Welding technique

Optimization of procedures
DI Gregor Girsch MBA
gregor.girsch@voestalpine.com

voestalpine Schienen GmbH

www.voestalpine.com
Welding technology
Good weldability is a MUST for the use of rail steels
Joint welding Flash Butt (FB); Aluminothermic (AT)
Repair welding

Targets for process optimization

High hardness to avoid dipping
Tighten Heat Affected Zone
Good results in bending-, hardness-tests and microstructures (no martensite)

Close cooperation between Elektro-Thermit and voestalpine Schienen for

development of AT welding procedures

Optimization of FB welding processes together with customers

Development of easy repair welding procedures

voestalpine Schienen GmbH

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 AUSTRALIA
Welding issues
Plastic deformation and break outs

AT-weld

breaks

dipping
Spalling in HEZ (FB weld)

voestalpine Schienen GmbH

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„Squats“ on welds

voestalpine Schienen GmbH

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FB welding optimization
No forced cooling for premium rail steels to avoid martensite formation
Adaption/Optimization of welding parameters (e.g. pre and post heating
impulses)

Further measures: web grinding, post heating

voestalpine Schienen GmbH
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Welding
FB weld production
Visit, inspection of FB welding procedure and recommendations in 2009
Common visit at FB plant (not working) in Aug 2011
Common detailed inspection and elaboration of optimization
recommendations for existing and planned new welding equipment in
beginning of 2012 (VALE+TTCI+VAS)
Feedback on VALEs quality procedure for FB welds
FB welds in track – issue with RCF “Squats”
Analysis of FB samples with RCF (metallographical)
Investigation on changes in operation and track characteristics at VALE
reasons
Exchange information and work on solution concepts with partners
Test welds and installation and observation in track (“weld test sites”)
voestalpine Schienen GmbH
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 AT welding technology
HPW – High Performance Weld
Technology: Container with alloying elements attached to plug.
Dissolving of alloying elements in head High hardness

380 - 420 HB
360 - 380 HB
340 - 360 HB

300 - 320 HB

Same base portion for all rail grades only different plug for each grade!
voestalpine Schienen GmbH
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