ONE-SHOT CRUCIBLE

Transcription

ONE-SHOT CRUCIBLE

Manual n° 80.20.5 - Edition February 2007- Page 1
MANAGEMENT AND SALES OFFICES
119 Avenue Louis Roche - BP 152 - 92231 GENNEVILLIERS - FRANCE TEL (33) 1.46.88.17.00 - FAX (33)01.46.88.17.01 - [email protected]
HEAD OFFICE : Z.I du Bas Pré - BP 9 - 59590 RAISMES - FRANCE TEL (33) 3.27.22.26.26 - FAX (33) 3.27.22.26.00 - [email protected]
PROCEDURE FOR
ALUMINOTHERMIC WELDING
PROCESS
APR
ONE-SHOT CRUCIBLE
25 +/-2 mm
GAP
LUTING
PREHEATING
VERSION N° 0.4
REF MAN/S/APR/AE-AP-ACP-OP/25/LU/CJ/02-2007/OR
February 2007
Manual n° 80.20.5
Ce document ne peut être communiqué, copié ou reproduit sans notre autorisation préalable. Les données fournies sont sujettes à changement sans préavis
CONTENTS
PART I
-
PART II
GENERAL OPERATING INSTRUCTIONS
-
PART III -
PARTIE I
-
PRELIMINARY WORKS
APPLICATION - WELDING EXECUTION
GENERAL OPERATING INSTRUCTIONS
PAGE
I/ 1 -
GENERAL REMARKS
I/
I/
I/
1.1 - Quality
1.2 - Before leaving for the job site
1.3 - Safety
I/ 2 -
CHECK OF THE JOINT TO BE WELDED
I/ 3 -
IDENTIFICATION
I/
I/
I/
I/
PARTIE II
3.1 - Consumables
3.2 - Marking of the welding kit box
3.3 - Marking of the portion bag
3.4 - Marking of the mould box
-
6
6
7
8
9
10
10
12
13
13
PRELIMINIRY WORKS
II/ 1 -
ONE-SHOT CRUCIBLE
15
II/ 2 -
CHECKING THE PREHEATING EQUIPMENT
16
II/
II/
II/
II/
2.1 - Preheating with air petrol
2.2 - Preheating with propane / air-pulsed
2.3 - Preheating with propane / air-compressed
2.4 - Preheating with oxy-propane
16
17
18
19
PARTIE III
-
APPLICATION - WELDING EXECUTION
PAGE
III/ 1 -
ADJUSTING THE JOINT
III/ 1.1 - Welding gap
III/ 1.2 - Vertical adjustment
III/ 1.3 - Horizontal alignment
III/ 1.4 - Twisting of the rails
III/ 1.5 - Gap checking
21
21
21
22
22
22
III/ 2 -
MOULDS SETTING
III/ 2.1 - Briquet setting
III/ 2.2 - Moulds setting
23
23
24
III/ 3 -
LUTING 25
III/ 4 -
PREHEATING
III/ 4.1 - Air petrol preheating
III/ 4.2 - Air-pulsed propane preheating
III/ 4.3 - Air-compressed preheating
III/ 4.4 - Oxy-propane preheating
26
27
29
31
33
III/ 5 -
POSITIONING AND CRUCIBLE LOADING
35
III/ 6 -
POURING
III/ 6.1 - After preheating
III/ 6.2 - Reaction
36
36
37
III/ 7 -
UNMOULDING
38
III/ 8 -
SHEARING
39
III/ 9 -
REMOVING RISERS
40
III/ 10 - ROUGH GRINDING
40
III/ 11 - DIFFERENT WEARS
40
III/ 12 - WELD FINISHING
III/ 12.1 - End grinding
III/ 12.2 - Cleaning
41
41
41
APPENDICES
Appendices 1 -A-B-C
Appendices 2 -A-B-C-D
Appendix
3
Appendix
4
Appendix
5
Welding hardware
Preheating hardware
Specific instructions for each profile
Micro-alloyed rails
Other track equiments
42
43
46
50
51
52
FOREWORD
This manual concerns instructions for successfully carrying out the welding
process Railtech of type :
APR with One-Shot crucible
APR
PROCESS IS B A S E D O N F O U R D I F F E R E N T P R E H E A T I N G S Y S T E M S
•
:
Air-pulsed petrol preheating
or •
Air-pulsed propane preheating
or •
Air-compressed propane preheating
or •
Oxy-propane preheating
(only for rail <75 kg and standard carbone grade)
Respect the general instructions and apply the specific requirements in
accordance with your worksite and rail profile.
T HIS
DOCUMENT DOES NOT REPLACE THE RAILWAYS SPECIFICATIONS AND
SAFETY INSTRUCTIONS CONCERNING EXECUTION OF WELDING OPERATIONS
AND RECEPTION OF WORKS AND DETERMINED BY THE CUSTOMERS
PART
I
PAR
T
ART
I
GENERAL OPERATING
INSTRUCTIONS
I/ 1 - GENERAL REMARKS
I/ 1.1 - QUALITY
Quality is achieved when all precautionary measures are required at each step of the works
in progress,
CHECK
The gap value, the tolerance span limits
Joint inspection
Rail adjustent
Moulds inspection
Moulds and briquette centering
Luting
Burner positioning
Preheating time
Preheating pressures
Portion and its correct composition
Crucible inspection
Crucible centering
Tapping time
Unmoulding time before shearing
Adjusting shear blades
Cooling time
Final grinding
It is recommended to carry out the weldings at a temperature over > -5 °C.
If the temperature is under this limit we get gas characteristics (flow/pressure) unappropriate
to achieve the expected quality level.
In Wet Weather :
All consumables (crucible, moulds, ...) and hardware
as weel as the work site should be carefully protected from rain.
I/ 1.2 - BEFORE LEAVING FOR THE SITE
Make sure that the operator disposes of the equipment necessary for the performance of the
works and more particularly :
Enough Kits to perform all welds and check if the portions are appropriate
to the profiles to weld and to the types of welds (See § I/ 3 - Identification)
Check the condition of the preheating equipment and if there are enough
consumables (not less than four cylinders in any case), connection,
flexibles joints, hoses, manometer, pressure reducers in perfect condition.
Complete set of hardware (base plate, jackets, mould clamp, ...(See
Appendix 1 - Welding hardware)
Control tools : straight edge, wedges, chronometer, gauge, ...
Procedure or welding draft in force on the network
The necessary equipment to prepare and to finish the welds : frame
aligners, grinding machine, and the necessary expendable (oil, petrol,
grinding disks, ...)
The tools necessary to perform small repairs such as hoses, etc...
Safety equipment (goggles, gloves, ...), safety signs and so on....
PART
I
I/ 1.3 - SAFETY
Welding includes all the usual risks to be found in on-site work.
The personal safety equipment is must be worn at all welding times
Fireproof industrial clothing
Leather gloves
Fireproof gloves
Safety shoes
Leggings
Safety goggles with side protections agains sparks (plain glasses)
Welder's goggles (protection glasses)
.... Consult the safety regulations in force in your network
(ex : Work within the track, warning band, fluorescent waiscoat, ...)
Bars are lying on shims separated by approx. 100 mm under the rail foot and by 200 mm from
each side of the joint to be welded. Protect the rubber pad under the rail (close to the weld) if
there is one.
200
200
100
100
25 mm
Clean (remove the grease) and brush rail ends in order to eliminate all traces of oxydation
(«rust»). A poorly cleaned rust deposit can cause compacity defects and porous areas ;
Check the dimensional quality (geometry, worn out places, ...) and note the anomalies ;
Check if there are no cracks (rail cutting where necessary) ;
Check if there are burr which can affect the correct positioning of the moulds (grinding where
necessary)
The gap shall be from 23 mm to 27 mm (25 +/- 2 mm)
In order to obtain this gap, it may be necessary to cut the rails. In this case use only a rail
saw. Strictly follow the safety instructions (notice) concerning the use of your saw.
It is strictly forbidden to weld directly on rail ends cut by means of a torch.
When the rail is cut in two times, the difference between the two planes which correspond to
the two cuts must not exceed 1,5 mm. Use equipment in good condition, correctly attached
to the rail, so as to obtain clean cutting surfaces within the squareness required.
CAUTION !
The cut shall then be carefully cleaned to remove all traces of rust
which can be of a consequence in welding quality.
PART
I
I/ 2 - CHECK OF THE JOINT TO BE WELDED
I/ 3 - IDENTIFICATION
I/ 3.1 - CONSOMABLES
I
M
P
O
R
T
A
N
T
In order to avoid any lack of the products necessary of the welding operation on
site all products are contained in a same package which is called KIT. To insure
full tightness of the kit it is protected by a plastic film.
Opening the kit : it is important to check if the original packaging has been
preserved, if it is correctly closed and shows neither deformation nor moisture
spots.
Only use the portion supplied in one kit only. Never
mix the components of 2 different kits available for
o t h e r g r a d e s o r p r o f i l e s.
Never use a torn open or defective bag. Do not add
anything else. Never mix 2 welding portions.
The kit consists of :
2 half moulds
1 briquet
1 plug
1 portion bag (plastic) watertight
PART
I/ 3.1.1 - KIT
I
I/ 3.2 - KIT MARKING
Kit marking has the following indications on the box
- on the one hand the tracing of the product
Preparation date
/
Item Code
30 JANV 2005
/
XXXXXXXX
- and on the other hand the use of the product : profile and the weld
type (process, gap, grade)
LUTING MOULDS KIT
Profile
Moulds
BURBACH N6 A120
Portion Process
606
APR CJ
Process
APR CJ
Gap
Grade
25
W
Batch
5V9630
The references indicated on the snapset adhesive label shall be kept for
tracing of the weld.
Item code
Process
/
xxxxxxxx
/ 606 APR CJ 25 W
Preparation date
30 JANV 2005
/
/
Batch
5V9630
I/ 3.4 - MOULDS MARKING
The mark of the mould packaging includes the following informations :
Profile
Moulds
BURBACH N6 A120
Process
APR
Date
Gap
25
Operator
30.01.05
35
Item code
xxxxxxxx
PART
I
I/ 3.3 - PORTION MARKING
II
PART
PRELIMINARY WORKS
II
PAR
T
ART
Some operations are relatively long but they are very important
to insure final welding quality and safety working conditions.
Therefore the welder shall takes all measures
for a right performance o the weld.
II/ 1 - ONE-SHO
T CR
UCIBLE
ONE-SHOT
CRUCIBLE
The one-shot crucible is made from a refractory compound by means of a resin .
It can be used as such and does not require any preparation. The fusible component
allowing the automatic tapping is placed during fabrication.
However to keep good safety conditions and quality it is absolutely necessary to check :
the original packing
the crucible is not damaged or wet
the crucible should be stored in standing
position in a dry place and free of moisture
the automatic tapping is not damaged
S a fe t y
In the exhaust of non tapping
The melting steel flows through the safety valve.
The crucible is then pulled out with the special fork. Never remove the crucible
manually.
In the exhaust of non tapping of the safety valve or crucible
Leave the crucible in its position still self destruction
II/ 2 - EXAMIN
ATION PRIOR TO
EXAMINA
PREHEA
TING
PREHEATING
II/2.1 - AIR PULSED PETROL PREHEATING
Preheating is performed by means of an air-pulsed petrol burner and a preheating set.
Check quantity of pretrol and correct oil level according to the instructions of the
manufacturers
Check the belt
Check the correct general condition of the set
Check air and petrol hoses connecting the tank and the surpressor
Check regulator is in good condition and pressure is adjusted 0,30 bar on the
manometer
II/2.3.2 - Burner checking
The nozzle walls can scale after a moment and it is necessary to remove those
scales.
Oxidation due to rail joint preheating damage the burner in such a way that the
opening base can be out of round. Therefore, the “air-petrol compound” coming
out is not enough concentrated inside the mould. The combustion conditions are
wrong and it is necessary to change the burner.
PART
II/2.3.1 - Before preheating
II
The engine of this group drives an air blower by means of a belt. This air blower pressurizes
the petrol tank. It supplies the air necessary to the burner's pulsed air-petrol combustion.
II/2.2 - AIR-PULSED PROPANE PREHEATING
The preheating is performed with a burner equipped with conventional valve, fed with airpropane.
The engine of this group drives an air blower by means of a belt. It supplies the air necessary
to the burner's pulsed air-propane combustion.
Check quantity and correct level of oil according to the instructions of the
manufacturers
Check the belt
Check the preheating is group is in perfect condition
Check air and propane hoses connecting the cylinder and the surpressor
Check regulator is in good condition and pressure is adjusted 0,30 bar on the
manometer
The nozzle walls can scale after a moment and it is necessary to remove those
scales.
Oxidation due to rail joint preheating damage the burner in such a way that the
opening base can be out of round. Therefore, the “air-propane compound”
coming out is not enough concentrated inside the mould. The combustion conditions are wrong and it is necessary to change the burner
II/2.3 - AIR-COMPRESSED PROPANE PREHEATING
The preheating is fedby the network or by a compressor and a propane cylinder.
Air-compressed and propane gas are directly connected to the burner where both
components are mixed.
II
The burner consists of a warming up chamber, a nozzle equipped with two
convergent openings and two setting taps for compressed air and propane flow
setting.
Check good general conditions of the set
Check hoses are not damaged
Propane cylinder must be checked to ensure that there is enough
propane for full duration of preheating procedure
Check regulator is in good condition and pressure is adjusted 1 bar
The nozzle walls can scale after a moment and it is necessary to remove
those scales.
Oxidation due to rail joint preheating damage the burner in such a way
that the opening base can be out of round. Therefore, the “air-compressed / propane compound” coming out is not enough concentrated
inside the mould. The combustion conditions are wrong and it is necessary
to change the burner.
PART
II/2.4 - OXY-PROPANE PREHEATING
IMPORTANT
This preheating is only possible for rail weight under 75 kg and for standard
carbone grade only.
The preheating is fed with a blowpipe, equipped with propane and oxygen hoses by
two pipes which are 10 mm in diameter and 10 m long under pressure.
II/2.4.1 -Safety measures before preheating set starting
Check gas cylinder are full enough to ensure a full duration of the
preheating procedure
Check the blowpipe is in good general condition
Check the regulator to obtain a good flame. The darting flame shall be
maintained of 15 to 25 mm
Check the hoses,
Check cylindres are in correct vertical position.
PAR
T III
ART
PERFORMANCE
PART
III
WELDING PERFORMANCE
III/ 1 - ADJUSTING THE JOINT
This adjustment is especially important because
it determines the geometric quality of the welding and insure its lifespan
III/ 1.1 - WELDING GAP
This is distance between two rails ends.
25 +/- 2 mm .
This space is measured with a graduate gauge on both
25 +/- 2 mm
sides of the rail, at the rail head and base, that is to say at
4 different places.
The limit values of the four measurements taken must fall
within the tolerance span determined above.
The wrong squareness shall not exceed a value of 1,5 mm
measured to the gap and remain within the limits of it.
III/ 1.2 - VERTICAL ALIGNMENT (PEAK)
The rails shall show a peak before welding. This peak is absolutely necessary
because it equilizes metal shrinking after cooling.The value of the peak must be
adjusted by the welder, depending on the track.
The importance of the slope shall be measured after finishing grinding. The railway
company shall indicate the final angle.
The rails shall never show hollows
Measurements approximatively 50 mm from the ends of the straight edge
0,5 to 1 mm
Straight edge 1 m
0,5 to 1 mm
III/ 1.3 - TWISTING OF THE RAILS
Check with the briquet the vertical angle of both
rails
Place the briquet under rail bases and see if
there is full contact.
III/ 1.4 - HORIZONTAL ALIGNMENT
Check the inside face of the rail
The 1 m straight edge shall have a full contact over its whole length
Check if the gap has kept its original shape
The gap must remain in the values of 25 +/- 2 mm
PART
III
III/ 1.5 - GAP CHECKING
III/
2 - MOULDS SETTING
III/ 2.1 - BRIQUET SETTING
Place the briquet in the bottom plate (check if
there is full contact).
Luting paste shall be applied into the two recesses on
either side of the briquet.
Cut the paste in excess ; the upper surface of the paste
layer shall exceed the upper surface of the briquet.
Place the bottom plate set under the rail and centre it
in relation to gap and rail.
Place the thumbs srew to the field side of the rail
and tighten the screws against the rail
Check the full contact of the bottom plate with the
rail
Fit each side plate into its half mould.
Center it in relation to the gap axis.
Place the second half mould
Tighten the whole with the clamp (don't break
the mould by too strong tightening)
Two moulds must be perfectly aligned
After clamping we recommend to cover the
top of the moulds with cardboard to prevent
any material falling into the moulds.
PART
III
III/ 2.2 - MOULDS SETTING
III/ 3 - LUTING
.
Apply a strip of luting paste into all the
recesses around the perimeter of the rail,
moulds joints, including the bottom of the
base.
Level carefully the paste exceeding the
higher lever of the bottom briquet.
After luting
Place the crucible support on the
moulds
III/ 4 - PREHEA
TING
PREHEATING
The good execution of preheating is essential for the lifespan of
the weld. It is thus compulsory to respect carefully the
specifications described below.
Preheating is an opreration of major importance. Its function
lies in the elimination of residual moisture from the moulds and
in a temperature increase of both rails and moulds.
With APR process the preheating can be achieved following different
possibilities.
Railtech recommends to preheat all APR welds with air pulsed petrol, air pulsed
propane or air compressed propane.
The oxy-propane preheating is nevertheless possible if rail weight is under 75 kg
(maximum A 100 and MRS 73) and for standard carbone grade only.
Air pulsed petrol preheating
(§ III/ 4.1)
or
Air pulsed propane preheating
(§ III/ 4.2)
or
Air compressed propane preheating (§ III/ 4.3)
or
Oxy- propane preheating
PART
III
(§ III /4.4)
Apply the specific requirements in accordance with your preheating type
III/ 4.1 - AIR PULSED PETROL PREHEATING
We recommend to operate with :
1 preheating unit
1 petrol hose 5 m Ø 20 mm
1 burner
III/ 4.1.1 - Preheating adjusment
Place the burner in its support and centre it in the
middle of the moulds. The lower part of the nozzle
must be placed 50 mm above the running surface
of the rail.
The nozzle must be centered in the middle of the
moulds according to the gap and the middle axis
of the rail.
Not damage the inner surfaces of the moulds
with the nozzle (to avoid sand fall).
III/ 4.1.2 - Burner lighting
Start the preheating unit
Open pretol tap
Light the torch and put it on the moulds aside the
burner (until the air petrol mixture in the moulds is
ignited).
Remove the torch and put it back in its cover
Adjust the air petrol flow to obtain a correct carburation (See instructions of the
unit manufacturing ), get blue flames at the exhaust of the burner and yellow
flames at the exhaust of the pipes (length : 10/15 cm)
Place the plug near an exhaust, its upper face against the flame in order to
warm it up (take care not block up the exhaust).
III/ 4.1.3 - Preheating time
During the preheating, check the colour of the rail ends by taking off the
burner from its support. The temperature of the rail must reach 850°C to
900°C
III/ 4.1.4 - Burner removing
Once the preheating is completed,
respect strictly the safety instructions :
1) Turn off the taps on the petrol tank
2) Wait for flame extinguishing
3) Stop the engine
III
During this preheating time prepare the crucible (voir § III/ 5)
PART
III/ 4.2 - AIR PULSED PROPANE PREHEATING
We recommend to operate with :
1 preheating unit
1 propane cylinder
1 burner
III/ 4.2.2 - Fitting the burner
Place the burner in its support and centre it in the
middle of the moulds. The lower part of the nozzle
must be placed 50 mm above the running surface
of the rail.
The nozzle must be centered in the middle of the
moulds according to the gap and the middle axis
of the rail.
Not damage the inner surfaces of the moulds
with the nozzle (to avoid sand fall).
III/ 4.2.2 - Lighting the burner
Start the preheating unit
Open propane tap
Light the torch and put it on the moulds aside the
burner (until the air propane mixture in the moulds
is ignited).
Remove the torch and put it back in its cover
Adjust the air propane flow to obtain a correct carburation (See instructions of
the unit manufacturing ), get blue flames at the exhaust of the burner and yellow
flames at the exhaust of the pipes (length : 10/15 cm)
Place the plug near an exhaust, its upper face against the flame in order to
warm it up (take care not block up the exhaust).
900°C
III/ 4.2.4 - Burner removing
III
1) Turn off the propane tap
2) Wait for flame extinguishing
3) Stop the engine
PART
III/ 4.3 - AIR COMPRESSED PROPANE
we recommend
1 burner
1 propane cylinder
1 regulator propane
1 propane hose 10 m Ø 10/17 mm norm NFT 47
1 hose 5 m Ø 20 mm
1 compressor
III/ 4.3.1 - Setting the burner
Place the burner in its support and centre it in the middle of the moulds. The lower part of
the nozzle must be placed 50 mm above the running surface of the rail.
The nozzle must be centered in the middle of the moulds according to the gap and the
middle axis of the rail.
Not damage the inner surfaces of the moulds with the nozzle (to avoid sand fall).
III/ 4.3.2 - lighting the burner
Open slightly the propane valve
Light the torch and place it under the burner to ignite the mixture
Place the torch on the moulds near to the burner
Open progressively and in the same time the propane tap and air-compressed tap
until the burner is ignited.
Adjust the flow to obtain correct carburation, a yellow flame of approx. 10 to 15 cm
Remove the torch
Place the plug by the exhaust with the upper side against the flame.
(take care not block the exhaust).
burner from its support. The temperature of the rail must reach 850°C
to 900°C
III/ 4.3.4 - Completion of preheating
1) First turn the propane feed off
2) Then the air-compressed feed
If there is backfire (whistling),
turn off propane feeding at once
III
PART
III/ 4.4 - OXY PROPANE PREHEATING
We recommend :
1 blowpipe
1 flash back arrestor oxygen
1 flash back arrestor propane
1 collar
1 regulator oxygen
1 regulator propane
10 m oxygen hose Ø 10/17 mm norm NFT 47
10 m propane hose Ø 10/17 mm norm NFT 47
III/ 4.4.1 - Blowpipe fitting
Fit the blowpipe in its support and centre the nozzle in the middle of the moulds.
The distance between the end of the nozzle and the rail top is 50 mm (d).
Remove the blowpipe from its support. Not
damage the inner surfaces of the moulds with
the nozzle (to avoid sand fall).
d
III/ 4.4.2 - Lighting the blowpipe
At first open the oxygen tap and then propane tap
Adjust progressively the gas flow until taps are completely open
The manometer of the propane and oxygen cylinders must indicate respectively
0,4 bar (6 PSI) and 1,5 bar (22 PSI).
The darting flame must be included within 15 mm and 25 mm
Propane and oxygen pressures must be maintained
throughout the duration of the preheating
Caution : low temperatures
After blowpipe lighting gas exhaust shall be regular and symmetric at both side pipe
in order to get 40 cm flames at the exhaust.
Place the plug by the exhaust with the upper side against the flame.
(take care not block the exhaust).
900°C
III/ 4.4.4 - Blowpipe removing
Remove the blowpipe and take care not to damage the inside of the moulds,
First turn the propane feed off and then the oxygen feed
If there is backfire (whistling),
turn off propane feeding at once
III
PART
III/ 5 - ONE-SHO
T CR
UCIBLE L
OADING
ONE-SHOT
CRUCIBLE
LO
Open the bag and pour the portion into the one-shot
crucible
Place the crucible by the working area
Place the ignitor in the portion ready to use,
Place the CJ fork near the work area.
Caution!
I
M
P
O
R
T
A
N
T
• It is important that only use the welding portion delivered with the
kit. Never mix the contents of
two different kits (never use
moulds from one kit, the welding portion from another, the
thimble from a third, etc ...). Never use a welding portion bag that
is gutted or incomplete. Do not add anything. Never mix two
welding charges.
• Never use a damaged or cracked crucible
• Always use the fork provided for this purpose (never manually)
III/
6 - POURING
Where welding in wet weather :
All consumables must be kept dry and wet rails dried prior welding
III/ 6.1 - AS SOON AS THE PREHEATING IS OVER
Put the plug into its lodging with the pliers provided for this purpose and slightly
drive it
III
No waste time between completion of the preheat and starting the reaction
PART
CAUTION !
III/ 6.2 - REACTION
The crucible is placed and centered on top of the
moulds.
Light the ignitor by contact with inside mould wall.
Don't dip the ignitor too much, only stitch it into the
portion (3 cm). Tapping time is affected by too long. The
measured values can be under the min. value i.e 17 seconds.
Put on the crucible cover
The reaction develops in a few seconds and the pouring will
automatically take place at reaction competion (if no tapping
see II/1).
Tapping time lasts from 17 to 27 seconds (from insertion of
the ignitor until the crucible taps). (conf. § II/ 1).
Tapping may be observed from the small gap between the
moulds and the one-shot crucible
The crucible is then removed with the fork to a safe position
The crucible support can then be removed
III/
7
- UNMOULDING
It is absolutely necessary to remove the mould before shearing
Time of equipment and mould removal
depends on the profile
Conf appendix 3
Specific to micro-alloyed rails
(see appendix 4)
Do not take off the base plate sand
Shear the upper part of the moulds with the
III
hot cut chisel and check the steel has set.
do not unmould if the steel has not set.
PART
Caution !
III/
8 - SHEARING
Shearing is performed when the weld is enough hard
Mould sand and loose paste must be be cleaned from the rail head each
side of the weld, by wire brushing.
Begin the shearing operation by running surface, rail head and risers.
There are two operating ways
hydraulic shearing with flat blades ; the connections and the rail base
exhausts shall be trenched or cut off with a sledge hammer
or
pneumatic shearing with a chipper or self hardening chisel with which it is
possible to carry out the three operations
It recommended to use a shearing machine instead of sledge hammer or hot cut chisel.
A shearing machine insures a better welding aspect.
Controlled cooling (appendix 4)
The weld for micro alloyed rails required controlled cooling :
Put the cooling retarder cap on the running surface immediately after
shearing, and let the maximum of sand around the web and base during
this operation
Kept it on for 8 minutes.
Retarder cap :
running surface ≤ 80 mm
running surface > 80 mm
Ref 82620500
Ref S0000262
III/ 9 - REMO
VING RISERS
REMOVING
There are two operating ways to remove the risers :
use an electric disk equipped with a disk allowing cold or hot shearing of the
risers
or
begin with hot notching. This operation shall be performed quickly after
shearing, if not metal is too hard. After notching break the risers.
III/ 1
0 - ROUGH GRINDING
10
rough grinding of the running surface of the rail shall be performed with a
approved surface grinding wheel.
No excess metal thickness greater than 0,5 mm
III/ 1
1 - DIFFERENT WEARS
11
For a weld realised with two rails which have different wear, do not forget to put some
support under the rail which have the maximum wear to avoid having a gap under this
one and therefore decreasing the life of the weld.
PART
III
Rough grinding of the rail head portion of the welding can be performed after shearing
or hot cutting is completed
III/
1
2 - FINISHING WELDING
12
III/ 12.1 - FINISH GRINDING
It is meant to get rid of any geometrical discontinuity due to welding. This
operation enables the weld to be checked up.
It may only take place after the welded section has been used several
times on traffic.
III/ 12.2 - CLEANING
Remove any remanant sand or felt
Remove all burrs with a grinding wheel
Grind down all burrs resulting from various parts that have been taken
away (risers, ...)
A ppendices
Appendices 1 -A-B-C
Welding hardware
Appendices 2 -A-B-C-D Preheating hardware
Appendix
3
Specific instructions
for each profile
Appendix
4
Micro-alloyed rails
Appendix
5
Other equipment
APPENDIX 1 - A
WELDING HARDWARE
Data
Ref
Bottom plate
(with 4 thumbs screws)
83100010
Thumb screw
83100011
Set of side plates
83100001
Plug tools
83432920
Ignitor box (100)
82632450
Gauge
S0000150
APPENDIX 1 - B
CJ
HARD
W ARE
HARDW
One-shot crucible
Conf appendix 3
Clamp assembly for CJ
81250701
CJ support
S0000182
CJ Fork
82631410
APPENDIX 1 - C
LUTING
LUTING MOULDS
Container of paste (10 kg)
83661130
WORN RAIL
Felt box (30)
83661115
APPENDIX 2 - A
PREHEATING
AIR PULSED PETROL PREHEATING
1
2
Burner
part1
part2
Hose length 5m Ø 20 mm
Preheating unit GP 40
Ref 11211020
Burner support
A45
to
A75
A100 to
A150
Torch
Ref S0000166
Ref S0000167
Ref 39960002
Ref 21214001
Ref 21214002
Ref S0000146
APPENDIX 2 - B
AIR PULSED PROPANE PREHEATING
1
2
Burner
part 1
partie 2
Propane hose 10 m
Propane regulator
Hose length 5m Ø20 mm
Preheating unit GP 40
Ref 11211019
Burner support
A45
to
A75
A100 to
A150
Torch
Ref
Ref
Ref
Ref
Ref
S0000166
S0000167
39960003
48102016
39960002
Ref 21214001
Ref 21214002
Ref S0000146
APPENDIX 2 - C
AIR-COMPRESSED PROPANE PREHEATING
Air compressed propane burner
Hose propane 10 m Ø10/17 mm norm NFT 47
Regulator propane
Flash back arrestor propane
Ref 11212013
Ref 39960003
Ref 48102016
Ref 48302028
Burner support
A45
to
A75
A100 to
A150
Ref 21214001
Ref 21214002
Torch
ReF S0000146
APPENDIX - D
OXY PROPANE PREHEATING
1
2
BLOWPIPE
part 1
part 2
Ref 11231007
Ref S0000232
Propane hose 10 m Ø10/17 mm norm NFT 47
Oxygen hose 10 m Ø10/17 mm norm NFT 47
Ref 39960003
Ref 39960006
Propane regulator
Oxygen regulator
Ref 48102016
Ref 48102015
Propane flashguard
Oxygen flashgard
Ref 48302028
Ref 48302029
Ref 48302006
Ref 48302005
Propane flash back arrestor
Oxygen flash back arrestor
collar (x4)
Ref 48301073
Burner support
A45
to
A75
A100 to
A150
Gas lighter
Ref 21214001
Ref 21214002
Réf 48402002
APPENDIX 3
SPECIFIC INSTRUCTIONS FOR EACH PROFILE
Ref KIT
Ref
CJ
Profile
unmoulding
after casting
Weight
(m)
(A) mm
(B) mm
(C) mm
D (mm)
(min)
71140001
83450116
N° 1 A 45
3-4
22.10
45.00
125.00
55.00
24
71140002
83450116
N° 2 A 55
4-5
31.80
55.00
150.00
65.00
31
71140003
83450116
N° 3 A 65
5-6
43.10
65.00
175.00
75.00
38
71140004
83450116
N° 4 A 75
7-8
56.20
75.00
200.00
85.00
45
71140005
83450116
N° 5 A 100
8-9
74.30
100.00
200.00
95.00
60
71140006
83450113
N° 6 A 120
8-9
100.00
120.00
220.00
105.00
72
71140008
83450113
N° 7 A 150
9 - 10
150.30
150.00
220.00
150.00
80
71147021
83450116
MR 77
8-9
77
100.00
200.00
100.00
60
71147001
83450113
MR 151
9 - 10
150.30
150.00
220.00
150.00
80
71147012
83450116
MRS 51
8-9
51.59
63.50
127.00
127.00
25.4
71147010
83450116
MRS 52
8-9
52.09
65.09
131.76
131.76
23.81
71147002
83450116
MRS 67
8-9
66.97
87.31
131.76
146.05
31.75
71147013
83450113
MRS 73
8-9
73.63
70.00
146.00
157.00
32
71147014
83450113
MRS 85
8-9
84.83
109.22
152.40
152.40
31.75
71147011
83450113
MRS 86
8-9
85.53
102.00
165.00
102.00
80.3
71147009
83450113
MRS 87 A
8-9
86.80
101.60
152.40
152.40
34.93
71147003
83450113
MRS 87 B
8-9
86.80
102.40
152.40
152.40
38.1
71147007
83450113
MRS 125
9 - 10
125.00
120.00
180.00
180.00
40
71147022
83450116
BS 56
7-8
56.00
76.00
171.00
101.50
35
71147020
83450116
BS 89
8-9
89.00
102.00
178.00
114.00
51
71147016
83450113
BS 164
9 - 10
164.00
140.00
230.00
150.00
75
71147023
83450116
KP 70
8-9
52.00
70.00
120.00
120.00
28
71147024
83450116
KP 80
8-9
63.00
87.00
130.00
130.00
32
71147006
83450113
KP 100
8-9
90.00
108.00
150.00
150.00
38
71147008
83450113
KP 120
9 - 10
118.00
129.00
170.00
170.00
44
APPENDIX 4
SPECIFIC INSTRUCTIONS
FOR MICRO ALLOYED RAILS
(320 CR GRADE)
Ref KIT
Ref
CJ
Profile
time(min)
preheating *
Weight
unmoulding
(m)
(A) mm
(B) mm
(C) mm
D (mm)
after casting
71140010
83450116
N° 2 A 55
6
4-5
31.80
55.00
150.00
65.00
31
71140011
83450116
N° 4 A 75
12
7-8
56.20
75.00
200.00
85.00
45
71140005
83450116
N° 5 A 100
16
8-9
74.30
100.00
200.00
95.00
60
* with good general conditions of the set
RETARDER CAP :
running surface ≤ 80 mm
Ref 82620500
running surface > 80 mm
Ref S0000262
APPENDIX 5
TRACK EQUIPMENT
TOOLS
ITEM
QTY
REF
Wire brush
1
48401004
Electronic timer
1
48703001
Plug holder
1
83432920
Hot cut chisel 5 kg
1
48401110
Ballast fork 9 dents
1
48401050
Adjustable plier 0 to 46
1
48401131
Adjustable spanner 0 to 30
1
48401010
Set of srewdrivers ATH 8
1
48401015
Set of 5 flat spanner
1
48401130
Tool box
1
48401008
Hand hammer
1
48401013
Hammer
1
48401005
Set of number punch
1
48409002
Set of letter punch
1
48409003
Set of gauges
1
48701005
Waste box
1
11319002
Copper hammer
1
48401014
Metal jerrican 20 litres
2
48401052
Metal jerrican 5 litres
2
48401051
Funnel
2
48409001
Tarpaulin
1
19311001
ADJUSTMENT OF RAILS
ITEM
QTY
REF
2
14221022
6
47901024
Straight edge 1 m
1
19123001
1m bevelled straight edge
1
19123002
HC 355 rail saw
Disc 355 x 3,6 x 25,4
Gauge tie rods for curve radius < 350 m
1 pair
Wooden edge
20
11114002
Lifting rail device for peak adjusment
2
11115002
QTY
REF
Marteau burineur
1
11321002
Chisel
1
11322001
Shearing machine
1
11333001
1 pair
11335015
Hydraulic unit with Honda engine
1
19511007
Hot cut chisel
2
11311001
Foot riser cold cutter
1
11311002
Sledge hammer
1
48401109
SHEARING
ITEM
Blades
GRINDING
ITEM
Or
QTY
REF
Pneumatic grinding
1
14314001
Flexible grinding machine
1
or
Flaxible shaft Lg 4,5 m
1
14341002
Rapid coupling
1
14342002
grinding lapidary head
1
14343013
disc guard 115 x 50
1
14343006
Grinding wheel 115 x 50
1
47901006
Disc guard 150 x 40
1
14343007
Grinding wheel 150 x 40
1
47901009
QTY
REF
SAFETY EQUIPMENT
ITEM
Leather gloves
1
48801002
Fireproof gloves
1
48801003
Safety shoes
1
Leggings
1
48801004
Welding goggles with tinted glass
1 pair
48802001
Safety goggles, clear glass for grinding
1
48802003

ONE-SHOT CRUCIBLE

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