Head Production Kamlesh Sir

23 22
01

I i Probe 0 2MHz DC
porosity hole slaginclusion in head uptomidweb of AT welded joint

there refer totransverse crack which occurs in weld metal

may be dueto inclusion porosity and void in welde

GfÉcalled por sites but largergasbubbles are called

Pinholes are always visible on the surface Porosity is common name given to
thevoidgotcreated becauseof entrapped gave

in
IFF
TRmode
981 50 initial echo 2500 3000
0
11 5920Mls angle 0
connect 0 DCprobe put it on 11W 17 Block afterapplying
couplant on 100mm width side
set 1st reflected peak at 3.3 division wing probe zero
place Gate over it and read the beam path depth shall be 100 mm
second
reflected peak will appear at 6.7 third peakat 10.0

if last peakis not at 10.0 velocity may be adjusted to set

the last peak at 10.0
the equipment is calibrated for 3001200 mm longitudinal wave
for ODC probe
to varity the calibration put probe on top of rail head the
back peakposition will be at 5.2 for 52kg rail and 5.7
for 60 kg rail

Cii Sensitivity Place 0 normal probe on test rail The reflection from
3mm dia hole in headof std.AT welded fat piece shall be
set to 60 of full screen heightby suitable manuplation of
control
gain
 30hole
mm

Fyfe
affair
t I
www.t
themiddle of flange
through the weld

Defect classification
I Initial testing
flawsignal of height 30 and above obtained by normal probe from
the head region to be declared as DFWN
b flaw signal of height more than 20 obtained by normal probe
from web or foot location to be declared as DEWN
DEWN

4720

DFW
a
fsng I.PT
For any flaw signal obtained by normal probe from theheadegion
i flaw signal 740 but 60 DFWO
ii flaw signal 60 DEWR

b For any flaw signalobtained by normal probe from web or foot

location
i 20 240 DFWO
flaw signal DFWR
flaw signal 40

0 60

60 DFWR 40 DEWO
790 DFWR
 81 Probe 70 2MHz Head Scanning
this is used to detect lack of fusion porosity blow hole
slag inclusion cracks in head of AT welded joint
II Calibration
select range 165 mm with range controlkey
select mode TTR ie single crystalmode
set delay 0 probe zero
feed shear wave velocity 3230Mls
feedangle70
connect 70 2MHz singlecrystal probe and put it on 11h41 block
afterapplying couplent and direct the beam towards 100mm curvature
move the probe slightly to and fro to get maximize signal
probe zere ispeakd 6no or by wing Gate read beam
wing
100
path mm
to verify the calibration direct the probe towards 25 mm
curvature and maximize the peak put the Gate on this peak
the beam path shall be 25mm

the equipment is calibrated for 165 mm shear wave

g6 Seneitivity
3 hole
25mm

ftp ftp tom

This
3mm hole
I
themiddle of flange
through the weld

131 Test procedure

Place the probe on the rail head on one side of AT welded
reinforcement and move toward the weld in zig zag manner This
exercise shall be repeated 2 3 times The same shall be carried out
from both sides of the weld
 4 defect classification

If ifeng.int re of Este

1 A bunch of moving signals more than 10 of FSH shall also be

considered as defective weld and to be declared as DFWN

II PeriodicTesting
1 A welded joint showingmoving signal of 40 or more and upto
60 of FSH shall be classified as DFWO
A welded joint showingmoving signal of more than 60 of FSH
to be classified as DFWR
in A bunch of moving signals more than 10 of FSH shall
also be considered as defective weld to be declared as DEWR

8.1 45 2 MHz probe

87 I 45 2MHz probe AT weld Foot Scanning
This scan it and to inspect the clustered defect micro porosities
and half moon shaped defect at the bottom of weldfoot

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 8.7.1.1 Range calibration
i feedrange 275 mm with range control
key
ii select mode TTR i e single crystalmode
set delay 0
set probe zero 0
feed shear wave velocity 3230m s
feedangle 45
connect45 2MHz single crystalprobe and put it on 11W IV1 Block
afterapplying couplant and direct thebeam towards 100 mm curvature
move the probe slightly to and froto get maximize signal
Wing probe zero set this peak at 3.6 or by wing the Gate read
beampath 100mm

to verify the calibration direct the probetowards 25 mm curvature

and maximize the peak put the GATE on peak beam path shall be 25mm
the equipment is calibrated for 275 mm shear wave

8.7.1.2 Sensitivity setting when is standard block here

Place4512MHz probe on the railhead surface at a distance equal

to thehight rail from theenterofatheld
of

tt
f

move the probe 20 mm either side of this position probe indexmarking

to pick up half moon crack in central region of weldreinforcement
This exercise shall be carried out two three times from each side
of the weld and signal from simulated flawshould appear at a
distance
of approximately 400mm for 52 kg rail
The signal so obtained shall be adjusted to 60
control
of FSH by manuplating
the
gain
8.7.1.3 Test procedure
probe shall be placed on the rail head at a distance equal to
the height of rail from center of AT weld This testing technique
will scan the bottom of the weld in the central zone
 the scanning shall also be repeated from other side of the weld
with beam directing toward the foot region oftheweld

8.7.1.4Defect classification
I Initial testing
Any flew signal obtained by this probe of 209 height or more
shall classified as defective AT welded joint DF WN
II periodic testing
Any flaw signal obtained by this probe of 20 height or more
shall be classified as defective AT welded joint DFWR
45 2MHz single crystal probe tandem probe scanning
Thetandemprobe rig scan on the rail table by 45 probe is need
to detect any vertically orienteddefectsuch as lack of fusion located
at head ndion.com wd uptowIotjuntnaree
111Range Calibration
The equipment shall be set for a depthrangeof 275 mm

wing V1 block
Sensitivity setting
Place the tandem rig on the railhead and attach 45 probes such
that the beam direction is as shown below Adjust the height of
reflected beam received by receiver probe Rx 100 FSH
increase the gain further by 10dB This gain shall be used for
normal testing of AT weld by this set up

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t.FI
eat
rig

Fyi
É offlineof
rig
131Test procedure Place the tandem
rig on the rail head The datumline of
the rig shall be in line with center line of weld Test the weld with
semitivitysetting as mentioned above This exercise shall be repeatedfrom
otherside of the weld
 defect classification
any flaw signal of 30 of FSH shall be classified
In If eating

II Periodic testing
Any flaw signal of 40 of FSH shall be considered as DFWR

8 7012MHz Side looking SL probe

This procedure shallbeused for the detection of half moonshaped transverse
defect with a pair of 70 side looking probesusingtransmitter receiver
method
1 Range calibration
calibrated for a depthrangeof 165mm shear wave

Sensitivity setting
setrange 165 mm velocity 3250m s DC Angle 70
connect the cables of SI probes to transmitter and receiver socket in
such a way that the dish of SLcrystal face is inward i e towards
simulated half moon shaped defect Place the 70 SL Tx and Rx probes
on the upper zone of flange at a distance of 85 mm on either side of
flenge
move the probes slowly in the slight
Zigzag manner towards the weld upto a
distanceof 20mm fromweldcoller Setthe
T signal obtained fromsimulated half
moondefect to 60 of FSH with thehelp
of gaincontrol This gain setting will be
utilized duringtesting of weld
702M
Effghfffmancrack
AT weld

of t tile
I tetra

Ritt m not run

If
Plane showing ptsii.in of 255 tidtooking SL probe
on rail flingle
 Test procedure
place the transmitter and receiver 70 SL probes at position
as mentioned above move the probe slowly in a
zigzag manner towards
theweld Theposition of transmitter and receiver probesfrom a defect
signalmay vary depending uponthe location of half moon defect This
is alsodone from other side of weld

14 defect classification
periodic testing thedefect signalof 20 of FSH or more is to be
classified as DFWR

FlangeTesting by 70 2MHz 20 20 mm single crystal probe_

This scanning is done for detecting lack of fusion porosity blow hole
slag inclusion in flange of ATweld
111Range calibration Theequipment shall be set for a depth range of165mm
shearwave

sensitivity settings
7012MHz single crystal probe shall be connected to the socket
available in ultrasonic equipmentThe selector switch shall be setto
singlecrystalmode

I
60
ña im ga
FSH on the screen
t tm sdtir

is

OCA

BI
 3 Test procedure
70 probe shall be placed on the flange at a suitable distance
180mm crossponding to fig shown below such that Ultrasonic
directed toward the weld The probe shall thereafter
waves are
be moved slowly in zig zag manner towards the weld

k
4 defect classification
I Initial telling
Awelded joint showing flawecho of 30 vertical height or more
is to be declared as DEWN

II Periodic testing
11 A welded jointit showing flaw echo of 40 vertical height or more
and upto 60 to be declared
as DFWO
A welded joint showing flew echo of more than 60 vertical
height is to be declared as DFWR
8.1 Initial USED testing of AT welds and subequentfeeling within
theguaranteeperiodof contract
A thermit welding done in setu shall be joggledfish plated with
two clampe and supported on wooden blocks of 300 450 mm length
untill teeted a goodby USED

Thedefective joints DEWN bared on the criteria as mentioned

above shall not beallowed to remain in service for initial USED
teeting of AT welde
during Subsquent testing within the guarantee periodof contract
defectivejoints DFWO or DFWR shall be cropped re welded and
tested again The rewelded joints shall be scanned ultrasonically
again with the same set of acceptance criteria
 8 11 Periodic testing of welds in service
Theperiodic testing of weld wing O 2MHz 702MHz 4502MHz
and 70 2MHz SL probes shall be done

8 72 Procedurefor initial periodic ultrasonic Examination of 75mm

gap AT welded Joints
8.12.1 Standard test sample
The sensitivity of ultrasonic equipment shall be set with respect
to AT weld standard test sample of 1.5m length having simulated
flaw at standard location

iii
siden IT

ii n t. t
Topview

1
standard A To welded Rail piece with artificial flaws
for sensitivity setting of ultrasonic equipment to examine
75 mm wide gap At welde
Sensitivity setting
lead The signal from the simulated flaw of 3mm dia hole in the head
shall be set to 60 of FSH with 0,2MHz and 70,2MHz
probes for detection of discontinuities in rail head

Flange For Flange testing a signal from a saw out of 30 mm in the

weld metal in the flange 15mm away fromthe edge of the weld
coller shall be set to 60 of FSH wing 70 2MHz probe
 3 defect classification

IT O 70 probes rejection criteria will be same

as for 25 mm gap AT weld joints

b flange with 70,2MHz probe any moving signal of height

more than 20 of FSH shall be treated as defective weld DEWN
II PeriodicTesting

Head egection criteria will be same as

for withggpdpffgbg.int
25mm

b
Flange with 70 2MHz probe any moving signal more than 20
of FSH shall be treated as defective weld DFWR
classification of defects
8.13 defects detected by 0,2MHz 70 2MHz 45 2MHz and
70 2MHz SL probes with RDSO approved customised AT Weld
tester existing machine
8.14 Action to be taken after detection of defects in AT welds

IMRW
OBS W

in addition welds classified as defective DF NO DFWR in

periodic testing of AT welde wing hand probing
DFWO
DFWR

8.15 Frequency of testing

1 periodic testing by SRT DRT wing O FO probes

Route Routes having GMT Testing frequency once in

All M G Route 2.5 5years

25 5 3 year
5 2years
 Route Routes havingGMT Testing frequency once in
All BG routes 55 2years
rail head center 7558 1 year 12month
andgaugeface 78512 9month
corner non gauge 712516 6 month
face corner 716524 4 month
testing 724540 3 month
740260 2month
60480 month
780 1 month

Route Routes havingGMT Testing frequency once in

Allmainline BG
on CC18 24 15h
routes 78512 6 months
temp20M 712516 4 monthe
tempzone III 716524 3month
52kg 0 UTS 724540 2 month
740560 If month
60580 month
780 20day
 8N Probe calibration scanned Acceptance creteria
Somitivity
Area
11 02MHz V1 block shiftweldedteet Head 3 fun 40 Egg
300mmbaidu.d.nlpiece
3mycehead DFWO
Web 20 DFWN 20 40
60 of FSH 740 DFWR

7482MHz
2 11WV1 block ATweldedfeet Lead ismovingsignal 40 60 DEWO
165mmstyle piece 30 DEWN 60 DEWR
3mydehead 1 bunch of
movingbunchofmoving
60 of FSH signal710 FSHsignal710
DEWN DFWR
sff.hn
Flange v1 block
iweldedtee 702MH2165mmsheaneaf
e m tf flagg Danny
5 9601
ofFSH
3 70 V1 blockmode
Em shear diffal weldfoot Periodictesting
acethe70s halfmoon defectsignal 20
robes on theupperzone simulated half defect DFWR
theflangeat a distance moon shapeddefect
I
QI L setthe signalobtained
theweldupto20mmfrom to 60 ofFSH
eld coller

4 45 2MHz V1 block signalfromsimulated AT weld

placethe probeon 275 mm Cold
appearat foot
initial tifjp.mn
ail headsurface TTR SC a distance ofapproximately
scanning
400mm
for 5269201
ofweld Periodictesting
bottom
thesignalsoobtainedshallin central 720 DFWR
beadjustedto 60 of
FSH fk
m probe
38Thside
5 45 2MHz V1 block tandem on railhead datumlineof initial testing
rig
singlecrystalProbe range 275mm Adjustthe heightof rigshallbein flawsignal 30 DFWA
place the tandem Theequipment reflectedbeam to linewithcenter
rig on the rail headshallbeset in 100 of FSH Increaselineofweld Periodictesting
and attach45 probes T Rdoublecrystal theGainfurther Any flawsignal 740 DFW
by 10dB
 the frequency of testing of AT welde with above listed probes
by hand probing shall be under
5 No Type of weld Typeof testing Testing schedule

1 Conventional Periodic tests Every 40 GMT or 5 years whichever

ATweld is earlier

Held Acceptancetest Immediately afterwelding

First periodic test 20 GMT 1 year whichever is
Efferhaving GMT Frequency
4 Further feet
band on GMT 780 1
year
60580 If year
45 60 2 year
30545 3 years
715 30 4 years
0 15 5 year
The testing interval
reduced
of USFD testing of defective AT welds should be
by 50 of normal testinginterval of AT welds to avoid fractures
of defective welde

The frequency of USFD testing of AT welds on loop line shallbe followed

1 Acceptance test immediately afterwelding
1 1st periodic test after 1 year
is Further test i once in every fiveyears for passenger runningloops
Ii not to be carried out for non passengerrunning loops

flawsignal Vs signals coming dueto geometrical configuration of weld

 Iimofa.tw
n

Alumino thermic

specialized procen wed for joining railway tracks

details of the procen
1 Prepration
identify the section ofrailway track that needs welding
remove any impurities or contaminations from the rail and to
ensure a clean weld

2 Materials
Aluminiumpowder this server at reducing agent
iron oxide the oxidising agent typically in the form of iron ore
additional elements may be added to control the properties of weld
3 Equipment
crucible A refractory
container where reaction takes place
mold A heat resistant mold placed around the rail ende to shape
themolten metal
ignition system A device to initiate the chemical reaction
4 Chemicalreaction
The aluminium powder reacts exothermically with the iron oxide
producing molten iron and aluminium oxide
this reaction is highly exothermic generating temperature exceeding
2500 C

5 Welding process
the aluminium oxide slag floats to the top is removed
the molten iron fille the gap b w the rail ends in themold
themolten metal solidifies creating a strong and continue weldedjoint

6 Post weld inspection

After cooling the welded joint undergoes inspection for quality
integrity
Ultrasonic testing and othermethods may be employed to ensure
the weld meets specified standarde

7 Advantages
AT weld provide a robust durable joint
it creates a continue smooth track
reducing wear on train wheels

8 Application
AT weld is mainly need in railwaymaintainance construction
 Process of FB W Flash Bult Welding
FBW is a technique used in rail and metalworking industries
to join two pieces of weld typically raik
stepby step process
1 Prepration
ensure the rail ends are clean and properly aligned
the rail ende are trimmed to precise lengths to facilitate a seamless
weld
2 Clamping
the rail ende are firmly clamped into position ming a FB welding mlc
the clamping mechanism holds the two pieces in place ensuring they
are in close contact

3 Heating Preheating
An electric current is passedthrough the railende causing them to
heat up
the initial heating is done to bring the rail ends to an elevated temp
reducing the force required for subsquent forging
4 Flash upsetting
The rail ende are brought into contact and a high current is pared
throughthem
the internee heat generated at the contact point causes the metal to
become molten forming a flash

5 Forging
Themachineapplies pressure to forge and upset the molten metal
The excess flash is pushed away leaving behind a clean and uniform
joint
6 Cooling
the welded joint is allowed to cool and solidify
controlled cooling is evential to ensure the desiredmetallurgical
properties of the weld

7 Finishing
The excess material from the flash is removed leaving a smooth and
continous welded joint
8 quality control The finished weld undergoes various quality control
tests including ultrasonic testing to ensure it meets specified Std
 Ch 9 Ultrasonic Testing of Flash Butt and Gas Pressure
welded joints
pulse echo A scan method

probes used
only 2X and 70

totest head
to tert web Foot

9 2 Codeof Procedure

Iii 0 4MHzdoublecrystal probe 0 2MHzsingle crystal probe shallbe lured

to check equipment characteristics

Cii pece of 2.5 in length having std simulated defects at standard

avg.gg CUT
110 SAW

it FT
es es
IF
a Iii eat
50hole
evilis Calibration block 60 50 50 mm

I p S ion

dirt rent and extreme

lineage from weed spatter scale
roughner each side of the weld
distance equal to 200mm
on
for a

couplant
depending upon availability feasibility oil grease water

Calibrate the depthrange of VFD with help of 60 50 50 mm

steel block
 9.1 Calibration lenitivity testing
Iii calibrate the digital ultrasonic weld teeter
25mm
for 165 mm shear
11W V1 block 100 mm
after calibration switch over to T Rdouble crystal mode

connect the 45 probes one to transmitter connectorand other to receiver

connector Placethe 45 probes on standard rail peice a show in fig

A
assign
hole
c s

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