No. W-503/5/2/7(Vol-II) Computer No.

25429 Date: As signed

Sr. DEN (Co)-BRC

Sub: AT weld failure.

1. AT Weld failure took place at Km 339/7-5 between ST-BRC section in BRC division on 10.03.2024.
The ATW has been fractured transversally at the weld collar section due to lack of fusion visible
throughout lower web area and complete flange section with revelation of bare parent metal.
2. The AT weld was executed on 09.03.2024 and failed very next day on 10.03.2024. The weld was
untested.
3. It is observed that the AT weld was improperly trimmed at the web section and both the risers are not
grinded fine finished in accordance with rail flange profile.
4. Improper fitting of bottom mould & improper sealing of moulds with looting sand has resulted in molten
metal leakage at rail bottom and at weld collar edge section on the fracture side.
5. The photos of the fractured AT weld are appended below:-

Molten metal leakage at weld collar edge

Molten metal leakage at rail bottom

In this connection, demonstration of AT weld execution was witnessed by Shri. Kamlesh More,
SSE/Metallurgy/CCG at BH yard in BRC division on 20.03.2024 using portion of M/s. Pandrol Welding &
Equipment India Pvt. Ltd.
Deficiencies and suggestions for AT weld execution are detailed below:
1. Notified gap between the rail ends should be maintained between 24mm to 26mm i.e. tolerance of
±1mm. No Alumino-thermic weld should be carried out when gap is more or less than specified as the
less gap leads to Porosity & more gap leads to lack of fusion. During demonstration the weld gap is
noted to be 26mm at the rail top and 28mm at the rail bottom.
2. While cutting the rail ends using abrasive cutter, the squareness of the rail ends should be maintained.
After cutting the rail ends, burr at the bottom of the flange and around rail section should be removed
by chiselling or grinding. The burr was not removed during AT weld execution.
3. Maximum leakages occur due to wrong packing of moulds. The looting sand contains 6% moisture.
Excess moisture in looting sand leads to porosity in weld. The quality of looting sand can be checked
by making a ball of it & dropping it from the chest height, it should break into pieces. If it stuck the floor,
that indicates moisture is excess & if it break into sand it indicates moisture is less. Avoid welding in
rain. During AT weld demonstration it is noted that, the looting sand used for packing of moulds
was getting cracked during preheating process which could leads to leakage of molten metal.