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AS 1085.15-1995 Railway permanent way material - Aluminothermic rail welding

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Date: 13 Feb 2005

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rail welding
Australian Standard

Part 15: Aluminothermic

Railway permanent way material
AS 1085.15—1995
 This Australian Standard was prepared by Committee CE/2, Railway Permanent Way
Materials. It was approved on behalf of the Council of Standards Australia on
28 October 1994 and published on 5 April 1995.

The following interests are represented on Committee CE/2:

Bureau of Steel Manufacturers of Australia
Cement and Concrete Association of Australia
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Rail Track Association Australia

Railways of Australia Committee

Review of Australian Standards. To keep abreast of progress in industry, Australi an Standards are subject
to periodic review and are kept up to date by the issue of amendments or new editi ons as necessary. It is
important therefore that Standards users ensure that they are in possession of the latest edit ion, and any
amendments thereto.
Full details of all Australi an Standards and related publications will be found in the Standards Australia
Catalogue of Publi cati ons; this informati on is supplemented each month by the magazine ‘The Australi an
Standard’, which subscribing members receive, and which gives details of new publi cati ons, new edit ions
and amendments, and of withdrawn Standards.
Suggesti ons for improvements to Australian Standards, addressed to the head offi ce of Standards Australi a,
are welcomed. Noti fi cati on of any inaccuracy or ambiguity found in an Australian Standard should be made
without delay in order that the matter may be investigated and appropriate action taken.

This Standard was issued in draft form for comment as DR 94211

 AS 1085.15 —1995

Australian Standard
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Railway permanent way material

Part 15: Aluminothermic

rail welding

First published as AS 1085.15—1995.

Incorporating:
Amdt 1—1997

PUBLISHED BY STANDARDS AUSTRALIA

(STANDARDS ASSOCIATION OF AUSTRALIA)
1 THE CRESCENT, HOMEBUSH, NSW 2140
ISBN 0 7262 9422 5
 AS 1085.15— 1995 2

PREFACE

This Standard was prepared by the Standards Australia Committee on Railway Permanent
Way Materials.
The objective of this Standard is to provide Australian railway authorities with requirements
for the supply of aluminothermic welding materials for steel rail.
The terms ‘normative’ and ‘informative’ have been used in this Standard to define the
application of the appendix to which they apply. A ‘normative’ appendix is an integral part
of a Standard, whereas an ‘informative’ appendix is only for information and guidance.

CONTENTS
Page
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1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. .. ... ............ 3

2 REFERENCED DOCUMENTS . . . . . . . . . . . . . . .. .. ..... ..... ... .. .. .. 3
3 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . .. ... .. .. .. .. ... ....... 3
4 DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . .. . ... .. .. .. .. ... ...... 5
5 GENERAL REQUIREMENTS . . . . . . . . . . . . . . .. ........... ... .. .. .. . 5
6 TESTING AND COMPLIANCE . . . . . . . . . . . . . .. .... ... ...... ... .. .. . 7

APPENDICES
A PURCHASING GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
B MEANS FOR DEMONSTRATING COMPLIANCE WITH THIS STANDARD . 17
C FATIGUE TEST FOR ALUMINOTHERMIC FUSION WELDS . . . . . . . . . . . . 19
D SLOW BEND TEST FOR ALUMINOTHERMIC FUSION WELDS . . . . . . . . . 23
E FLOW CHARTS FOR RETESTING PROCEDURE . . . . . . . . . . . . . . . . . . . . 25

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 3 AS 1085.15— 1995

STANDARDS AUSTRALIA

Australian Standard
Railway permanent way material

Part 15: Aluminothermic rail welding

1 SCOPE This Standard sets out the requirements for the supply of aluminothermic
welding materials for steel rail.
NOTES:
1 Guidelines to purchasers on information needing to be supplied at the time of calling
tenders or quotations are detailed in Appendix A.
2 Alternative means for determining compliance with this Standard are given in Appendix B.

2 REFERENCED DOCUMENTS The following documents are referred to in this

Standard:
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AS
1085 Railway permanent way material
1085.1 Part 1: Steel rails
1085.11 Part 11: Head-hardened rails
1199 Sampling procedures and tables for inspection by attributes
1399 Guide to AS 1199—Sampling procedures and tables for inspection by
attributes
1816 Metallic materials—Brinell hardness test
2193 Methods for calibration and grading of force-measuring systems of testing
machines
2205 Methods of destructive testing of welds in metal
2205.5.1 Part 5.1: Metallographic tests—Macro test—Cross-section examination
2205.6.1 Part 6.1: Hardness tests — Weld joint hardness test
2207 Methods for the ultrasonic testing of fusion welded joints in steels
AS/NZS
ISO 9000 Quality management and quality assurance standards
ISO 9000.1 Part 1: Guidelines for selection and use
ISO 9004 Quality management and quality system elements
ISO 9004.1 Part 1: Guidelines
SAA
HB18 Guidelines for third-party certification and accreditation
HB18.44 Guide 44—General rules for ISO and IEC international third-party
certification schemes for products
AREA Part 4: Manual for railway engineering: Rail

3 DEFINITIONS For the purpose of this Standard, the definitions below apply.
3.1 Administrative definitions
3.1.1 Approved (approval) —approved by or approval of the regulatory authority.
3.1.2 Authorized —authorized by the regulatory authority or its nominated representative.

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 AS 1085.15— 1995 4

3.1.3 Manufacturer —any persons or organization responsible for the manufacture and
supply of aluminothermic fusion weld materials, including the supplier.
3.1.4 Purchaser—any persons, organizations or regulatory authority for whom the
manufacturer has contracted to manufacture and supply aluminothermic fusion weld
materials.
3.1.5 Regulatory authority —the appropriate body or bodies legally empowered to
control the manufacture and maintenance of main line railway systems in the relevant
location and region.
3.1.6 Specified —stated in writing in any document (including orders, drawings or
specifications, or a combination of these) which forms a part, or the whole, of the contract
between the purchaser and the manufacturer.
3.1.7 Statutory authority —the appropriate body having statutory powers to control the
construction and maintenance of main line railway systems in the relevant location and
region.
3.2 Technical definitions
3.2.1 Aluminothermic welding—a welding process in which an aluminothermic reaction
takes place within a crucible and the resultant molten metal flows into a weld joint
contained by a mould. The by-product, aluminium oxide slag, is contained in a side
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receptacle.
3.2.2 Batch — the quantity of portions produced in a single production run without
change of material type, properties or quantity per portion.
3.2.3 Break load—the load at which the test weld breaks when subjected to a three-point
slow bend test as specified in Clause 6.4.1.3.
3.2.4 Closing portion — granular refractory material which glazes when subjected to the
heat of the aluminothermic reaction to seal the thimble to the crucible.
3.2.5 Cold shut—prematurely chilled pieces of metal forming unfused discontinuities
within the weld metal.
3.2.6 Consumables —material consumed in the performance of a weld (see Clause 5.2).
3.2.7 Crucibles—conical-shaped refractory, usually in a steel shell, for containing the
portion during ignition, reaction and pour.
3.2.8 Elastic response limit — the upper limit of the linear portion of the load- deflection
curve.
3.2.9 Fusion zone—penetration of the parent rail by weld metal.
3.2.10 Heat affected zone—section of the parent rail outside the fusion zone that has
mechanical properties altered by the welding process.
3.2.11 Hot tear —fracture in the weld caused by tension on the weld during
solidification of the molten metal.
3.2.12 Igniter—device, usually a special ‘ignition tape’ used to ignite the portion and
initiate the aluminothermic reaction.
3.2.13 Inclusions —slag or other foreign non-metallic matter entrapped during welding.
3.2.14 Luting material—refractory material used to seal the mould components around
the rail.
3.2.15 Mould unit—Preformed refractory receptacles that are placed around the rail at
the gap to be welded and which receive the molten metal from the crucible.
3.2.16 Porosity—cavities formed by entrapped gas during the solidification of molten
metal.

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 5 AS 1085.15— 1995

3.2.17 Portion—a prepared package containing the correct quantity of aluminothermic

powder for the type of weld to be made.
3.2.18 Pouring mode —path by which molten metal enters the mould cavity, e.g. side
pour and centre pour.
3.2.19 Proof test—mechanical testing and chemical analysis of a batch of portions as
specified in Clause 6.3 to verify conformance to specification.
3.2.20 Short head—insufficient weld metal head.
3.2.21 Shrinkage crack—crack in the weld metal occurring during solidification. It can
be on the surface or in the body of the weld.
3.2.22 Softened zone—area on heat affected zone of railhead where surface hardness is
below that of parent rail.
3.2.23 Thimble—refractory insert sealing the bottom of the crucible. Contains a fusible
insert to hold the molten metal until the aluminothermic reaction is complete and then
automatically taps the metal into the mould.
3.2.24 Type test—mechanical testing and chemical analysis of prototype weld samples.
3.2.25 Weld metal head —weld metal remaining above the head profile after
solidification.
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3.2.26 Weld process

3.2.26.1 Existing weld process—a weld process currently in use as an approved process.
3.2.26.2 New weld process—a weld process using substantial variation of rail,
consumables or heating procedure to that of any approved process.
3.2.27 Weld reinforcement — weld metal external to parent rail profile.
3.2.28 Weld type
3.2.28.1 Existing weld type—a weld type currently in use with approved shape and
physical or chemical properties.
3.2.28.2 New weld type—a weld type having substantial variation of shape, physical or
chemical properties to that of any approved type.

4 DESIGNATION
4.1 Weld types The weld types covered in this Standard shall be—
(a) SGW—standard gap weld with an initial rail gap up to and including 40 mm. It
may be supplied with or without reinforcement under rail foot, e.g. crane rail;
(b) WGW—wide gap weld with an initial rail gap of greater than 40 mm; and
(c) SJW—standard junction weld used to weld dissimilar rail sections using an initial
rail gap of up to and including 40 mm.
4.2 Weld processes The weld processes covered in this Standard shall be—
(a) LPH—long preheat process requiring a preheat temperature of 900 to 1000°C at the
rail ends prior to welding;
(b) SPH—short preheat process requiring a preheat temperature of 600 to 700°C at the
rail ends prior to welding; and
(c) other welding processes falling outside these temperature ranges which may be
considered provided they fulfil all other requirements of this Standard.

5 GENERAL REQUIREMENTS
5.1 Weld The consumables shall produce a weld having physical and chemical
properties as specified in Clause 6.

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 AS 1085.15— 1995 6

5.2 Consumables The consumables shall consist of—

(a) portion;
(b) moulds;
(c) crucible;
(d) thimble;
(e) igniter;
(f) luting material; and
(g) closing portion.
5.3 Packaging and labelling
5.3.1 Outer packaging and labelling The requirements for outer packaging and
labelling shall be as follows:
(a) All consumables shall be packed so that the total mass of each outer container shall
not exceed that specified by the purchaser to meet occupational health and safety
requirements.
(b) Consumables used to carry out an individual weld may be supplied in kit form
comprising the items listed in Clause 5.2 except the igniter which shall be supplied
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separately, and the crucible which may also be supplied separately.

(c) Outer packing must be suitable to prevent damage or loss during transport and
handling.
(d) The company identification, process and type of weld, rail profile, hardness code,
batch number, date of manufacture, expiry date (if appropriate), items and number
of units contained must be clearly marked in block letters on each outer container,
as applicable to individual items.
(e) All packaging shall comply with requirements of the relevant statutory authority for
transport of dangerous goods.
5.3.2 Component packaging and labelling The requirements for component packaging
and labelling shall be as follows:
(a) Each portion batched shall be sealed in a plastic bag or other packaging accepted by
the purchaser to prevent moisture coming into contact with the portion material, and
to prevent leakage or damage during transport and storage. It shall be clearly
marked with the following information:
(i) Company name.
(ii) Rail size or section, weld process, weld type and hardness code.
(iii) Batch number.
(iv) Date of batching.
(b) Mould units shall be supplied in a suitable container and packed with partitioning of
sufficient flexibility to protect them from breakage during transport and storage.
(c) Crucibles shall be packed in a suitable container to avoid damage during
transportation.
(d) A thimble and closing portion shall be packed and individually sealed either in the
same or separate containers or other approved packaging suitable to prevent damage
during transport. If the thimble is supplied separate to portions the packaging shall
be clearly marked with the weld process(es) it is to be used for.
(e) Igniters shall be packed in a suitable container, but because of a potential fire
hazard they shall NOT be packed with the portions.

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 7 AS 1085.15— 1995

(f) Dry luting material may be supplied either as individual packages for each weld or a
package for multiple welds in the correct quantities. Packaging shall be suitable to
prevent spillage in transit and storage.
(g) Premixed luting materials shall be supplied either as individual sealed packages for
each weld or a resealable package for multiple welds. Packaging shall be suitable to
minimize damage or drying out during transit and storage.

6 TESTING AND COMPLIANCE

6.1 General requirements
6.1.1 Approval of weld process Before commencing the production of any weld
portion, the manufacturer shall submit samples of prototype weld portion to be tested for
the approval of the relevant weld processes and types in accordance with Clause 6.2.
6.1.2 Type tests Tests as detailed in Clause 6.4 shall be conducted for type testing of
welds manufactured from samples of prototype weld portion.
6.1.3 Proof tests Apart from type testing, the manufacturer shall carry out routine proof
testing on batches of manufactured weld portions as given in Clause 6.3 to ensure
continuing compliance with this Standard.
6.1.4 Test welds All welds submitted for tests detailed in Clause 6.4 shall have weld
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metal head height recorded prior to removal and finishing by grinding to match the
rail-head profile.
6.2 Type testing —acceptance procedures
6.2.1 Procedures All testing procedures shall be drawn from the following steps, with
the number of test samples specified in Clause 6.2.2:
(a) Select random weld portions from samples submitted by the manufacturer in
sufficient number for required tests.
(b) Prepare the laboratory test welds to replicate field effects as specified by the
purchaser. Reserve remaining weld portions for conducting field test welds in track.
Rail used in test pieces shall be representative of that of the intended weld
application. Where not otherwise agreed between the purchaser and the supplier,
new rail shall be used.
NOTE: A visual inspection should be carried out on the laboratory test welds as specified in
Clause 6.4.5.
(c) Conduct a hardness test as specified in Clause 6.4.1.1 and a chemical analysis as
specified in Clause 6.4.3 on all laboratory test welds.
(d) Select random samples out of the laboratory test welds and conduct fatigue test as
specified in Clause 6.4.1.2.
(e) Conduct slow bend test as specified in Clause 6.4.1.3 on laboratory test welds
including the fatigue-tested samples from Step (d).
(f) Conduct visual inspection as specified in Clause 6.4.5 on the break faces of each
test weld in Step (e).
(g) Section the remaining weld sample and conduct macroscopic test as specified in
Clause 6.4.2 on sections of sample.
(h) Carry out field test welds in the track under manufacturer’s scrutiny by using the
reserved weld portions specified in Step (b). Conduct ultrasonic test as specified in
Clause 6.4.4 and visual inspections as specified in Clause 6.4.5 on field test weld
samples.
6.2.2 Number of test welds These shall be as shown in Table 1.

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 AS 1085.15— 1995 8

TABLE 1
NUMBER OF TEST WELDS

New weld Existing weld processes or types with

New weld processes or new rails
processes or types with
Clause Variation in rail
types minor Variation in
metal chemistry
(see Note 1) variations rail section
or UT S
(see Note 2) (see Note 3)
(see Note 4)
6.2.1(a) 11 7 10 10
6.2.1(b) 7 3 6 6
6.2.1(c) 7 3 6 6
6.2.1(d) 3 Nil 3 (optional) 3
6.2.1(e) 6 3 6 6
6.2.1(f) 6 3 6 6
6.2.1(g) 1 Nil Nil Nil
6.2.1(h) 4 4 4 4

NO TES:
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1 Figures in Column 2 apply to all new weld processes or types and when variations
are proposed in—
(a) rail metal chemistry;
(b) specified weld gap;
(c) preheat;
(d) pouring mode; and
(e) mould cavity design.
2 Figures in Column 3 apply when variations are proposed in—
(a) mould external shape or size (where cavity design is unaltered);
(b) luting material; and
(c) thimble design or material.
3 Figures in Column 4 apply when variations are proposed in—
(a) rail section; and
(b) mould material to other than predominantly sand.
4 Figures in Column 5 apply when variations are proposed in rail chemistry or in rail
ultimate tensile strength.

6.3 Proof testing of batches After the weld processes or types have been proved by
type testing, specimens from each batch of weld portions shall be randomly selected as
required to represent that batch.
The selected weld portions shall be used to prepare test welds in the laboratory to
replicate field effects as specified by the purchaser.
Each test weld shall be proof tested as follows:
(a) Hardness test as specified in Clause 6.4.1.1(a).
(b) Slow bend test as specified in Clause 6.4.1.3.
(c) Chemical analysis test as specified in Clause 6.4.3.
(d) Visual inspection test as specified in Clause 6.4.5.
NOTES:
1 In the absence of a quality system or documented procedure, specimens from each batch of
weld portions produced should be randomly selected at a frequency of 1 in 200 to represent
that batch.
2 The minimum batch size should be agreed between the purchaser and manufacturer.

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 9 AS 1085.15— 1995

6.4 Testing
6.4.1 Mechanical tests
6.4.1.1 Hardness test Hardness testing consists of the following:
(a) Weld metal hardness After the weld has been ground flush with the head of the
rail, three Brinell hardness tests shall be made on the top of the railhead,
transversely across the centre-line of the weld (see Figure 1). The Brinell tests
(HB 10/3000) shall be made using a 10 mm ball with a force of 29.4 kN in
accordance with AS 1816 and shall be at minimum intervals of four times the
diameter of the indentation.
(b) Hardness traverse After removal of surface decarburization to a maximum
grinding depth of 0.5 mm, a hardness traverse shall be taken longitudinally along
the centre-line of the top of the welded rail generally in accordance with
AS 2205.6.1. The traverse shall extend across the entire weld region including the
parent rails, heat affected zones and fusion zone.
6.4.1.2 Fatigue test Fatigue testing of the rail foot shall be in accordance with
Paragraph C2 of Appendix C. Fatigue testing of the web, when specified by the purchaser
shall be in accordance with Paragraph C3 of Appendix C.
6.4.1.3 Three-point slow bend test Slow bend tests shall be in accordance with
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Appendix D.
6.4.2 Macroscopic test The macro test is required for type testing only. The test weld
shall be sectioned longitudinally along the centre-line of the welded rail so as to include
all the heat affected zone on both sides of the weld for at least 20 mm. The macro test
shall be carried out in accordance with AS 2205.5.1.
6.4.3 Chemical analysis Where chemical analysis is required, the weld sample shall be
sectioned as shown in Figure 2 to produce a specimen for the determination of chemical
composition. The determination shall be made at the positions indicated in Figure 2.
Alternatively, a riser from a test weld may be substituted as a specimen for chemical
analysis.
6.4.4 Ultrasonic test Where ultrasonic testing is required, the field test welds shall be
tested in accordance with AS 2207, UBM-1, level 1, with the weld ground flush with the
top and sides of the head of the rail. All testing will normally be carried out from the top
of the railhead.
Angle probes of 70° and 35° with crystal size ≥20 mm2 shall be used. Scanning shall be
undertaken from positions 1 and 2 in AS 2207.
6.4.5 Visual inspection The complete weld shall be visually inspected in accordance
with Clause 6.5.5(a) and the test weld break faces shall be inspected in accordance with
Clause 6.5.5(b).
6.5 Criteria for acceptance
6.5.1 Mechanical tests
6.5.1.1 Hardness test The following shall be included:
(a) Weld metal hardness When tested in accordance with Clause 6.4.1.1(a), the
average of the hardness tests taken transversely across the centre-line of the weld
shall be within the limits given in Table 2.
(b) Hardness traverse When tested in accordance with Clause 6.4.1.1(b), the hardness
values shall be presented in graphical form as shown in Figure 3.
NOTE: The purpose of the test is to provide an indication of the width of the softened zone,
the minimum hardness in the heat affected zone and any centre-line softening. The
purchaser may choose to set limits for these at the time of ordering.

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 AS 1085.15— 1995 10
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NOTE: Y = minimum spacing as specified in Clause 6.4.1.1 (a).

FIGURE 1 HARDNESS TEST LOCATION (TRANSVERSE)

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 11 AS 1085.15— 1995

FIGURE 2 POSITION FOR CHEMICAL ANALYSIS OF WELD MATERIAL

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FIGURE 3 SCHEMATIC OF HARDNESS TRAVERSE FOR TYPE TESTING

6.5.1.2 Fatigue test When tested in accordance with Clause 6.4.1.2, the test specimen
shall be able to sustain a maximum stress of 230 MPa at rail foot for 3 × 106 cycles
without failure. The fatigue test load shall be calculated by the following equation:

. . . 6.5(1)

where
F = fatigue test load in Newtons

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 AS 1085.15— 1995 12

σ = stress at rail foot in Megapascals

= 230 MPa
W = section modulus in millimetres cubed
L = distance between supports in millimetres.
NOTE: The test covered by this Clause examines rail foot fatigue failure. Other fatigue failure
modes can be examined by other methods.
6.5.1.3 Slow bend test When tested in accordance with Appendix D, the break load
recorded and the load at limit of elastic response shall be within the limits given in
Table 2.
6.5.2 Macroscopic test When tested in accordance with Clause 6.4.2 the specimen shall
comply with the requirements of Table 3.
6.5.3 Chemical analysis When tested in accordance with Clause 6.4.3, the chemical
composition of the weld metal shall be within the following limits:
(a) Aluminium (Al) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 to 0.65%
(b) Chromium (Cr) . . . . . . . . . . . . . . . . . . . . . . . . 0.2% max. (for plain carbon steel)
(c) Phosphorus (P) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06% max.
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(d) Silicon (Si) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5% max.

(e) Sulphur (S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06% max.
NOTES:
1 If the analysis is carried out spectrographically, all other elements should be reported.
2 For alloy rails, the chromium limit should be agreed between the purchaser and the supplier.
6.5.4 Ultrasonic test When tested in accordance with Clause 6.4.4, the weld shall
conform to the relevant purchaser’s acceptance criteria and show no defects such as —
(a) cold shut;
(b) porosity;
(c) inclusion; or
(d) shrinkage crack.
6.5.5 Visual inspection When tested in accordance with Clause 6.4.5, the following
shall apply:
(a) The complete weld shall show satisfactory external appearance and shape, and show
no evidence of a short head. Nominal weld metal head height of 15 mm is
satisfactory. Porosity at the railhead surface shall be grounds for rejection.
(b) The breakfaces shall conform to the limits shown in Table 3.
6.6 Retest
6.6.1 General If a test fails due to improper sample preparation or defect in the rail the
test may be discarded. Retest requirements for type and proof testing shall be as per
Table 4.
6.6.2 Type test Where results of type testing fail to satisfy the criteria specified in
Clause 6.5, samples from the same prototype production batch may be re-submitted for
retest in accordance with the requirements specified in Figure E1 of Appendix E.
6.6.3 Proof test Where results of proof batch testing fail to satisfy the criteria specified
in Clause 6.5.1.1 and Clause 6.5.1.3, samples from the same production batch may be
submitted for retest in accordance with the requirements specified in Figure E2 of
Appendix E.

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 13 AS 1085.15— 1995

TABLE 2
TEST REQUIREMENTS

Minimum rail UT S Minimum

Nominal Weld Minimum
elastic
rail size Weld type hardness break load
MPa response limit

kg/m Head Foot Brinell kN kN

68 HH SGW, WGW 1100 900 340 to 380 1425 713

60 HH SGW, WGW 1100 900 340 to 380 1110 555
50 HH SGW, WGW 1100 900 340 to 380 805 403

68 SGW, WGW 900 900 260 to 300 1425 713

60 SGW, WGW 900 900 260 to 300 1110 555
53 SGW, WGW 900 900 260 to 300 935 468

53* SGW, WGW 800 800 220 to 260 805 403

50 SGW, WGW 900 900 260 to 300 805 403
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47 SGW, WGW 900 900 260 to 300 710 355

47* SGW, WGW 700 700 210 to 250 610 305

41 SGW, WGW 700 700 210 to 250 550 275
31 SGW, WGW 700 700 210 to 250 350 175

60–53 SJW 900 900 260 to 300 935 468

60–50 SJW 900 900 260 to 300 805 403
53–50 SJW 800 800 220 to 260 805 403

53–47 SJW 800 800 220 to 260 710 355

50–47 SJW 900 900 260 to 300 710 355
47–41 SJW 700 700 210 to 250 550 275

* Rail rolled prior to 1981.

NO TES:
1 The slow bend test is used to check the effect of the weld on rail bending.
2 Hardness based on UTS head.
3 Break loads based on 85% of nominated rail minimum UTS to correspond with minimum strength in the heat
affected zone.
4 The minimum elastic response limit is 50% of the specified minimum break load.
5 When the rail used in the test is of a hardness different to that of the portion tested, the break load applicable
is that specified for the rail used.
6 The rail sizes nominated refer to rails rolled in accordance with AS 1085.1 and AS 1085.11 or in the case of
68 kg rail to AR EA part 4 and to older rails rolled to the Australian Standard applicable at the time of
manufacture.
7 HH denotes head hardened rail.

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 AS 1085.15— 1995 14

TABLE 3
PERMISSIBLE LEVELS OF IMPERFECTIONS

Imperfections Maximum allowable

Cracks Not allowed
Lack of fusion Not allowed
Undercut Not allowed
Shrinkage porosity Not allowed
Cold shuts Not allowed
Inclusions Head: none greater than 1 mm2
Web and foot: none greater than 15 mm2
Gas porosity Head: none greater than 1 mm2
Web and foot: any one gas pore <40 mm2
Total porosity <60 mm 2
Weld reinforcement Smoothly blended to the parent rail
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TABLE 4
RETEST REQUIREMENT FOR TYPE AND PROOF TESTING

Retest
Clause Test
For type test For proof test
6.4.1.1 (a) Hardness No Yes. If average hardness of individual test
welds is within 10 Brinell points of specified
range (see Appendix E—Flow chart for retest
procedure)
6.4.1.2 Fatigue No Not applicable
6.4.1.3 Slow bend:
(a) Elastic response No Yes. If within 5% of specified load
load
(b) Break load No
6.4.3 Chemical analysis No No
6.4.4 Ultrasonic Yes. If required Not applicable
6.4.5 Visual inspection No No

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 15 AS 1085.15— 1995

APPENDIX A
PURCHASING GUIDELINES
(Informative)

A1 GENERAL Australian Standards are intended to include the technical provisions

necessary for the supply of a product referred to in a particular Standard, but do not
purport to contain all the necessary provisions of a contract. In a number of cases, the
purchaser is either asked to state the requirements or give a choice of optional
requirements and these are contractual matters to be agreed upon between the purchaser
and the manufacturer.
This Appendix contains explanations, advice, and recommendations on the information to
be supplied by the purchaser at the time of enquiry or order and by the manufacturer after
an order has been placed. Its aims are to prevent misunderstanding and to result in the
purchaser receiving satisfactory products and service.

A2 INFORMATION TO BE SUPPLIED BY THE PURCHASER The purchaser

should supply the following information at the time of calling tenders or quotations for
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the manufacture and supply of consumables for field aluminothermic fusion welding:
(a) The number and part of this Australian Standard, i.e. AS 1085.15.
(b) The nominal rail size to be welded.
NOTE: If rail is not to an Australian Standard, lengths of rail as required for test weld
purposes should be provided by the purchaser.
(c) Any limits to the width of the softened zone or minimum hardness in the heat
affected zone and any centre-line softening as determined by the hardness traverse
(Clause 6.5.1.1(b)).
(d) Type of weld, processes and gap size required (Clauses 4.1 and 4.2).
(e) Quantity of welds required.
(f) Specific requirements for laboratory test-welds as specified in Clauses 6.2.1(b) and
6.3.
(g) Whether a test certificate or certificate of compliance is required (see
Paragraph A4).
(h) Maximum mass of pack suitable for manual handling.
(i) Any requirements not covered by this Australian Standard.

A3 INFORMATION TO BE SUPPLIED BY THE MANUFACTURER The manu-

facturer should supply the following information:
(a) The contents of any kit.
(b) What additional consumables are required to successfully complete the specified
weld.
(c) The manufacturer’s recommendations or quantities for consumables referred to in
Item (b).

A4 INDEPENDENT TESTS In the event of a dispute over the compliance of the weld
with the requirements of this Standard, the purchaser and the supplier should agree to
have referee testing carried out by an independent laboratory, whose results should be
accepted as final. A laboratory registered by the National Association of Testing
Authorities, Australia, for this field and class of testing is recommended.

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 AS 1085.15— 1995 16

A5 CERTIFICATES OF COMPLIANCE AND TEST CERTIFICATES

A5.1 Certificates of compliance A certificate of compliance states that the material
has been tested and results comply with the requirements of this Standard, i.e.
AS 1085.15.
A5.2 Test certificates A test certificate shows the results of testing related to—
(a) tests performed by the manufacturer for the purpose of establishing compliance with
the appropriate material specification; or
(b) additional tests required by the purchaser.

A6 INSPECTION The intention of the purchaser to undertake any of the following

functions at the manufacturer’s works should be notified at the time of enquiry or order,
and should be accomplished in a manner which will not interfere with the operation of the
works. The purchaser is entitled to:
(a) Inspection of the weld materials.
(b) Inspection of the production process.
(c) Selection and identification of the test samples.
(d) Witness the tests being made.
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The manufacturer should afford the purchaser all reasonable facilities to satisfy himself or
herself that the weld is in accordance with the Standard.

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 17 AS 1085.15— 1995

APPENDIX B
MEANS FOR DEMONSTRATING COMPLIANCE WITH THIS STANDARD
(Informative)

B1 SCOPE This Appendix sets out the following different means by which compliance
with this Standard can be demonstrated by the manufacturer or supplier:
(a) Assessment by means of statistical sampling.
(b) The use of a product certification scheme.
(c) Assurance using the acceptability of the supplier’s quality system.
(d) Other such means proposed by the manufacturer or supplier and acceptable to the
customer.

B2 STATISTICAL SAMPLING Statistical sampling is a procedure which enables

decisions to be made about the quality of batches of items after inspecting or testing only
a portion of those items. This procedure will only be valid if the sampling plan has been
determined on a statistical basis and the following requirements are met:
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(a) The sample must be drawn randomly from a population of product of known
history. The history must enable verification that the product was made from known
materials at essentially the same time by essentially the same processes and under
essentially the same system of control.
(b) For each different situation, a suitable sampling plan needs to be defined. A
sampling plan for one manufacturer of given capability and product throughput may
not be relevant to another manufacturer producing the same items.
In order for statistical sampling to be meaningful to the customer, the manufacturer or
supplier needs to demonstrate how the above conditions have been satisfied. Sampling and
the establishment of a sampling plan should be carried out in accordance with AS 1199,
guidance to which is given in AS 1399.

B3 PRODUCT CERTIFICATION The purpose of product certification is to provide

independent assurance of the claim by the manufacturer that products comply with the
stated Australian or international Standard.
The certification scheme should meet the criteria of an ISO Type 5 scheme as specified by
SAA HB18.44 in that, as well as full type testing from independently sampled production
and subsequent verification of conformance, it requires the manufacturer to maintain an
effective quality plan to control production to ensure conformance with the relevant
Standard.
The certification scheme serves to indicate that the products consistently conform to the
requirements of the Standard.

B4 SUPPLIER’S QUALITY SYSTEM Where the manufacturer or supplier can

demonstrate an audited and registered quality management system complying with the
requirements of the appropriate or stipulated Australian or international Standard for
supplier’s quality systems, this may provide the necessary confidence that the specified
requirements will be met. The quality assurance requirements need to be agreed between
the customer and supplier and should include a quality or inspection and test plan to
ensure product conformity.
Guidance in determining the appropriate quality management system is given in
AS/NZS ISO 9000.1:1994 and AS/NZS ISO 9004.1:1994.

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 AS 1085.15— 1995 18

B5 OTHER MEANS OF ASSESSMENT If the above methods are considered

inappropriate, determination of compliance with the requirements of this Standard may be
assessed by being based on the results of testing coupled with the manufacturer’s
guarantee of product conformance.
Irrespective of acceptable quality levels (AQLs) or test frequencies, the responsibility
remains with the manufacturer or supplier to supply products that conform with the full
requirements of the Standard.
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 19 AS 1085.15— 1995

APPENDIX C
FATIGUE TEST FOR ALUMINOTHERMIC FUSION WELDS
(Normative)

C1 SCOPE This Appendix sets out the method for fatigue testing of aluminothermic
fusion welds at foot and web of welded rail section.

C2 FATIGUE TEST FOR RAIL FOOT OF WELDED SECTION

C2.1 Principle The welded rail section shall be subjected to fatigue-loading conditions
such that the foot is placed in longitudinal tension. The maximum load shall not exceed
that specified in Clause 6.5.1.2, and the minimum load shall not exceed 10 kN.
C2.2 Apparatus A testing device, preferably a servo-hydraulic testing machine which
is capable of supporting the specimen centrally over the specified span width (1000 mm)
shall be used to produce the maximum and minimum loads. The testing machine shall be
capable of applying such loads in a cyclic manner for a duration of 3 × 10 6 cycles. If a
testing machine is used it shall comply with the accuracy requirements for Grade A or
Grade B testing machines given in AS 2193.
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C2.3 Procedure The procedure for fatigue testing the rail foot of a welded rail section
shall be as follows:
(a) Mount the test specimen in the testing device so that it is located centrally in the
testing device over the specified support span width (see Figure C1).
(b) Restrain the test specimen by means of clamps or other fixing devices on the rail
foot. Such clamps or fixing devices shall allow the specimen to rotate about the
support in such a manner that the effective section properties are not affected.
(c) Apply to the test specimen 3 × 10 6 cycles of loading between the minimum vertical
load and the maximum vertical loading through a hardened steel ball or other means
to simulate point load (if necessary, a small indentation may be machined into the
rail head to locate and adequately restrain the load applicator) to the centre of the
rail head. The cycle loading shall be applied at a loading frequency between 5 Hz
and 10 Hz.
C2.4 Report The following shall be reported:
(a) Date of testing.
(b) Reference to this test method, i.e. AS 1085.15, Appendix C.
(c) Applied test loads, as follows:
(i) Minimum vertical load.
(ii) Maximum vertical load.
(d) Number of test cycles and loading frequency.
(e) Any fatigue cracks that occur.

C3 FATIGUE TEST FOR WEB OF WELDED SECTION

C3.1 Principle The weld rail section shall be subjected to fatigue-loading conditions
so that the web is placed in vertical bending to specified minimum and maximum values.
Sufficient vertical load shall be applied at a location on the edge of the railhead to
produce the maximum load eccentricity obtained under the service conditions for which
the welds are intended. The point of application shall be established by agreement
between the purchaser and the manufacturer. The maximum vertical load adopted in the

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 AS 1085.15— 1995 20

test which will produce the maximum vertical bending stress at the web shall be
established by agreement between the purchaser and the manufacturer. In general, this
load will be equal to the maximum dynamic wheel load obtained under service conditions.
The minimum vertical load adopted in the test shall be equal to 0.0 kN, or as near to this
value as can be satisfactorily achieved with the testing device (in no cases shall the
minimum vertical load be greater than 10 kN). The test shall be conducted over a
specified number of loading cycles.
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DIMENSIONS IN MILLIMETRES

FIGURE C1 TYPICAL TESTING ASSEMBLY FOR RAIL FOOT FATIGUE TEST

C3.2 Apparatus The apparatus required shall be a testing device. The testing device,
preferably a servo-hydraulic testing machine which is capable of supporting the specimen
centrally over the specified span width, or providing continuous support over the entire
section, shall be used to apply a vertical load at the edge of the railhead of the specimen
to produce the maximum vertical bending stress in the web. The testing device shall be
capable of applying the required minimum and maximum vertical loads in a cyclic manner
for a duration of 3 × 10 6 cycles. If a testing machine is used it shall comply with the
accuracy requirements for Grade A or Grade B testing machines given in AS 2193.
C3.3 Procedure The procedure for fatigue testing the web of a welded rail section
shall be as follows:
(a) Mount the test specimen in the testing device so that it is located over the specified
support span width (see Figure C2(a)) or continuously supported (see Figure C2(b)).
(b) Restrain the test specimen by means of clamps or other fixing devices on the rail
foot of the specimen.
(c) Apply to the test specimen 3 × 106 cycles of loading between the minimum vertical
load and the maximum vertical loading through a hardened steel ball or other means
to simulate point load (if necessary, a small indentation may be machined into the
rail head to locate and adequately restrain the load applicator) to the edge of the rail
head. The cyclic loading shall be applied at a loading frequency between 5 Hz and
10 Hz.
NOTE: A higher loading frequency may be used, provided it can be demonstrated that the
requirements regarding the control of the minimum and maximum vertical loads are satisfied.

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 21 AS 1085.15— 1995

C3.4 Report The following shall be reported:

(a) Date of testing.
(b) Reference to this test method, e.g. AS 1085.15, Appendix C.
(c) Applied test loads, as follows:
(i) Minimum vertical load.
(ii) Maximum vertical load.
(d) Number of test cycles and loading frequency.
(e) Any fatigue cracks that occur.
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AS 1085.15— 1995

FIGURE C2
22

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FATIGUE TEST
TYPICAL TESTING ASSEMBLY FOR HORIZONTAL SPLIT WEB
 23 AS 1085.15— 1995

APPENDIX D
SLOW BEND TEST FOR ALUMINOTHERMIC FUSION WELDS
(Normative)

D1 SCOPE This Appendix sets out the method for conducting the static slow bend test
for aluminothermic fusion welds.

D2 PRINCIPLE The welded rail section shall be subjected to static loading under
three point bending conditions so that the foot is placed in longitudinal tension. The load
shall be increased in a controlled manner until the welded rail section fails. The break
load and deflection at fracture shall be recorded.

D3 APPARATUS The following apparatus is required:

(a) Testing stand A structurally rigid stand shall be used as a support for the test
weld.
(b) Testing device A device, preferably a hydraulic testing machine, shall be used for
applying the load at the weld centre-line. The device shall be capable of applying a
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load greater than the appropriate test load specified in Table 2. If a testing machine
is used it shall comply with the accuracy requirements for Grade A or Grade B
testing machines given in AS 2193.
(c) Measuring device A measuring device shall be used, accurate to 1.0 mm, suitable
for indicating deflection measurements on the welded rail section.

D4 PROCEDURE The procedure for slow bend test for welded rail sections shall be
as follows:
(a) Mount the test specimen in the test stand centrally over the specified span width
(see Figure D1).
(b) Restrain the test specimen by means of clamps or other fixing devices.
(c) Apply the test load, without shock, at a maximum loading rate of between 4.5 and
5 kN/s to the weld centre-line through a thrust piece until failure occurs.
(d) Continuously record the load and deflection of the rail at midspan throughout the
test until failure.
(e) Carry out visual inspection.

D5 REPORT The following shall be reported:

(a) Date of testing.
(b) Reference to this test method, i.e. AS 1085.15, Appendix D.
(c) Midspan deflection at the specified elastic response load.
(d) Midspan deflection at the specified minimum break load.
(e) Load and midspan deflection at failure.
(f) Conditions of fracture face.

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AS 1085.15— 1995

FIGURE D1
24

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DIMENSIONS IN MILLIMETRES

TYPICAL TESTING ASSEMBLY FOR SLOW BEND TEST

 25 AS 1085.15— 1995

APPENDIX E
FLOW CHARTS FOR RETESTING PROCEDURE
(Normative)

E1 SCOPE This Appendix provides flow charts to illustrate the retesting procedure for
type testing and proof testing of aluminothermic fusion weld for rails.

E2 FLOW CHARTS FOR RETESTING PROCEDURE

E2.1 Type testing The retesting procedure for type testing of prototype samples in
accordance with Clause 6.6.2 is graphically illustrated in Figure E1.
E2.2 Proof testing The retesting procedure for proof testing of batch samples in
accordance with Clause 6.6.3 is graphically illustrated in Figure E2.
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FIGURE E1 FLOW CHARTS TO ILLUSTRATE RETESTING PROCEDURE FOR

TYPE TESTING OF PROTOTYPE SAMPLES IN ACCORDANCE WITH CLAUSE 6.6.2

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 AS 1085.15— 1995 26
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FIGURE E2 FLOW CHARTS TO ILLUSTRATE RETESTING PROCEDURE FOR PROOF

TESTING OF BATCH SAMPLES IN ACCORDANCE WITH CLAUSE 6.6.3

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