 4.6 MAINTENANCE OF EQUIPMENT
24 - 4.7 INSPECTION AND TESTING OF FINISHED WELD
25 - 4.8 MARKING AND RECORDS
25 - 4.8.1 Marking
25 - 4.8.2 Records
26 - APPENDIX A - COMMENTARY ON THE STANDARD
26 - A1 GENERAL
26 - A2 INFORMATION ON METHODS NOT COVERED BY THIS STANDARD
26 - A2.1 Changes from AS 1085.15-1995
27 - A3 ALUMINOTHERMIC WELDING-DESIGNATION OF WELD TYPES
27 - A4 ALUMINOTHERMIC WELDING-QUALITY CONTROL OF PRODUCTION OF CONSUMABLES
28 - APPENDIX B - INFORMATION TO BE SUPPLIED WHEN SPECIFYING WELDING FOR STEEL RAIL
28 - B1 FLASH BUTT WELDING
28 - B2 ALUMINOTHERMIC WELDING
28 - B3 ELECTRIC ARC WELDING
29 - APPENDIX C - MEANS FOR DEMONSTRATING COMPLIANCE WITH THIS STANDARD
29 - C1 SCOPE
29 - C2 STATISTICAL SAMPLING
29 - C3 PRODUCT CERTIFICATION
30 - C4 SUPPLIER™S QUALITY MANAGEMENT SYSTEM
30 - C5 OTHER MEANS OF ASSESSMENT
31 - APPENDIX D - QUALIFICATION OF PERSONNEL
31 - D1 GENERAL
31 - D2 WELDERS
31 - D3 QUALIFICATION TESTING OF WELDERS
32 - APPENDIX E - VISUAL INSPECTION AND ALIGNMENT
32 - E1 VISUAL INSPECTION
32 - E2 JOINT GEOMETRY TEST
32 - E2.1 Surface alignment
35 - E2.2 Surface slope
35 - E3 WELD COLLAR TEST
35 - E4 SIZE OF IMPERFECTIONS
36 - APPENDIX F - ULTRASONIC TESTING
36 - F1 SCOPE
36 - F2 TESTING FOR QUALIFICATION
36 - F2.1 General
36 - F2.2 Test required for each weld process
36 - F2.3 Report
36 - F3 ROUTINE TESTING OF FINISHED WELDS
36 - F3.1 General
37 - F3.2 Details for routine testing of finished welds
37 - F3.3 Measurement of size
37 - F3.4 Report
38 - F4 TEST METHOD
38 - F4.1 General
38 - F4.2 Horizontal imperfections (0° probe)
38 - F4.3 Head zone test (70° probe)
38 - F4.4 Head zone test (0° probe)
39 - F4.5 Web test (38° probe)
39 - F4.6 Foot test (70° probe)
41 - APPENDIX G - HARDNESS TESTS
41 - G1 SCOPE
41 - G2 WELD METAL HARDNESS FOR ALUMINOTHERMIC WELDING
41 - G2.1 General
41 - G2.2 Report
42 - G3 HARDNESS TRAVERSE FOR FLASH BUTT AND ALUMINOTHERMIC WELDS
42 - G3.1 Principle
42 - G3.2 Procedure
44 - G3.3 Parent rail hardness variation
44 - G3.4 Report
44 - G4 HARDNESS TRAVERSE FOR ARC WELDS
44 - G4.1 Principle
44 - G4.2 Procedure
45 - G4.3 Report
46 - APPENDIX H - MACROSCOPIC TESTS
46 - H1 SCOPE
46 - H2 FUSION ZONE-SHAPE AND DIMENSION
46 - H2.1 Procedure
46 - H2.2 Records
46 - H2.3 Report
47 - H3 VISIBLE HEAT-AFFECTED ZONE-RUNNING SURFACE
47 - H3.1 Procedure
47 - H3.2 Report
48 - APPENDIX I - MICROSCOPIC TESTS
48 - I1 SCOPE
48 - I2 PROCEDURE
49 - I3 REPORT
50 - APPENDIX J - CHEMICAL ANALYSIS
50 - J1 SCOPE
50 - J2 PROCEDURE
50 - J3 REPORT
51 - APPENDIX K - SLOW BEND TEST
51 - K1 SCOPE
51 - K2 PRINCIPLE
51 - K3 APPARATUS
51 - K4 PROCEDURE
52 - K5 ASSESSMENT OF FRACTURE FACES
52 - K6 REPORT
53 - APPENDIX L - FATIGUE TEST
53 - L1 SCOPE
53 - L2 STAIRCASE FATIGUE TEST
53 - L2.1 Principle
53 - L2.2 Apparatus
54 - L2.3 Determination of stress to load relationship
54 - L2.4 Test pieces for fatigue strength determination
54 - L2.5 Fatigue strength procedure
55 - L2.6 Data analysis
56 - L2.7 Assessment of fracture faces
56 - L2.8 Report
57 - L3 FATIGUE TEST FOR WEB OF WELDED SECTION (OPTIONAL)
57 - L3.1 Principle
57 - L3.2 Testing conditions
57 - L3.3 Apparatus
58 - L3.4 Procedure
59 - L3.5 Report
60 - APPENDIX M - QUALIFICATION OF A FLASH BUTT WELDING PROCEDURE
60 - M1 SCOPE
60 - M2 GENERAL REQUIREMENTS
60 - M3 TESTING FOR QUALIFICATION AND REQUALIFICATION
60 - M3.1 General
60 - M3.2 Qualification for junction and step welds
60 - M3.3 Preparation and allocation of test welds
61 - M3.4 Qualification of flash butt welding procedure
63 - APPENDIX N - QUALIFICATION OF AN ALUMINOTHERMIC WELDING PROCEDURE
63 - N1 SCOPE
63 - N2 GENERAL REQUIREMENTS
63 - N3 TESTING FOR QUA
63 - N3.1 General
64 - N3.2 Qualification for group 1 rails (60 kg)
64 - N3.3 Qualification for rails in other groups
64 - N3.4 Qualification for other types of rail
64 - N3.5 Qualification for junction and step welds
65 - N3.6 Preparation and allocation of test welds
66 - N3.7 Qualification of aluminothermic welding process
68 - N4 TESTING FOR REQUALIFICATION
68 - N4.1 General
69 - N4.2 Parameters
72 - APPENDIX O - QUALIFICATION OF AN ARC WELDING PROCEDURE
72 - O1 SCOPE
72 - O2 GENERAL REQUIREMENTS
72 - O3 QUALIFICATION OF WELDING PROCESS
72 - O3.1 Prequalified consumables
72 - O3.2 Qualification tests
72 - O3.3 Qualification of an arc welding procedure
73 - O4 REQUALIFICATION

Sets out performance requirements and tests for welding of steel rail. Gives detailed requirements for flash butt welding, aluminothermic welding and metal arc welding (for repairs). Qualification of the welding procedure is covered, including criteria for requalification when parameters are changed. Test methods are given in appendices.

This Standard specifies performance requirements for welds in steel rail in accordance with AS1085.1 or rails that are shown to be metallurgically equivalent, for use in railway track. The following processes are covered:(a) Joining of rails by flash butt welding.(b) Joining of rails by aluminothermic fusion welding.(c) Repair of the railhead by arc welding.This Standard covers the joining of rails and the repair of the railhead by welding using the processes described. Other welding is outside the scope of this Standard and should be covered by documentation other than this Standard.The Standard does not provide strength properties of welds for use in design nor cover the welding of austenitic manganese steels.NOTES:1 Commentary on the background to the Standard is given in AppendixA.2 Guidance on information to be supplied when ordering or supplying is given in AppendixB.3 Guidance on the means for demonstrating compliance with this Standard is given in AppendixC.4 Rail steel is considered to be very difficult to weld for structural purposes. It is not recommended that welded rail be used in applications other than railway track.5 Rail produced to specifications other than AS1085.1 may require a separate qualification process. Appropriate testing may need to be determined.

Originated as AS 1085.15-1995.
Revised and redesignated as AS 1085.20-2006.