EN-13674-1

EUROPEAN STANDARD

FINAL DRAFT prEN 13674-1

NORME EUROPÉENNE EUROPÄISCHE NORM

November 2002

ICS 45.080

English version

Railway applications - Track - Rail - Part 1: Vignole railway rails 46 kg/m and above Applications ferroviaires - Voie - Rail - Partie 1: Rails vignole de masse supérieure ou égale à 46 kg/m

Bahnanwendungen - Oberbau - Schienen - Teil 1: Vignole Breitfußschienen ab 46 kg/m

This draft European Standard is submitted to CEN members for formal vote. It has been drawn up by the Technical Committee CEN/TC 256. If this draft becomes a European Standard, CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration. This draft European Standard was established by CEN in three official versions (English, French, German). A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the Management Centre has the same status as the official versions. CEN members are the national standards bodies of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom. Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without notice and shall not be referred to as a European Standard.

EUROPEAN COMMITTEE FOR STANDARDIZATION COMITÉ EUROPÉEN DE NORMALISATION EUROPÄISCHES KOMITEE FÜR NORMUNG

Management Centre: rue de Stassart, 36

© 2002 CEN

All rights of exploitation in any form and by any means reserved worldwide for CEN national Members.

B-1050 Brussels

Ref. No. prEN 13674-1:2002 E

prEN 13674-1:2002 (E)

Contents Foreword......................................................................................................................................................................4 1

Scope ..............................................................................................................................................................7

2

Normative references ....................................................................................................................................7

3

Terms and definitions....................................................................................................................................8

4

Information to be supplied by the purchaser..............................................................................................8

5

Steel grades....................................................................................................................................................9

6

Profile drawings/properties/mass ..............................................................................................................10

7

Manufacture..................................................................................................................................................10

7.1

Product integrity ..........................................................................................................................................10

7.1.1

Factory production control .........................................................................................................................10

7.1.2

Best practice manufacture..........................................................................................................................10

7.2

Blooms ..........................................................................................................................................................10

7.3

Rails...............................................................................................................................................................10

7.4

Identification.................................................................................................................................................10

1.1.1

Branding .......................................................................................................................................................10

7.4.2

Hot stamping ................................................................................................................................................11

7.4.3

Cold stamping ..............................................................................................................................................11

7.4.4

Other identification ......................................................................................................................................11

8

Qualifying tests ............................................................................................................................................12

1.1

Procedure .....................................................................................................................................................12

8.2

Fracture toughness (KIc) .............................................................................................................................12

8.2.1

Test pieces and test methods.....................................................................................................................12

8.2.2

Qualifying criteria ........................................................................................................................................12

8.3

Fatigue crack growth rate ...........................................................................................................................13

8.3.1

Test method..................................................................................................................................................13

8.3.2

Test pieces....................................................................................................................................................13

1.1.3

Number of tests and test conditions .........................................................................................................13

8.3.4


8.4

Fatigue test ...................................................................................................................................................13

8.4.1

Test method..................................................................................................................................................13

8.4.2

Test pieces....................................................................................................................................................14

8.4.3

Number of tests and test conditions .........................................................................................................14

8.4.4


8.5

Residual stress in rail foot ..........................................................................................................................14

8.5.1

Test method..................................................................................................................................................14

8.5.2

Test pieces....................................................................................................................................................14

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8.5.3

Measurements..............................................................................................................................................14

8.5.4


8.6

Variation of centre line running surface hardness of heat treated rails ................................................14

8.7

Tensile strength and elongation ................................................................................................................15

8.8

Segregation ..................................................................................................................................................15

8.9

Other qualifying requirements ...................................................................................................................16

9

Acceptance tests .........................................................................................................................................16

9.1

Laboratory tests...........................................................................................................................................16

9.1.1

General..........................................................................................................................................................16

9.1.2

Chemical composition.................................................................................................................................16

9.1.3

Microstructure..............................................................................................................................................20

9.1.4

Decarburisation............................................................................................................................................21

9.1.5

Oxide cleanness...........................................................................................................................................21

9.1.6

Sulfur prints..................................................................................................................................................21

9.1.7

Hardness.......................................................................................................................................................22

9.1.8

Tensile tests .................................................................................................................................................22

9.1.9

Retest procedures .......................................................................................................................................23

9.2

Dimension tolerances..................................................................................................................................23

9.2.1

Profile ............................................................................................................................................................23

9.2.2

Straightness, surface flatness and twist ...................................................................................................24

9.2.3

Cutting and drilling ......................................................................................................................................27

9.3

Gauges..........................................................................................................................................................27

9.4

Inspection requirements/tolerances for internal quality and surface quality .......................................27

9.4.1

Ultrasonic test requirements ......................................................................................................................27

9.4.2

Surface quality .............................................................................................................................................29

Annex A (normative) Rail profiles ...........................................................................................................................44 Annex B (normative) Standard test method for the determination of the plane strain fracture toughness (KIc) of rails ...............................................................................................................................68 Annex C (normative) Method for the determination of rail foot surface longitudinal residual stresses .........74 Annex D (normative) Limiting sulfur prints ............................................................................................................77 Annex E (normative) Profile and drilling gauges...................................................................................................91 Annex F (informative) Comparison of steel designations referred to in this standard compared to those in EN 10027-1 and EN 10027-2 .......................................................................................................105 Annex ZA (informative) Clauses of this European Standard addressing essential requirements or other provisions of EU Directives. .....................................................................................................................106 Bibliograhy ..............................................................................................................................................................107

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prEN 13674-1:2002 (E)

Foreword This document prEN 13674-1:2002 has been prepared by Technical Committee CEN /TC 256, "Railway applications", the secretariat of which is held by DIN. This document is currently submitted to the Formal Vote. This document has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association, and supports essential requirements of EU Directive(s). For relationship with EU Directive(s), see informative annex ZA, which is an integral part of this document. The most commonly used standards of the world for the supply of railway rails have been reviewed during the preparation of this standard. However, modern rail production technology and the requirements of high speed railways within the Community have demanded a completely new look at the philosophy and content of this part of EN 13674. Whenever possible this part of EN 13674 is performance based, recognises the European Quality System standard EN ISO 9001 and requires manufacturers to offer the latest proven technology to consistently satisfy the demanding quality of the required product. This part of EN 13674 has two major divisions: 1)

qualifying tests;

2)

acceptance tests.

The qualifying tests introduce a number of performance requirements not previously seen in national or international standards. They also include typical results from relevant acceptance tests. Rail grading is based on hardness rather than tensile strength. The acceptance tests have been designed to control those characteristics of the rail steel and rail that are of relevance to the production of high quality rails and the demands of the railway. The steel grades covered by this part of EN 13674 reflect trends in railway usage and heat treated rails are included. The standard includes rail profiles for Vignole rails having a linear mass 46 kg/m and above. To ensure the supply of high quality rails, some restrictions on production processes have been imposed. This part of EN 13674 is the first of a series of standards for rails. Railway applications-Track : 

Part 1: Vignole railway rails 46 kg/m and above



Part 2: Switch and crossing rails used in conjunction with Vignole railway rails 46 kg/m and above



Part 3: Check rails



Part 4: Vignole railway rails from 27 kg/m to, but excluding 46 kg/m

Other standards planned for publication include the following: Special purpose rail-Part 1:Grooved and associated construction. 4

prEN 13674-1:2002 (E)

Flash butt welding of new rails 220 and 260 grade rails in a fixed plant. Flash butt welding of new 260 Mn and 350 HT grade rails in a fixed plant. Flash butt welding of new 220 and 260 grade rails by mobile welding machines at sites other than at a fixed plant. Flash butt welding of 220 and 260 grade reusable rails. Flash butt welding in association with crossing construction. Approval of aluminothermic welding processes. Tests for qualification of aluminothermic welders, approval of contractors and acceptance of welds. Restoration of rails by electric arc welding. Annexes A, B, C, D and E are normative. Annex F is informative. This document includes a Bibliography.

5

prEN 13674-1:2002 (E)

Introduction This Introduction provides an explanation of the concepts, and reasoning used in the production of this standard. Its inclusion also ensures that during future revisions restrictions are removed as technology progresses and to hold them where it has not, thus ensuring continued safety as new producers, products and technologies are introduced. The standard supersedes other standards covered by the scope and applies to all procurements falling inside the th requirements of the European Procurement Directive (93/38/EEC of 14 June 1993). In addition CEN required, where possible, a performance based standard, taking into account safety implications and at the same time addressing modern production technology and the requirements of high-speed railways. As a result of the Directive it was recognised that there would be few opportunities (and these would have to be for transparent safety considerations) for derogation from the standard to operate between the user and the manufacturer. The standard reflects this change in philosophy from the traditional content of rail standards. A review was undertaken of the most commonly used rail standards of the world. All relevant aspects important to both user and manufacturer were considered with the aim of ensuring that all of the content had specific usefulness and relevance. For example rail grading and much of the standard has been based on hardness rather than tensile strength. Whilst the two are directly related, hardness is very quick and cheap to carry out and provides more relevant guidance to the user particularly where properties vary in different parts of the profile. Since many rail manufacturers would have not have previously carried out proving trials, the standard includes a prerequisite for all manufacturers to prove conformity against a set of qualifying test criteria at the time of tendering. The Qualifying tests include all “normal” acceptance test results plus new ‘type-casting’ features such as fracture toughness, fatigue and residual stress. To provide users with the necessary confidence, acceptance limits have been based on results from rail known to have performed well in demanding track installations. One aspect of the standard which is a complete break from tradition is the inclusion of quality assurance and inspection clause as part of product integrity. In order that quality management systems are consistent across all manufacturers and that users have the best assurance for the consistency of required product quality on this safety critical component of the track, the rail standard recommends that the manufacturers quality assurance systems are at least equivalent to the requirements of EN ISO 9001. The inclusion of this requirement also reduces the need to incorporate detailed method and calibration descriptions on items such as normal chemical composition determination and the need to define more extensive testing. Ideally manufacturing techniques should not be referenced in a product standard. However, some rail attributes are either not known in an exact manner or are not measurable with satisfactory statistical significance. In such cases best practice manufacturing techniques have been included as a last resort. The equipment specified is that which gives the best probability of achieving the required product for use in track. In the future new technology can add to, but preferably will reduce or delete such items. Examples of areas where the technological state of the art renders the standard less than complete include: 

oxide/oxygen relationships;



hydrogen test techniques;



roller straightening effects on residual stresses;



roller straightening effects on contact scrub;



measurement and effect of residual stresses throughout the rail.

6

prEN 13674-1:2002 (E)

1

Scope

This European Standard specifies Vignole railway rails of 46 kg/m and greater linear mass, for general and high speed railway track usage. Seven pearlitic steel grades are specified covering a hardness range of 200 to 390 HBW and include non heat treated carbon manganese steels; non heat treated alloy steels; and heat treated carbon manganese and low alloy steels. There are 21 rail profiles specified in this Standard. Two classes of rail straightness are specified, differing in requirements for straightness, surface flatness and crown profile. Two classes of profile tolerances are specified.

2

Normative references

This European Standard incorporates by dated or undated reference, provisions from other publications. These normative references are cited at the appropriate places in the text, and the publications are listed hereafter. For dated references, subsequent amendments to or revisions of any of these publications apply to this European Standard only when incorporated in it by amendment or revision. For undated references the latest edition of the publication referred to applies (including amendments). EN 10002-1, Metallic materials - Tensile testing - Part 1: Method of test at ambient temperature. EN 10163-1, Delivery requirements for surface condition of hot rolled steel plates, wide flats and sections - Part 1: General requirements. EN 10276-1, Chemical analysis of ferrous materials - Determination of oxygen in steel and iron – Part 1: Sampling and preparation of steel samples for oxygen determination EN ISO 6506-1, Metallic materials – Brinell hardness test – Part 1: Test method (ISO 6506-1:1999). ISO 1099, Metals - Axial load fatigue testing. ISO 4968, Steel - Macrographic examination by sulfur print (Baumann method). BS 6835-1, Method for determination of the rate of fatigue crack growth in metallic materials - Fatigue crack growth rates of above 10-8 m per cycle. DIN 50602, Microscopic examination of special steels using standard diagrams to assess the content of non-metallic inclusions. ASTM E399, Standard test method for plane strain fracture toughness of metallic materials.

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prEN 13674-1:2002 (E)

3

Terms and definitions

For the purposes of this European Standard, the following terms and definitions apply. 3.1 heat one liquid steel melt tapped out of a converter or electric arc furnace which includes after continuous casting a given number of blooms relating to the weight of the heat and the extension of the mixing zone. In the case of sequence casting the blooms belonging to the mixing zone should be clearly defined. 3.2 sequence any number of heats, of the same steel grade, which undergo continuous casting in tundishes. Tundishes can be used in parallel if the caster has many strands. 3.3 heat treated rail rail that has undergone accelerated cooling from austenitizing temperature during the metallurgical transformation period 3.4 re-heated rail all rolled rail that has undergone re-austenitization for heat treatment purposes 3.5 mill heat treated rail heat treated rail that has not undergone re-austenitization after rolling 3.6 rolling process process between the blooms leaving the heating furnace and exiting the finishing pass 3.7 isothermal treatment process process whereby blooms are held for a period of time at an elevated temperature for diminishing the hydrogen content NOTE 1 For maximum efficiency this is as near to (but below) the pearlite to austenite transformation temperature as is practically possible. NOTE 2

This process is sometimes referred to as sub critical diffusion annealing.

3.8 qualifying tests special tests and criteria which are relevant to some aspects of the service performance of rails. Acceptance tests also form part of the qualifying tests. 3.9 acceptance tests tests carried out as part of the process and product control system, normally on a heat, sequence or tonnage basis

4

Information to be supplied by the purchaser

The purchaser shall provide the supplier with the following information at the time of tender or order: a)

the rail profiles (see annex A);

b)

the steel grades (see clause 5);

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prEN 13674-1:2002 (E)

c)

the profiles class, ‘X’ or ‘Y’ (see 9.2.1);

d)

the straightness class ‘A’ or ‘B’ of rail as specified in 9.2.2;

e)

the lengths of rail (see 9.2.3 and Table 10);

f)

undrilled or drilled rail ends to take fish bolts, and location and dimensions of holes when required (see 9.2.3);

g)

any special treatments to be applied to bolt holes;

h)

tolerances for bolt holes to which special processes are to be applied;

i)

paint code requirements (see 7.4.4).

5

Steel grades

The seven steel grades are given in Table 1. The five hardness ranges of the steel grades shall conform to those given in Table 1. The steel grade designations referred to in this standard are compared to those in EN 10027-1 and EN 10027-2 in informative annex F. Table 1 — Steel grades Grade a

Hardness range (HBW)

R 200

200 to 240

R 220

220 to 260

R 260

260 to 300

R 260 Mn

260 to 300

R 320 Cr

320 to 360

R 350 HT

350 to 390

b

R 350 LHT

350 to 390

b

Description Carbon – manganese (C-Mn) Non heat treated Carbon – manganese (C-Mn) Non heat treated Carbon – manganese (C-Mn) Non heat treated Carbon – manganese (C-Mn) Non heat treated Alloy (1 %Cr) Non heat treated Carbon – manganese (C-Mn) Heat treated Low alloy, heat treated

Branding lines No branding lines

_______

____

_______ _______ _______

_______ _______ _______ ______

_______

________

______

_______

_______

______

a b

See Table 5 for chemical composition/mechanical properties. See Table 7 for hardness requirements.

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prEN 13674-1:2002 (E)

6

Profile drawings/properties/mass

Rail profiles, dimensions, properties and linear masses are given in annex A. The tolerances of certain dimensions shall be as given in Table 8. All other quantities are informative only. NOTE

7

Linear masses have been calculated based on the density of steel of 7,85 g/cm3.

Manufacture

7.1 7.1.1

Product integrity Factory production control

All Vignole rails shall be produced under a comprehensive system of factory production control which shall ensure confidence in the conformity of the finished product. The system shall address this European Standard to ensure that the finished products consistently comply with requirements to achieve the product integrity necessary to provide assurance of product safety in track. Manufacturers shall demonstrate continuing compliance, including documented evidence, with the factory production control system required. Manufacturers having a factory production control system which complies with EN ISO 9001 are recognised as satisfying the minimum requirements specified by this clause. 7.1.2

Best practice manufacture

The product shall be manufactured to the best practices as defined in 7.1. NOTE This is to ensure that the rail attributes, described in the introduction, which are not known in an exact manner or are not practically measurable, achieve the required high level of product integrity in track.

7.2

Blooms

Blooms made from basic oxygen steel or electric arc furnace steel that has been secondary ladle arc refined, vacuum degassed and continuously cast, shall be used for the manufacture of rails.

7.3

Rails

7.3.1 The manufacturer shall operate a procedure for the effective removal of scale during the rolling and straightening processes. 7.3.2

The cross-sectional area of the rail shall not exceed one ninth that of the bloom from which the rail is rolled.

7.3.3 Rail straightening shall be by a two stage roller straightening process which straightens the rail about its XX and YY axes as defined in the rail profiles shown in annex A. End deviations or a localised deviation on the rail may be corrected using pressing. NOTE

7.4 7.4.1

Other mandatory processes are described in the relevant clauses within the standard.

Identification Branding

Brand marks shall be rolled in relief on one side and in the middle of the web (see annex A) of each rail at least once every 4 m. The brand marks on the rails shall be clearly legible and shall be 20 mm to 25 mm high, raised between 0,6 mm and 1,3 mm. 10

prEN 13674-1:2002 (E)

The branding line(s) to denote grade shall be 50 mm in length for the long branding line and 25 mm in length for the short branding line. The brand marks shall include: a)

the identification of the mill;

b)

the steel grade as shown in Table 1;

c)

the last two figures of the year of manufacture;

d)

the rail profile identification as shown in annex A.

EXAMPLE

ROLLING MILL

___ _______ 96 60 E 1

(60 E 1 profile rail rolled 1996 and 260 HBW carbon-manganese rail steel grade).

ROLLING MILL

___ _______ _______

96 60 E 1

(60 E 1 profile rail rolled 1996 and 350 HBW heat treated carbon-manganese rail steel grade).

7.4.2

Hot stamping

In addition to the branding requirements of 7.4.1 each rail shall be identified by a numerical and/or alphabetical code system, hot stamped on the non-branded side of the rail web by machine and each rail shall be hot stamped at least once every 5 m. NOTE

Subsequent cutting could result in more than one rail length having the same identity.

The figures and letters used shall be clearly legible and shall be 16 mm high. The stamped characters shall have a flat or radius face (1 mm to 1,5 mm wide) with bevels on each side. The letters and numbers shall be on a 10° angle from vertical and shall have rounded corners. The stamping shall be between 0,5 mm and 1,5 mm in depth along the centre of the web. The design shall be as shown in Figure 1. The identification system employed shall be such as to enable the hot stamped marking to be collated with: a)

the number of the heat from which the rail has been rolled;

b)

the number of the strand and position of bloom within the strand;

c)

the position of the rail in the bloom (A, B ... Y).

In the event of identification marks having been removed, omitted or requiring alteration, re-identification of such marks shall be made by rotary burr. 7.4.3

Cold stamping

Cold stamping shall only be used on the cut face of the rail within the central portion of the head, at the request of the purchaser. 7.4.4

Other identification

Rails of straightness class A shall be identified with a green mark and the position of the green mark is to be specified by the purchaser. The steel grade may additionally be identified using paint. The purchaser shall specify the colour and position of the paint application. 11

prEN 13674-1:2002 (E)

8

Qualifying tests

8.1

Procedure

8.1.1 The manufacturer shall describe any bloom slow cooling or isothermal treatment process used to demonstrate compliance with the requirements of 9.1.2.2. 8.1.2 All qualifying tests as specified in 8.2 to 8.9 shall be undertaken at least once every five years and as a result of any significant production process change for all grades, with the exception of 8.7.1, where predictive equation approval is carried out on an ongoing basis. In addition the residual stress test shall be carried out on all available grades every 2 years. The manufacturer shall only carry out testing on the 60 E 1 profile or the heaviest section produced. All rail grades and profiles supplied shall conform to the qualifying criteria in accordance with 8.2 to 8.9. The results for the grades to be supplied shall be provided at the time of tendering. In the event of a manufacturer not having produced the rail grade prior to the tender enquiry he shall have the option of carrying out such tests on the first available sequence. When the qualifying criteria have been complied with, compliance with the standard is demonstrated and consequently the manufacturer is qualified. 8.1.3 The samples in accordance with 8.1.4 and 8.1.5 shall be removed from finished roller straightened rails. These samples shall not be subject to any further mechanical or thermal treatment (other than the treatment of ageing of the tensile test pieces as described in 9.1.8.3). 8.1.4 Test pieces for fracture toughness, fatigue crack growth rate and fatigue tests (see 8.2, 8.3 and 8.4 respectively) shall be taken from 3 sample rails at least 3 m from the cut ends of the rail. Sample rails shall be from different heats and different strands. 8.1.5 For residual stress tests (see 8.5) there shall be 6 sample rails and the test pieces shall be taken at least 3 m in from each rail end. 8.1.6 All tests should be carried out by a laboratory that operates an approved and audited quality assurance system conforming to requirements at least equivalent to EN ISO 9001. 8.1.7 The purchaser shall have access to all test records, calibrations and calculations that contribute to the final results. 8.1.8

8.2 8.2.1

All test results shall be reported to the purchaser.

Fracture toughness (KIc) Test pieces and test methods

Tests shall be performed in accordance with annex B. 8.2.2

Qualifying criteria

The value of K1c shall comply with Table 2.

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Table 2 — Minimum single and minimum mean values of KIc Steel grade

NOTE

8.3

Minimum single value

Minimum Mean

KIc (MPa m+1/2)

KIc (MPa m+1/2)

200 and 220

30

35

260 and 260 Mn

26

29

320 Cr

24

26

350 HT

30

32

350 LHT

26

29

*

In some circumstances kQ values can be used for the purpose of qualification - see B.6.

Fatigue crack growth rate

8.3.1

Test method

Tests shall be carried out in accordance with the general requirements of BS 6835-1. 8.3.2

Test pieces

A three point bend, single edge notch test piece, of the dimensions and location within the rail shown in Figure 2 shall be used. 8.3.3

Number of tests and test conditions

A minimum of 3 tests from each sample rail shall be performed under the following conditions: 

test temperature shall be within the range + 15 °C to + 25 °C;



R = 0,5 (R = minimum cyclic load/maximum cyclic load);



3 point bend test piece loading span shall be 4 W (see Figure 2);



cyclic loading frequency shall be within the range 15 Hz to 40 Hz;



environment - laboratory air.

8.3.4

Qualifying criteria

Fatigue crack growth rates (m/Gc) shall not exceed the values given in Table 3. Table 3 — Fatigue crack growth rates Steel grades All grades except 200 and 320 Cr

8.4 8.4.1

∆ K = 10 MPa m½

∆ K = 13,5 MPa m½

17 m/Gc

55 m/Gc

Fatigue test Test method

Constant amplitude fatigue tests shall be carried out in accordance with ISO 1099.

13

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8.4.2

Test pieces

The test pieces shall be machined from the sample rail as shown in Figure 3. 8.4.3

Number of tests and test conditions

A minimum of 3 test pieces shall be tested from each sample rail under the following conditions: 

test temperature shall be within the range + 15 °C to + 25 °C;



control variable shall be axial strain amplitude;



the strain cycle shall be symmetrical about the initial, zero load.

8.4.4

Qualifying criteria

For a total strain amplitude of 0,00135, the life of each specimen shall be greater than 5 × 106 cycles. NOTE

8.5 8.5.1

Life is defined as the complete separation of the specimen.

Residual stress in rail foot Test method

The residual stresses in the rail foot shall be determined in accordance with annex C. 8.5.2

Test pieces

Each of the 6 test pieces from the rail section shall be 1 m in length and shall be taken from rails as described in 8.1.3 and 8.1.5. NOTE Only a small part of the test piece will be destroyed for the purpose of measuring residual stress; the remainder can be used for other qualifying approval tests.

8.5.3

Measurements

Longitudinal residual stress determinations shall be made on the rail foot of each of the 6 test pieces described in 8.5.2. The location of the measurements is shown in Figure C.1. If data are available for straightness class A rails then class B rails of the same profile need not be tested. 8.5.4

Qualifying criteria

The maximum longitudinal residual stress in the foot shall be 250 N/mm2 for all steel grades.

8.6

Variation of centre line running surface hardness of heat treated rails

This clause only applies to heat treated rails. For the longest length of rail produced by the manufacturer, a one metre length of rail shall be taken from each end and at 20 m intervals from one end of the rail. These shall be hardness tested (HBW) along their length at 25 mm intervals on the centreline of the running surface after 0,5 mm has been ground away. The hardness results shall be no more than ± 15 HBW from the mean result obtained.

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8.7

Tensile strength and elongation

8.7.1 Predictive equations relating chemical composition to tensile strength and elongation shall be calculated using multiple regression analysis for all non heat treated rails produced. The following procedure shall be carried out: 

development of a predictive equation;



confirmation of the predictive equation;



periodic updating of the predictive equation;



corrective action.

8.7.2 Manufacturers shall calculate, using multiple regression analysis for all naturally hard steel grades produced, predictive equations relating chemical composition to tensile strength and elongation. Each manufacturer shall derive its own predictive equations. The predictive equations shall be produced from a minimum number of 100 heats and a maximum number of 200 heats. The equations shall be created by carrying out one valid tensile test per heat. Tensile tests shall be carried out in accordance with 9.1.8.2 and 9.1.8.3. The predictive equations shall produce results which are within a scatter band governed by the following limits: tensile strength

:

12,5 MPa (1 standard error);

elongation

:

1,0 % (1 standard error).

8.7.3 The results of the predictive equations shall be compared with experimentally determined tensile strength and elongation results as described in 9.1.8. This comparison will be achieved by carrying out one valid tensile test every 2 000 tonnes or at least every tenth heat. The experimental results shall be within plus or minus 25 MPa tensile strength and plus or minus 2 % elongation of those obtained from the predictive equations. 8.7.4 The results of the experimental tensile strength and elongation tests obtained from 8.7.3 shall be used to update the predictive equations. These results shall be accumulated and the equations updated annually. The updated equations shall be based on the last 200 results. 8.7.5 If results from the predictive equations or the experimental results are outside the limits set in 8.7.2 and 8.7.3 then: a)

the manufacturer shall carry out an investigation;

b)

the problem will be resolved by the manufacturer taking appropriate corrective action;

c)

the manufacturer shall report the findings of a) and b) to the purchaser;

d)

if the problem cannot be resolved to the satisfaction of the purchaser, the manufacturer or potential manufacturer shall have failed the approval requirements as specified in 8.1.1. If the physical tests themselves are within the requirements of Table 5 a) the product is satisfactory.

8.8

Segregation

Full section transverse test pieces shall be sulfur printed in accordance with ISO 4968. For this purpose rail sulfur prints shall be taken from each strand from the beginning of every heat, excluding the mixing zone, for five heats.

15

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The samples shall be assessed and classified according to the limiting figures of annex D. For the process to be accepted, all samples shall be classified as acceptable.

8.9

Other qualifying requirements

In addition to the results of the tests described in 8.2 to 8.8 inclusive the manufacturer shall provide a complete set of results for the acceptance tests described in 9.1. Samples for these tests shall be taken from the rails used for the qualifying tests as described in 8.1.3.

9

Acceptance tests

9.1

Laboratory tests

9.1.1

General

Laboratory tests shall be performed, during production, at frequencies as stipulated in Table 4. Results for each laboratory test shall comply with the limiting values shown in Table 5. Additional information and other acceptance tests not covered by Table 5 shall comply with the requirements of 9.1.2 to 9.1.8 inclusive. All rails supplied shall meet the requirements of clauses 8 and 9. 9.1.2 9.1.2.1

Chemical composition General

The liquid chemical composition shall be determined for each heat. When the solid chemical composition is checked, this shall be carried out at the position of the tensile test piece. Liquid and solid chemical composition shall conform to the requirements of Table 5 a). 9.1.2.2

Hydrogen

The hydrogen content of the liquid steel shall be measured by determining pressure of hydrogen in the steel using an on-line immersion probe system. At least two liquid samples shall be taken from the first heat of any sequence using a new tundish and one from each of the remaining heats and analysed for hydrogen content (see Table 4). The first sample from the first heat in a sequence shall be taken from the tundish at the time of the maximum hydrogen concentration. The heats shall be assessed according to hydrogen content in accordance with Table 6. The blooms from group 1 heats shall be deemed to be satisfactory. The blooms from group 2 heats shall be slowly cooled or isothermally treated and all heats shall be tested in the rail form.

16

prEN 13674-1:2002 (E)

Table 4 — Testing frequency Relevant subclause Chemical composition

9.1.2

Steel grades 200, 220, 260, 260Mn, 320Cr

350 HT, 350 LHT

One per heat

One per heat

Hydrogen

9.1.2.2

One per heat (2 from first heat in sequence)

One per heat (2 from first heat in sequence)

Total oxygen

9.1.2.3

One per sequence a

One per sequence a

Not required for grades 200, 220 and 260

One per 50 tonnes of re-heated a,c

One per 1000 tonnes or part thereof for grades 260 Mn and 320 Cr

One per 100 tonnes of mill heat treated a,c

One per 1000 tonnes or part thereof a,b

One per 500 tonnes of re-heated and mill heat

Microstructure

Decarburisation

9.1.3

9.1.4

treated a,c Oxide cleanness

9.1.5

One per sequence a,b

One per sequence a,b or c

Sulfur print

9.1.6

One per 500 tonnes or part thereof a,b

One per 500 tonnes or part thereof a,b or c

Hardness

9.1.7

One per heat a,b

One per 50 tonnes of re-heated a,c One per 100 tonnes of mill heat treated a,c

Tensile

8.7 & 9.1.8

One calculation per heat/one per 2 000 tonnes a,b

One per 1 000 tonnes (test)a,c

a

Samples shall be taken at random but only rails from blooms outside the mixing zone between heats when continuously cast in sequence.

b

Samples shall be cut after rolling.

c

Samples shall be cut from heat treated rails.

17

prEN 13674-1:2002 (E)

Table 5 a) — Chemical composition/mechanical properties

200

220

260

260

10-4% (ppm) max.

% By mass

Steel sample grade C

Si

Mn

P max.

S

Cr

Al max.

V max.

N max.

Oa

Hb

Liquid

0,40/0,60

0,15/0,58

0,70/1,20

0,035

0,008/0,035

0,15 max

0,004

0,030

0,009

20

3,0

Solid

0,38/0,62

0,13/0,60

0,65/1,25

0,040

0,008/0,040

0,15 max

0,004

0,030

0,010

20

3,0

Liquid

0,50/0,60

0,20/0,60

1,00/1,25

0,025

0,008/0,025

0,15 max

0,004

0,030

0,008

20

3,0

Solid

0,50/0,60

0,20/0,60

1,00/1,25

0,025

0,008/0,025

0,15 max

0,004

0,030

0,008

20

3,0

Liquid

0,62/0,80

0,15/0,58

0,70/1,20

0,025

0,008/0,025

0,15 max

0,004

0,030

0,009

20

2,5

Solid

0,60/0,82

0,13/0,60

0,65/1,25

0,030

0,008/0,030

0,15 max

0,004

0,030

0,010

20

2,5

Liquid

0,55/0,75

0,15/0,60

1,30/1,70

0,025

0,008/0,025

0,15 max

0,004

0,030

0,009

20

2,5

Solid

0,53/0,77

0,13/0,62

1,25/1,75

0,030

0,008/0,030

0,15 max

0,004

0,030

0,010

20

2,5

Liquid

0,60/0,80

0,50/1,10

0,80/1,20

0,020

0,008/0,025

0,80/1,20

0,004

0,18

0,009

20

2,5

Solid

0,58/0,82

0,48/1,12

0,75/1,25

0,025

0,008/0,030

0,75/1,25

0,004

0,20

0,010

20

2,5

Liquid

0,72/0,80

0,15/0,58

0,70/1,20

0,020

0,008/0,025

0,15 max

0,004

0,030

0,009

20

2,5

Solid

0,70/0,82

0,13/0,60

0,65/1,25

0,025

0,008/0,030

0,15 max

0,004

0,030

0,010

20

2,5

Liquid

0,72/0,80

0,15/0,58

0,70/1,20

0,020

0,008/0,025

0,30 max

0,004

0,030

0,009

20

2,5

Solid

0,70/0,82

0,13/0,60

0,65/1,25

0,025

0,008/0,030

0,30 max

0,004

0,030

0,010

20

2,5

Rm min.

min. elong

Centre line running surface c

MPa

%

hardness HBW

680

14

200/240

770

12

220/260

880

10

260/300

880

10

260/300

1080

9

320/360

1175

9

350/390

1175

9

350/390

Mn

320 Cr

350 HT

350 LHT

18

a

See 9.1.2.3.

b

See 9.1.2.2.

c

See Figure 10.

prEN 13674-1:2002 (E)

Table 5 b) — Maximum residual elements Mo

Ni

Cu

Sn

Sb

Ti

Nb

Cu & 10 Sn

200, 220, 260, 260Mn

0,02

0,10

0,15

0,030

0,020

0,025

0,01

0,35

Cr + Mo + Ni + Cu + V

0,35

320 Cr

0,02

0,10

0,15

0,030

0,020

0,025

0,01

0,35

Ni + Cu

0,16

350 HT

0,02

0,10

0,15

0,030

0,020

0,025

0.04

0,35

Cr + Mo + Ni + Cu + V

0,25

350 LHT

0,02

0,10

0,15

0,030

0,020

0,025

0,04

0,35

Mo + Ni + Cu + V

0,20

19

prEN 13674-1:2002 (E)

Table 6 — Hydrogen content of heats Hydrogen content 10-4 % (ppm)

Heats

Steel grades 200 and 220

All other steel grades

Group 1

≤ 3,0

≤ 2,5

Group 2

> 3,0

> 2,5

If the hydrogen contents of the first samples of a first heat or the heat sample of a second or further heat do not comply with the requirements of Table 5 a) then the blooms made before those samples are taken shall be slowly cooled or isothermally treated. Also all blooms made before the hydrogen content eventually complies with the requirements in Table 5 a) shall be slowly cooled or isothermally treated. When testing of rails is required rail samples shall be taken at the hot saw at a frequency of one per heat at random. However on the first heat in a sequence, the rail sample shall be from the last part of a first bloom teemed on any strand. Hydrogen determination shall be carried out on samples taken from the centre of the rail head. If any test result fails to meet the requirements stated in Table 5 a) the heat shall be rejected. 9.1.2.3

Determination of total oxygen content

9.1.2.3.1

General

Total oxygen content shall be determined in the liquid steel, following solidification of the sample, or from the solid rail head, in the positions shown in Figure 4, and at the frequency shown in Table 4. For orders in excess of 5 000 tonnes at least 95 % of heats shall have a total oxygen content of less than 20 ppm. No more than 5 % of heats shall have a total oxygen content of up to 30 ppm. Heats with a total oxygen content greater than 30 ppm shall be rejected. For orders less than 5 000 tonnes, only one sample with total oxygen greater than 20 ppm, but less than 30 ppm, is allowed. Heats with total oxygen greater than 30 ppm shall be rejected. Any heats with total oxygen above 20 ppm shall require that all subsequent heats be tested until values below 20 ppm are achieved. 9.1.2.3.2

Preparation of the sample

The thickness of the transverse rail slice shall be 4 mm. Samples shall be prepared in accordance with EN 10276-1. 9.1.2.3.3

Measurement

The measurement of oxygen shall be made using an automatic machine. 9.1.3 9.1.3.1

Microstructure General

Microstructures shall be determined at a magnification of x 500. The microstructure shall be verified for 260 Mn, 320 Cr and heat treated rails in accordance with the requirements of Table 4. The testing position in the rail head shall be as shown in Figure 5.

20

prEN 13674-1:2002 (E)

9.1.3.2

Grades 200, 220

The microstructure shall be a mixture of pearlite and grain boundary ferrite. There shall be no martensite, bainite or grain boundary cementite. 9.1.3.3

Grade 260, 260 Mn

The microstructure shall be pearlitic but grain boundary ferrite may occur in these grades. The maximum grain boundary ferrite permitted is shown in Figure 6. There shall be no martensite, bainite or grain boundary cementite. 9.1.3.4

Grade 320 Cr

The microstructure shall be fully pearlitic with no martensite, bainite or grain boundary cementite. 9.1.3.5

Grades 350 HT, 350 LHT

The microstructure shall be pearlitic with no martensite, bainite or grain boundary cementite. The maximum grain boundary ferrite permitted is shown in Figure 6. 9.1.4

Decarburisation

No closed ferrite network shall be observed below 0,5 mm depth measured anywhere on the rail head surface. The decarburisation depth will be assessed by means of a hardness test at a frequency shown in Table 4. After a minimum of preparation of the rail surface (polishing) a hardness test according to the method indicated in 9.1.7 will be performed in three points. None of the results of hardness obtained shall be lower than the minimum value specified of the grade, reduced by 7HBW (example : 253HBW for grade 260). Photomicrographs showing the depth of decarburisation allowed are shown in Figure 7 and Figure 8 defines the rail head surface for decarburisation checks. 9.1.5

Oxide cleanness

Samples shall be prepared and assessed in accordance with DIN 50602. For orders less than 5 000 tonnes, only one sample with a K3 greater than 10 and less than 20 is allowed. Samples shall be taken from one of the last blooms of the last heat of the sequence but from each sample 2 specimens shall be tested. The following limits shall apply. Total index

10 < K3 < 20 for a maximum of 5 % of samples. K3 < 10 for a minimum of 95 % of samples.

The testing position in the rail head is shown in Figure 9. 9.1.6

Sulfur prints

Sulfur prints of transverse rail sections shall be prepared in accordance with ISO 4968 at the frequency shown in Table 4. All samples, including those intended for repeat test, shall be taken from outside the mixing zones of the heat. When part or all of an adjacent heat has been withdrawn due to non-conformance, tests shall be made in the mixing zones to determine the first conforming blooms. The sulfur prints shall conform to the requirements of annex D.

21

prEN 13674-1:2002 (E)

9.1.7

Hardness

Brinell hardness tests shall be carried out in accordance with EN ISO 6506-1 at the frequency shown in Table 4. The test conditions shall be as follows: 

tungsten carbide ball;



ball diameter 2,5 mm;



load 1,839 kN;



period of application 15 s.

Other measurement techniques, for example Rockwell or Vickers hardness testing, may be used, but in case of dispute Brinell hardness testing in accordance with EN ISO 6506-1 shall be used. The hardness values measured shall meet the requirements given in Table 7 for the relevant grade. In the case of the heat treated grades the mean value of position 2 shall be greater than the value of position 3 + 0,4 [(mean value of position 1) minus (value of position 3)]. Also the difference between any of the three position 1 s shall be no more than 30 HBW. The testing positions are shown in Figure 10. The hardness on the centre line of the head crown shall not vary by more than 30 HBW on any individual rail. For the steel grades 200, 220, 260, 260 Mn and 320 Cr the hardness shall only be tested for position RS. For heat treated rails hardness shall be tested in accordance with 8.6 over the centre line of the rail head at the positions shown in Figure 10. 0,5 mm shall be ground from the running surface before a hardness impression is made. Table 7 — Hardness testing positions and requirements Position

Rail Steel Grade 200

220

260

260Mn

320Cr

350HT

350LHT

320-360

350-390 b

350-390 b

1

340 min

340 min

2

331 min

331 min

3

321 min

321 min

4

340 min

340 min

Hardness (HBW) RS a

a

200-240

220-260

260-300

260-300

RS = Point on the centre line running surface.

b

If the hardness exceeds 390HBW, the rail is acceptable provided the microstructure is confirmed to be pearlitic, and the hardness does not exceed 405 HBW.

9.1.8 9.1.8.1

Tensile tests Steel grades 200, 220, 260, 260 Mn, 320 Cr

For rail steel grades 200, 220, 260, 260 Mn and 320 Cr the tensile strength and elongation shall be determined by the predictive equation described in 8.7.2.

22

prEN 13674-1:2002 (E)

If a manufacturer is temporarily unqualified, or if limited production quantities prevent qualification, then tensile testing shall be one per heat. The values determined by the predictive equation shall not be less than those quoted in Table 5. 9.1.8.2

Steel grades 350HT and 350LHT

For rail steel grades 350 HT and 350 LHT tensile tests shall be carried out at a frequency given in Table 4. Test samples shall be removed from the rail as shown in Figure 5. Results obtained shall comply with the values given in Table 5. 9.1.8.3

Method of test

The manufacturer shall determine the tensile properties in accordance with EN 10002-1 using a round tensile test piece with the dimensions as follows: 

diameter of 10 mm;



original cross-sectional area of 78,5 mm2;



original gauge length of 50 mm;



minimum parallel length of 55 mm.

Before testing at ambient temperature the tensile test pieces shall be maintained at a temperature of 200 °C for up to 6 h. In the case of dispute, before testing at ambient temperature the tensile test pieces shall be maintained at a temperature of 200 °C for 6 h. 9.1.9

Retest procedures

If any test fails to meet the requirements of 9.1.2 to 9.1.8 (but excluding hydrogen) then two tests shall be performed on samples from rails in close proximity to the original. Should either retest fail then rails shall be progressively tested until acceptable material is found. The failed material shall be rejected or in the case of heat treated material retreated and tested. For hydrogen and oxygen testing refer to the 9.1.2.2 and 9.1.2.3 respectively. If the results of an investigation under 8.7.5 or the qualification procedure, or the predictive equation indicate that certain rails are out of specification, then acceptance of such rails shall be based on experimental tensile test results. The minimum values in Table 5 shall in such cases apply.

9.2 9.2.1

Dimension tolerances Profile

The nominal dimensions of the rail profile (see annex A) and the actual dimensions anywhere on any rail shall not differ by more than the tolerances given in Table 8.

23

prEN 13674-1:2002 (E)

Table 8 — Profile tolerances * Reference points

Profile class (dimensions in mm)

(see Figure E.1)

Gauge figure number (see annex E)

Height of rail a < 165

X

Y

± 0,5

+ 0,5

*H - 1,0

≥ 165

± 0,6

3

+ 0,6 - 1,1

Crown profile Class A straightness

*C

Class B straightness Width of rail head

*WH

+ 0,6

+ 0,6

- 0,3

- 0,3

± 0,6

± 0,6

± 0,5

+ 0,6

4 5

- 0,5 Rail asymmetry

± 1,2

± 1,2

6,7

± 0,35

± 0,35

8

± 0,5

± 0,5

8

*As

Inclination of fishing surfaces (on the basis of 14 mm parallel to the inclined theoretical fishing surfaces) b

*IF

Height of fishing

*HF

< 165

± 0,6

± 0,6

Web thickness

≥ 165 *WT

+ 1,0

+ 1,0

- 0,5

- 0,5

Width of rail foot

*WF

± 1,0

+ 1,5 - 1,0

10

Foot toe thickness

*TF

+ 0,75

+ 0,75

11

Foot base concavity

- 0,5

- 0,5

0,3 max

0,3 max

9

a

The total height variation over any rail length shall not be greater than 1 mm for rails < 165 mm and 1,2 mm for rails ≥ 165 mm.

b

9.2.2

The maximum fishing tolerance on the head and on the foot is 0,35 mm but the total tolerance allowed is also 0,35 mm.

Straightness, surface flatness and twist

Flatness testing of the body shall be performed automatically. Tolerances for straightness, surface flatness and twist shall meet the requirements given in Table 9. Rejected rails may be subject to only one roller re-straightening. In cases of dispute on the results of the automatic technique, rail flatness shall be verified using a straight edge as shown in Table 9. When measuring sidesweep the rail shall be stood vertically on a suitable support that allows the rail to be unrestrained. If a measurement technique other than that given above is used, only the above shall be used in the case of dispute.

24

prEN 13674-1:2002 (E)

Table 9 — Straightness, surface flatness and twist tolerances 1

1

1m

V

2m

2 3

H

4 Key 1 2 3 4

BODY

Overlap Body Whole rail End “E

a

2

Key 1 V and H. Location of flatness measurements 2 The position of H is nominally 5 mm - 10 mm below the gauge corner on the side of the head

Vertical flatness

V

Class A d L ≤ 0,3 mm 3mc and ≤ 0,2 mm 1mc ≤ 0,45 mm 1,5 m c

b L

d

Horizontal flatness H

Class B d L c ≤ 0,4 mm 3m and ≤ 0,3 mm 1mc ≤ 0,6 mm 1,5 m c

1,5 m ≤ 0,5 mm

ENDS a

2m 1,5 m

b

L

2m d

and

Vertical straightness

≤ 0,3 mm and e ≤ 0,2 mm

Horizontal straightness

≤ 0,4 mm

≤ 0,7 mm

1md and e ≤ 0,2 mm

≤ 0,6 mm 1,5 m

If e > 0 F

2m

b L

and ≤ 0,4 mm

e

F

1md

d

End “E”

"to be continued"

25

prEN 13674-1:2002 (E)

Table 9 (concluded) Class B d

Class A L

Length of overlap

d

L

1,5 m

2m

b 1.0

OVERLAP a Vertical flatness V Horizontal flatness H

Upsweep and downsweep

≤ 0,4 mm ≤ 0,6 mm

1,5 m c 1,5 m c

≤ 0,3 mm ≤ 0,6 mm

10 mm e

2mc 2mc

10 mm e

L d

10

WHOLE RAIL

10 Side sweep Twist NOTE

Curve radius R > 1500 m See Figures 11 and 12

Curve radius R > 1500 m See Figures 11 and 12

It is unlikely that the manufacturer can supply rails < 54 Kg/m for class A tolerances.

a

Automatic measurement equipment shall measure as much of the rail as possible but, at least the body. If the whole rail satisfies the body specifications, then measurement of end and overlap is not mandatory.

b

Automatic measurement techniques are complex and are therefore difficult to define but the finished rail flatness shall be capable of being verified by straight edge as shown in the above drawings.

c

95 % of delivered rails shall be within limits specified, with 5 % of rails allowed outside the tolerances by 0,1 mm.

d

Reference L sliding over end E.

e

The ends of the rails shall not be up more than 10 mm when the rail is on its foot or on its head when standing on an inspection bed.

26

prEN 13674-1:2002 (E)

9.2.3

Cutting and drilling

The size and location of drilled holes, the squareness of rail ends and rail lengths shall be within the tolerances given in Table 10. Drilled holes and rail ends shall be deburred. For holes that are to be subject to special treatments the tolerances shall be in accordance with 4.h).

9.3

Gauges

The gauges required for manufacture are as shown in annex E. If other measurement techniques than those given in annex E are used, only those in annex E shall be used in case of dispute.

9.4

Inspection requirements/tolerances for internal quality and surface quality

9.4.1

Ultrasonic test requirements

All rails shall be ultrasonically tested by a continuous process ensuring that the entire rail length and 9.4.1.1 specified cross-sectional area are inspected. 9.4.1.2

The minimum cross-sectional area examined by the ultrasonic technique shall be:



at least 70 % of the head;



at least 60 % of the web;



the area of the foot to be tested shall be as shown in Figure 16.

By convention these areas are based on projecting the nominal crystal size of the probe. The head shall be tested from both sides and from the running surface.

27

prEN 13674-1:2002 (E)

Table 10 — Drilling and cutting tolerances Number 1

Dimensional requirement Drilling Diameter ≤ 30 mm > 30 mm Centring and positioning of the holes vertically and horizontally

2

Squareness of ends

Tolerance

± 0,5 mm ± 0,7 mm The horizontal position of the holes is checked using a gauge as shown in Figure E.12 which has a stop designed to come into contact with the end of the rail and pins designed to enter the holes. The diameter of the pins for horizontal and vertical clearances is smaller than the diameter of the holes by: - 1,0 mm for holes less than or equal to 30 mm in diameter; - 1,4 mm for holes greater than 30 mm in diameter; - the distances between the centre lines of the pins and the stop are equal to the nominal distances from the centre line of the holes to the end of the rail; - the gauge pins shall be able to enter the holes at the same time while the stop is touching the end of the rail. The vertical centring of the holes can be checked using a gauge as shown in Figure E.13. The side of the hole, left or right, is determined by proceeding from the side with the relief markings. 0,6 mm in any direction

0.6

0.6 0.6

0.6 3

a

28

a

Length - both ends drilled ≤ 24 m > 24 m ≤ 40 m - other (undrilled or one end drilled)

± 3 mm ± 4 mm ± 1 mm/per metre of rail (max. ± 30 mm on any rail) For special purpose undrilled rails the length tolerance is ± 6 mm up to 24 m and ± 10 mm for > 24 m rail.

The given rail lengths apply for + 15 °C. Measurements made at other temperatures are to be corrected to take into account expansion or contraction of the rail.

prEN 13674-1:2002 (E)

The sensitivity levels of the automatic equipment used shall be a minimum 4dB greater than the level 9.4.1.3 required to detect the artificial defects described in 9.4.1.4. An echo giving a possible defect indication shall be re-tested, using an increased sensitivity of 6dB in place of 4dB. Rails giving signals over the threshold in the rail using the increased sensitivity shall be rejected or cut back to remove the defective portion. The system shall incorporate continuous monitoring of interface or backwall echo signals. There shall be a calibration rail for each profile ultrasonically tested and the positions of the artificial 9.4.1.4 defects are given for the rail head, web and foot of the 60 E 1 profile in Figures 13, 14, and 15 respectively. Calibration rails for other profiles shall be based upon the 60 E 1 calibration rail and detailed drawings shall be made available to the purchaser. Other methods of calibration may be used but these methods shall be equivalent to that described above. The calibration rail shall be used to test the equipment at production speed at the beginning and once every 8 h of testing a particular profile. 9.4.2 9.4.2.1

Surface quality General

All rails shall be visually or automatically inspected on all faces for surface imperfections. In addition, the underside of the rail foot shall be inspected automatically in accordance with 9.4.2.6. All rails shall comply with the criteria defined at 9.4.2.2 and 9.4.2.3. Assessment and dressing of imperfections shall be in accordance with 9.4.2.5. 9.4.2.2

Hot marks, protrusions and seams

All protrusions on the running surface or the underside of the foot shall be dressed. Any protrusions affecting the fit of the fishplate at less than 1 m from the extremity of the delivered rail shall be dressed to shape. The depth of hot marks and seams, as defined in EN 10163-1, shall not exceed: 

0,35 mm for the running surface;



0,5 mm for the rest of the rail.

In the case of longitudinal guide marks, there shall be a maximum of two, to the depth limits specified, at any point along the length of the rail but no more than one of these shall be on the rail running surface. Recurring guide marks along the same axis are accepted as a single guide mark. The maximum width of guide marks shall be 4 mm. The width to depth ratio of allowable guide marks shall be a minimum 3:1. In the case of hot formed marks originating from the vicinity of the mill rolls, those which are recurrent along the same axis, at a distance equal to the roll circumference, shall be accepted as a single mark. They can be removed by dressing except those marks on the rail crown where a maximum of 3 per 40 m is allowed. 9.4.2.3

Cold marks

Cold marks are longitudinal or transverse cold formed scratches. The discontinuity depth shall be not larger than: 

0,3 mm for the rail running surface and underside of foot;



0,5 mm for the rest of rail.

29

prEN 13674-1:2002 (E)

NOTE It is difficult, or impossible to detect in track fatigue cracks initiating and propagating from the underside of the foot; therefore all practicable efforts should be made to avoid cold transverse marks in this area.

9.4.2.4

Surface microstructural damage

Any sign of surface microstructural damage resulting in martensite or white phase shall be dressed or the rail rejected. The dressed area shall be proved by suitable hardness testing. The hardness shall not be more than 50 HBW greater than the surrounding material. 9.4.2.5

Proving and dressing of surface imperfections

If the imperfection depth cannot be measured it shall be investigated by depth proving, and subsequently dressed to the criteria below, using a rotary burr, lamellar flap tool or grinding belt, providing the rail microstructure is not affected by the operation and the work is contour blended. The depth of dressing shall be not larger than: 

0,35 mm for the rail running surface;



0,5 mm for the rest of rail.

No more than three defects within a length of 10 m of rail and, over the whole length, a maximum of one defect per 10 m rail length shall be dressed or proved. After dressing profile tolerances shall be in accordance with Table 8 and flatness tolerances shall be in accordance with Table 9. 9.4.2.6

Automatic foot inspection

The rail shall be automatically inspected on the underside of the foot along its entire length. The equipment used shall be able to detect artificial imperfections with sizes as shown in Table 11. The artificial imperfections shall have a tolerance of + 0,1 mm. Table 11 — Dimensions of test imperfections Depth (mm)

Length (mm)

Width (mm)

1,0

20

0,5

1,5

10

0,5

An edge loss for the automatic technique is permitted for the extreme 5 mm of the flat portion of the foot width at each side. A suitable test rail containing artificial imperfections requires to be run every 8 h.

16 16

o

Figure 1 — Design of letters and numbers on a 10 angle for rail stamps 30

prEN 13674-1:2002 (E)

Dimensions in millimetres

B = 20 10

1

2

10

H

W = 45

2

3

=

45

10

=

115

115

Key 1

Notch machined into this face

2 3

Section through rail head Letter ‘H’ to be stamped on end face of test piece as shown

Figure 2 — Location and dimensions of fatigue crack growth test pieces

31

prEN 13674-1:2002 (E)

All dimensions in millimetres

45º

R 13

V

90º

10

R 80

18

✟

Intersecting point of the R 13 and R 80 radii (60 E 1 section) Location of the centre of the test piece

1

112 b

2 36 b

7,1 6,9

36 b

c

c

M 18 b

M 18 b

A

14,6 14,5

1,6

3

R 26 a,b 12,25 12,00

50 b

Key 1 2

Screw threads (both ends) to be concentric with Ø A within 0,005 Cylindrical within 0,005

3

Centre drill 26 mm radius shall run tangential with gauge diameter (datum dia’A’) without undercutting or leaving a shoulder

a b

General tolerance to be ± 0,2 mm unless otherwise stated

c

Specimen to be identified on each end

Figure 3 — Specimen for determining fatigue initiation life

32

prEN 13674-1:2002 (E)

30

12


45º

=

=

Figure 4 — Sampling positions in rail for total oxygen determination Dimensions in millimetres

R 13

✟

✟

R 80

90º

=

10

10

45º

=

Key

✟

Intersecting point of the R 13 and R 80 radii (60 E 1 section) Location at the centre of the tensile test piece

Area to be checked for microstructure

Figure 5 — Location of tensile test piece and microstructure checks

33

prEN 13674-1:2002 (E)

Photomicrograph x 500

Figure 6 — Photomicrograph and diagram showing maximum allowable ferrite at the grain boundaries for grades other than 200 and 220

34

prEN 13674-1:2002 (E)

← Surface of rail

← Limit of continuous ferrite network. This example shows decarburisation to a depth of 0,28 mm

Grades 200 and 220 ← Surface of rail

← Limit of continuous ferrite network. This example shows decarburisation to a depth of 0,25 mm

All grades other than 200 and 220

Figure 7 — Photomicrographs (x 100) showing depth of decarburisation allowed on the rail wear surface

35

prEN 13674-1:2002 (E)

L

2L /3

1

Key 1

Decarburisation limits apply to this part of rail head

Figure 8 — Range of extent of rail head surface for decarburisation checks

36

prEN 13674-1:2002 (E)

30

10

5

5


1 45º

20

20

Key 1

Face to be examined

Figure 9 — Oxide cleanness sampling position in rail head

37

prEN 13674-1:2002 (E)


2

1

1 2

10

RS

20

45º

R1

=

=

10

R2

10

4

5

3

4

Key 1,2,3 and 4

Location of hardness testing (see Table 7)

exact intersecting points of the radii

Figure 10 — Hardness testing positions Dimension in millimetres

≤ 2,5

NOTE If the rail shows evidence of twist being laid head up on an inspection bed, it will be checked by inserting feeler gauges between the base of the rail and the rail skid nearest the rail end. If the gap exceeds 2,5 mm the rail is rejected.

Figure 11 — Whole rail twist

38

prEN 13674-1:2002 (E)

1

2

3 00

20

0,0035 x c

10

c b

Key 1

Cross section 1 m away from the rail end

2 3

Gauge Cross section at the rail end

NOTE 1 rejected.

If the rotational twist in the end metre of the rail exceeds 0,2° as measured by the gauge illustrated above the rail is

NOTE 2 The relative twist between the cross-sections at the rail ends, and the cross-sections 1 m away from each end, should not exceed 0,0035 × c. The following measurements should be made with a specific gauge (1 m long), on each rail end, using as measuring references, points on the under surface of the foot following the measuring procedures below.

(*) : diameter of contact surfaces: 20 mm. Foot width b (mm) b < 130 130 ≤ b < 150 b ≥ 150

Distance between contacts (*) c (mm) 90 110 130

Figure 12 — Rail end twist

39

14

14

prEN 13674-1:2002 (E)

A

C

NOTE 1

Both flat bottomed holes are 2 mm diameter and 15 mm deep.

NOTE 2

Flat bottomed holes A and C are 8 ± 1 from B and D below. o

o

90

90

B

D

NOTE 1

Both flat bottomed holes are 2 mm diameter and 15 mm deep.

NOTE 2

Flat bottomed holes B and D are 90 to opposite

o

Figure 13 b)

40

30

30

Figure 13 a)

20

20

prEN 13674-1:2002 (E)

1

Figure 13 c) Key 1

Two mm diameter through hole Figure 13 — Location of artificial defects in rail head of 60 E 1 profile

41

prEN 13674-1:2002 (E)

5 5

10

10

=

All dimensions in millimetres measured from the centre line

=

10

10

1

Key 1

Centreline of web

NOTE 1

Flat bottomed holes are 2 mm diameter drilled to centre line of web.

NOTE 2

Flat bottomed holes are allowed to be ± 10 from horizontal.

o

Figure 14 — Location of artificial defects in rail web of 60 E 1 profile

42

prEN 13674-1:2002 (E)

1

Key 1

Two mm diameter through hole

Figure 15 — Location of artificial defect in rail foot of 60 E 1 profile

1

Key 1

Area to be tested

Figure 16 — Area to be tested in rail foot of 60 E 1 profile

43

prEN 13674-1:2002 (E)

Annex A (normative) Rail profiles

The rail profiles listed are new designated and accurately dimensioned profiles developed from the previous less accurately dimensioned profiles listed. Table A.2 and Figure A.22 define the transition references. Table A.1 — List of profiles and previous rail profiles

44

Figure No

Profile

Previous profile

A.1

46 E 1

SBB I

A.2

46 E 2

U33

A.3

46 E 3

NP 46

A.4

46 E 4

46 UNI

A.5

49 E 1

DIN S49

A.6

49 E 2

S49 T

A.7

49 E 3

DIN 549 b

A.8

49 E 4

HUSH 113lb/54 Kg

A.9

50 E 1

U50E

A.10

50 E 2

50EB-T

A.11

50 E 3

BV 50

A.12

50 E 4

UIC 50

A.13

50 E 5

50 UNI

A.14

50 E 6

U 50

A.15

52 E 1

52 RATP

A.16

54 E 1

UIC 54

A.17

54 E 2

UIC 54 E

A.18

54 E 3

DIN S54

A.19

55 E 1

U55

A.20

56 E 1

BS 113lb BR Variant

A.21

60 E 1

UIC 60

prEN 13674-1:2002 (E)

Dimensions in millimetres 65 B A

45

R 80

R 300

R 13

14,3

Y

R1

1:4 R 6

16

R 30 R 30

1

26,7

14

R 30

R 3 0

62,5

69,35

145

15

X

15

26,95

14

18 R 6

25

1:4 R1

R2

Y 125

Key 1

Centre line of branding

Cross-sectional area Mass per metre Moment of inertia x-x axis Section modulus - Head Section modulus - Base Moment of inertia y-y axis Section modulus y-y axis

: : : : : : :

58,82 46,17 1641,1 217 236,6 298,2 47,7

cm2 kg/m cm4 cm3 cm3 cm4 cm3

Indicative dimensions : A = 18,881 mm B = 43,881 mm

Figure A.1 — Rail profile 46 E 1

45

prEN 13674-1:2002 (E)


47

1:20

R 60

R 200

R 13

13,42

Y

R2

1:3

R7

X

145

X 1

R7

62,5

67,86

15

1:10

R2

R3

Y 134

Key 1


Cross-sectional area : 58,94 Mass per metre : 46,27 Moment of inertia x-x axis : 1642,7 Section modulus - Head : 213 Section modulus - Base : 242,1 Moment of inertia y-y axis : 329,3 Section modulus y-y axis : 49,1 Indicative dimensions : A = 27,946 mm B = 40,588 mm



46

10,5

27

R 20

1:3

prEN 13674-1:2002 (E)

Dimensions in millimetres 73,72 B A

42,5

1:16,5

R 80

R 300

R 13

14,18

Y

R 1,5

1:4 R 6

R 80 14

R 80

142

X

30

X 14

25

1

R 120

62,25

70,36

R 120

R 6

R3

R1

25

1:4

Y 120

Key 1


Cross-sectional area : 59,44 Mass per metre : 46,66 Moment of inertia x-x axis : 1605,9 Section modulus - Head : 224,2 Section modulus - Base : 228,2 Moment of inertia y-y axis : 307,5 Section modulus y-y axis : 51,3 Indicative dimensions : A = 23,015 mm B = 53,761 mm



47

prEN 13674-1:2002 (E)

Dimensions in millimetres 65 A

13.75

Y

R1

1:4

45

R 400

1:20

R 14

16

R5

14 X

30

145

X

1

1:4

5

18

R1

R2 Y 135

Key 1


Cross-sectional area : 59,78 Mass per metre : 46,9 Moment of inertia x-x axis : 1688 Section modulus - Head : 221,6 Section modulus - Base : 245,2 Moment of inertia y-y axis : 338,6 Section modulus y-y axis : 50,2 Indicative dimensions : A = 38,378 mm

cm2 kg/m cm4 cm3 cm3 cm4 cm3 Figure A.4 — Rail profile 46 E 4

48

25

R

22,5

62,5

68,84

14

prEN 13674-1:2002 (E)


14

Y R 13

51,5

R 300

R 80 R2

R 80

R7

R 80

14

R 120

14

0 R 1,5

R3

27,5

R7

10,5

62,5

1

R 120

R4

52

73,41

30

149

X

125

Key 1


Cross-sectional area : 62,92 Mass per metre : 49,39 Moment of inertia x-x axis : 1816 Section modulus - Head : 240,3 Section modulus - Base : 247,5 Moment of inertia y-y axis : 319,1 Section modulus y-y axis : 51,0 Indicative dimensions : A = 15,267 mm B = 46,835 mm



49

prEN 13674-1:2002 (E)


13,62

Y

50,5

R2

R 400

1:16

R 14

1:3 R 80

R7 14

R 80

148

X

30

X

14

24,5

1

R 120

1:3

R7 1:7,81

27,5

R 40 R 1,5

R3

10,5

62,5

72,97

R 120

Y 125

Key 1


Cross-sectional area : 62,55 Mass per metre : 49,10 Moment of inertia x-x axis : 1796,3 Section modulus - Head : 239,4 Section modulus - Base : 246,2 Moment of inertia y-y axis : 318,4 Section modulus y-y axis : 50,9 Indicative dimensions : A = 40,471 mm



50

prEN 13674-1:2002 (E)


14

Y R 13

48,5

1:15.2

R 300

R 80

R2 1:3

R 80

R7 14

R 80

30

146

X

X

14

R7 1:7,81

R 1,5

R3

27,5

1:3

10,5

52

62,5

1

R 120 R 40

70,95

R 120

Y 125

Key 1





51

prEN 13674-1:2002 (E)


14,75

Y R 13

49,4

1:20

R 300

R 80

R3 1:2,7 5

22

X 22

R1

5

1

1:10 30,2

45,4

R 20

50,02

6

1:2,7

R2

R3

Y 140

Key 1





52

110

R

11

X

8

R 8

prEN 13674-1:2002 (E)


13,58

Y

49

R 200

R 60

1:20

R 13

R2 1:3 2

R1

X 1

R1

2

66

72,44

15,5

153

X

R 20

1:10

R3

R2

11,5

28

1:3

Y 134

Key 1


Cross-sectional area : 64,16 Mass per metre : 50,37 Moment of inertia x-x axis : 1987,8 Section modulus - Head : 246,7 Section modulus - Base : 274,4 Moment of inertia y-y axis : 365 Section modulus y-y axis : 54,5 Indicative dimensions : A = 30,942 mm B = 43,838 mm



53

prEN 13674-1:2002 (E)


44

1:20

R 80

R2

R 300

R 13

14,3

Y

1:3

R 8

X

59

X

151

,81 R 30

1

R 30

,81

10

67,5

70,96

15

R 8

1:8

R2

R5

Y 140

Key 1





54

11,13

28

R 10

1:3

prEN 13674-1:2002 (E)

Dimensions in millimetres 70 B A 14,23

Y

R 13

155

14

R 450

C

48

1:20

R7

R 450

X

R 300

R 80

R2 1:3

X

R 450 R7 1:8,31

R1

27

R 40

1:3

Y

R3

10

67

75

75,70

1

133

Key 1





55

prEN 13674-1:2002 (E)


14,1

Y

R 13

49,4

1:20

R 300

R 80 1:2,7

R3

5

R 508 X

CL

R 508

15

X

152

15,5

R2

2

R8

R 50

65,3

8 R 15

1:8,01

28

75

1:2,

R3 R2

10

R 20

75,36 to X-X axis 75,1 to CLR 508

1

Y 125

Key 1





56

prEN 13674-1:2002 (E)


13,62

Y

50,5

R2

R 400

1:16

R 14

1:3 R 80

R7

X

30

X

148

14

R 80

14

R7 1:3

27,5

1:8

R2

R3

10

62,5

52

1

R 120 R 40

71,85

R 120

Y 135

Key 1


Cross-sectional area : 63,62 Mass per metre : 49,9 Moment of inertia x-x axis : 1844 Section modulus - Head : 242,1 Section modulus - Base : 256,6 Moment of inertia y-y axis : 362,4 Section modulus y-y axis : 53,7 Indicative dimensions : A = 40,471 mm



57

prEN 13674-1:2002 (E)


13,58

Y R 13

49

1:20

R 200 R 60

1:3

R2

153

R 12 X

X 1

R 12

66

71,74

15,5

1:10 R3 Y

R2

140

Key 1





58

11,2

28

R 20

1:3

prEN 13674-1:2002 (E)


Key 1


Cross-sectional area : 66,43 Mass per metre : 52,15 Moment of inertia x-x axis : 1970,9 Section modulus - Head : 247,1 Section modulus - Base : 280,6 Moment of inertia y-y axis : 434,2 Section modulus y-y axis : 57,9 Indicative dimensions : A = 42,456 mm



59

prEN 13674-1:2002 (E)


14,1

Y

49,4

1:20

R 80

R 300

R 13

R3 1:2,7

5

R 8 2 R2

25,4

R 508

C

X

16

R 508

159

X

69,9

R 508 R 16

1:10

30,2

R 20

5

1:2,7

R2

R3

Y 140

Key 1





60

11

75,13

46

1

prEN 13674-1:2002 (E)


13,85

Y R 13

51,4

1:20

R 300

R 80

R2 1:2,7 5 R8

2

R2

X

16

CL R 508

161

25,4

R 508

X

6

1:10

30,2

R 20

5

1:2,7

R2

R3

12

69,9

76,2

R 508 R1

77,53

1

Y 125

Key 1





61

prEN 13674-1:2002 (E)


67 B A

14

Y

55

1:17,2

R 80

R 300

R 13

1:3

R 16

R5

16

CL R 500 X-X axis

X

X

154

R 500

R 50

64

75,07

1

R 40

0 R 16

1:7,81 R3 Y 125

R2 Key 1





62

12

29

1:3

prEN 13674-1:2002 (E)


1V113,4

Y

53

R 200 R 60

1:20

R 13

R2 1:3 2

X

X 1

19

R1 66,5

2

1:3

1:10

R2 R3

14

31

R 23

70,74

155

R1

Y 134

Key 1


Cross-sectional area : 71,37 Mass per metre : 56,03 Moment of inertia x-x axis : 2150,4 Section modulus - Head : 255,2 Section modulus - Base : 304 Moment of inertia y-y axis : 418,4 Section modulus y-y axis : 62,4 Indicative dimensions : A = 27,946 mm B = 40,588 mm



63

prEN 13674-1:2002 (E)


49,21

1:20

R 80

R 305

R 12,7

14,53

Y

R3 1:2,7

5

R8

X

158,75

20

X

R1

69,85

5

R 20 1:10

30,16

5

1:2,7

R 1,5

R3

Y

140

Key 1





64

11,2

74,51

1

prEN 13674-1:2002 (E)


14,3

Y

51

1:20

R 80

R3

R 300

R 13

1:2,7

5

R7

R 35 19,5

R 120

16,5 172

R120 X 32

X

1

R 40

16,5

28,75

19,5

R 120

76,25

80,92

R 120

R 35

R7 5

R2

R4

150

11,5

31,5

1:2,7

Y

Key 1





65

43,88

65,00

14,30

12,77

98,18

81,95

74,47

53,99

7,28

3,13

24,74

6,52

2,32

1

2

b

1 b

h1

h2

h3

l1

l2

l3

u1

u2

u3

66

46E1

Ref.

0

4,79

23,20

0

4,79

32,38

65,91

79,19

94,53

12,15

13,42

62,00

40,59

46E2

2,16

6,54

29,79

2,39

6,81

50,73

72,27

81,34

98,13

11,86

14,18

73,72

53,76

46E3

prEN 13674-1:2002 (E)

0,85

4,63

25,84

1,71

5,48

58,99

71,93

81,03

99,71

13,28

13,75

65,00

38,38

46E4

1,32

5,99

26,55

2,41

7,06

33,13

68,40

79,02

94,56

11,92

14,00

67,00

46,84

49E1

1,32

5,99

26,61

2,41

7,06

33,13

68,40

79,02

94,58

13,11

13,62

67,00

40,47

49E2

1,32

5,99

26,54

2,41

7,06

33,13

68,40

79,02

94,55

11,80

14,00

67,00

47,03

49E3

-

7,20

22,99

0

10,53

32,92

15,19

44,85

58,73

11,89

14,75

70,00

50,87

49E4

-

8,21

24,52

0

8,21

32,13

63,87

86,64

100,05

12,13

13,58

65,00

43,84

50E1

1,54

6,61

27,93

1,54

6,61

30,54

78,22

88,41

103,49

12,00

14,30

72,00

52,05

50E2

1,01

5,78

27,65

2,44

7,19

31,40

76,90

88,99

104,35

12,01

14,23

70,00

49,98

50E3

Rail profile

0,26

11,25

26,53

1,67

11,49

33,08

57,33

88,32

101,73

12,04

14,10

70,00

49,73

50E4

1,32

5,99

26,61

2,41

7,06

32,74

68,40

79,02

94,45

13,11

13,62

67,00

40,47

50E5

0

8,21

24,52

0

8,21

32,13

63,87

86,64

100,05

12,13

13,58

65,00

43,84

50E6

Table A.2 — Rail transition references (see Figure A.22)

0,36

6,98

22,24

1,39

8,00

23,81

57,85

77,99

93,52

11,98

12,62

65,00

42,46

52E1

0,69

7,30

26,03

1,54

12,02

35,92

66,04

92,25

107,75

12,04

14,10

70,00

49,73

54E1

0,69

7,30

25,36

1,54

12,02

34,97

66,04

92,25

107,16

12,08

13,85

67,01

46,31

54E2

0,24

11,18

23,57

1,52

12,41

32,13

54,58

83,20

93,90

11,92

14,00

67,00

46,84

54E3

0

8,21

21,50

0

8,21

32,21

60,04

82,80

95,24

12,15

13,42

62,00

40,59

55E1

0

5,27

23,92

0

9,87

33,01

70,54

92,16

107,36

11,61

14,53

69,85

51,23

56E1

3,20

8,25

26,83

3,20

8,25

36,61

87,06

101,50

118,57

12,00

14,30

72,00

52,05

60E1

prEN 13674-1:2002 (E)

2

b

b'

1

ul u2

h3

h2

hl

u3

L3 L2 L1

1 Key 1 Transition point 0,01 mm

Figure A.22 — Principal rail transition references

67

prEN 13674-1:2002 (E)

Annex B (normative) Standard test method for the determination of the plane strain fracture toughness (KIc) of rails

B.1 Test methods This test shall be performed in accordance with the requirements of ASTM E399 except where superseded by the requirements specified in this part of EN 13674. The requirements specified in this part of the EN 13674 apply only to the determination of plane strain fracture toughness of railway rail steels covered by the definitions and requirements of this standard.

B.2 Test pieces B.2.1

The location of the test piece in the rail’s transverse section is shown in Figure B.1.

B.2.2 The thickness “B” of all test pieces shall be 25 mm. For any rail head transverse profile the test piece width “W” shall be the maximum achievable of the following dimensions: 40 mm; 45 mm; 50 mm.

B.3 Number of tests A minimum of 5 tests from each sample shall be performed.

B.4 Test conditions NOTE

It is recommended that the chevron notch in ASTM E399 is used to avoid crack front curvature problems.

B.4.1 Fatigue pre-cracking shall be carried out in the temperature range + 15 °C to + 25 °C using a stress ratio in the range > 0 < + 0,1. Fatigue pre-cracking shall be carried out at a cyclic frequency in the range 15 Hz to 120 Hz. The final crack length to test piece width ratio shall be in the range 0,45 to 0,55 and during the last 1,25 mm of crack growth Kmax shall be in the range 18 MPa m1/2 to 22 MPa m1/2. B.4.2 The single edge notched bend test piece shall be loaded under displacement control using three point bending with a loading span (S) equal to four times the test piece width (W). B.4.3 Tests shall be performed at a test temperature of - 20 °C ± 2 °C. Test piece temperature shall be measured using a beadless thermocouple spot welded to the test piece at the location shown in Figure B.2.

B.5 Analysis of test data B.5.1 The calculation of KQ shall be in accordance with ASTM E399. The checks made to establish whether this value is a valid KIc shall be in accordance with ASTM E399 except for the requirements of B.5.2 to B.5.6. 68

prEN 13674-1:2002 (E)

B.5.2 Pmax/PQ shall be less than 1,10 for force-crack mouth opening curves where pop-in does not occur before the intersection of the curve with the 95 % secant. There shall be no Pmax/PQ criterion for other types of curve. B.5.3 The linearity of force-crack mouth opening curves Ia, Ib, IIa and III (see Figure B.3) shall be checked in the following manner. Measure the distance (v1) between the tangent OA and the force-crack mouth opening curve at a constant force of 0,8 PQ. Measure the distance (v) between the tangent OA and the force-crack mouth opening curve at a constant force of PQ. For a test result to be valid v1 ≤ 0,25 v. B.5.4 The linearity of force - crack mouth opening curves IIb and IIc (see Figure B.3) shall be checked in the following manner. Measure the distance between the tangent OA and the force - crack mouth opening curve at constant forces of 0,8 PQ and PQ recording these values as v1 * and v* respectively. Measure the crack mouth opening values arising from all “pop-ins” that occur up to PQ; this is done by measuring the horizontal distance travelled along the crack mouth opening axis between the start and finish of each “pop-in”. Sum the values for “pop-ins” occurring below 0,8 PQ and for those occurring between 0,8 PQ and PQ recording them as ∑ v1pi and ∑ vpi respectively. For a test result to be valid [v1 *- ∑ v1pi] ≤ 0,25 [v* - (∑ vpi + ∑ v1pi)] B.5.5

The linearity criterion cannot be applied to force - crack mouth opening curve IV.

B.5.6

For all force - crack mouth opening curves the KQ value shall be subjected to the validity check that the test

piece thickness (B) and crack length (a) are equal to, or greater than, the value of 2,5 (KQ/Rp(2))2, where Rp(2) is the 0,2 % proof stress at the fracture test temperature of - 20 °C.

B.6 Reporting of results All measurements required to calculate the test result and to show that the test conditions were as specified in the test procedure shall be recorded. * * values or KQ values; where KQ values are those KQ values All results shall be reported as either KIc values KQ which failed the validity criteria due only to one or more of the following:

1)

Pmax/PQ > 1,1;

2)

Exceedence of the 2,5 (KQ/Rp(2))2 criterion;

3)

Crack mouth opening displacement - force relationship.

* results shall be recorded. For each grade of rail tested these The mean and standard deviation of both KIC and KQ

results shall be included in a table giving the following information.

69

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Steel Grade

0,2 % Proof Stress at - 20 °C N/mm2

Mean KIC (MPa m

Number of KIC

1/2

)

results

Sample standard deviation (MPa m

1/2

)

Mean KQ

Number of KQ results

(MPa m

1/2

)

Sample standard deviation (MPa m

1/2

)

The value to be used for the acceptance criteria is that of the mean KIC and shall be based on a minimum of five KIC values. * values shall be included with any KIC values in the mean When five KIC values have not been obtained any KQ value to be used for the acceptance criteria. In this event the number of test results shall be at least ten.

All values of KIC and K*Q shall be above the minimum value specified in Table 2..

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B 12,5

1

2

12,5

2

W

H

3

=

=

Key 1 2

Notch machined in this face Section through rail head

3 Letter ‘H’ to be stamped on end face of test piece as shown B = 25 W = see B.2.2 For all other test piece proportions see ASTM E399

Figure B.1 — Location and section of fracture toughness test pieces

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1

2

5

3

10

Key 1

Notch

2 3

Thermocouple to be placed in the shaded zone Fatigue crack tip

Figure B.2 — Location of thermocouple on fracture toughness specimens

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prEN 13674-1:2002 (E)

Key 1 2

Force, P Crack mouth opening displacement (v)

Key 1 2

Force, P Crack mouth opening displacement (v)’ Figure B.3 — Force - Crack mouth opening curves

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Annex C (normative) Method for the determination of rail foot surface longitudinal residual stresses

C.1 Procedure Residual stresses shall be estimated by first attaching an electrical strain gauge on the rail foot surface. The surface to which the gauge is attached shall be progressively isolated from the rail and the relaxed strains shall then be used to estimate the stresses which have been relieved whilst the original residual stresses are taken to be those values but with a change of sign.

C.2 Strain gauges and their location Electrical strain gauges of the encapsulated type shall be used, 3 mm in length with a gauge factor accuracy of better than ± 1 %. The strain gauge shall be attached to the surface of the rail foot in order to measure longitudinal strain at the positions as shown in Figure C.1. The surface of the rail foot shall be prepared and the strain gauge shall be attached, in accordance with the recommendations of the strain gauge manufacturer. Any surface preparation shall not itself result in a change of the residual stresses in the rail foot. NOTE

The strain gauge should be located at the centre of the 1 m length of the sample rail set aside for this work.

Readings shall be taken from the strain gauges. While cooling the rails to maintain a constant temperature, two saw cuts shall be made to remove a 20 mm thick slice from the centre of the rail length (Figure C.2). A second set of measurements shall be taken. The residual stresses shall be calculated from the differences between the first and second sets of relieved strains by multiplying by 2,07 × 105 N/mm2.

74

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1 Key 1

Strain gauge

Figure C.1 — Location of strain gauge to measure rail foot surface longitudinal residual stresses

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500

4

2

1

20

3

500

2

Key 1

Centreline

2 3

Saw cut Strain gauge

4

Rail foot

Figure C.2 — Slice removed from the rail

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prEN 13674-1:2002 (E)

Annex D (normative) Limiting sulfur prints

The limiting sulfur prints presented in this annex are summarised in Table D.1. Table D.1 — Limiting sulfur prints Figure

Limiting sulfur print

Classification

D.1

Perfect

Acceptable

D.2

Small negative and positive segregation

Acceptable

D.3

Negative segregation in the web

Acceptable

D.4

Small positive segregation

Acceptable

D.5

Dendritic structure

Acceptable

D.6

Spotty segregation over the total cross section

Acceptable

D.7

Negative segregation-zone arising from electromagnetic stirring

Acceptable

D.8

Negative rim

Not acceptable

D.9

Positive segregation from internal hot cracks in the blooms

See Figure D.9

D.10

Subsurface pin holes

Not acceptable

D.11

Double positive segregation in the web

Not acceptable

D.12

Central web segregation extending into head and/or base

Not acceptable

D.13

Scheme of sulfur prints of rails rolled from continuously cast blooms

See Figure D.13

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Classification: acceptable

Figure D.1 — Perfect sulfur print

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Figure D.2 — Small negative and positive segregation

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Figure D.3 — Negative segregation in the web

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Figure D.4 — Small positive segregation

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Figure D.5 — Dendritic structure

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Figure D.6 — Spotty segregation over the total cross-section

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Figure D.7 — Negative segregation - zone arising from electromagnetic stirring

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Classification: not acceptable

Figure D.8 — Negative rim

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Classification: acceptable for crack length < 5 mm for not heat treated and < 3 mm for heat treated materials acceptable for added length of single cracks < 10 mm

Figure D.9 — Positive segregation from internal hot cracks in blooms

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Figure D.10 — Subsurface pin holes

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Figure D.11 — Double positive segregation in the web

88

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Figure D.12 — Central web segregation extending into head and/or base

89

X max

X max

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Classification: Central web segregation extending into head and/or base not acceptable exceeding the following threshold values X max: Profile: 46E1 to 54 E3 All other profiles

max. acceptable extension x 15 mm Nil

Figure D.13 — Schematic diagram defining extent of allowable web segregation

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Annex E (normative) Profile and drilling gauges

The gauges for manufacture as specified in 9.3 are shown in the figures which are summarised in Table E.1. Table E.1 — Summary of figures Figure E.1

Datum references for tolerances

Figure E.2

Datum references for decision

Figure E.3

Height of rail

Figure E.4

Crown profile

Figure E.5

Width or rail head

Figure E.6 and E.7

Asymmetry

Figure E.8

Fishing height HF and inclination IF

Figure E.9

Web thickness

Figure E.10

Width of rail foot

Figure E.11

Foot toe thickness

Figure E.12 and E.13

Drilling gauges

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WH As

b'

b

C

As

=

=

=

=

=

=

=

14

=

H

14

HF

WT

IF

14

=

= =

TF

=

=

=

=

=

14

WF

Figure E.1 — Datum references for tolerances (see Table 8 and Figure A.22)

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1

0

1

2

2

3

3 3 14

3 4

14

4

5

5

5

5

14

14

4 6

3 3

4 3 3

6

Datum 0 0 1 2 3 4, 5 5 4,5 6

6

6

Reference - Height - must not + must pass - Crown profile - must + must not pass the wedge - Width of rail head - must not + must touch - Rail asymmetry - must not + must touch - Inclination of fishing surfaces - Height of fishplating - must + must not touch - Web thickness - must not + must pass - Thickness of rail foot - - must not touch the web + must touch the web - Width of rail foot - must not + must pass

Figure No. E.3 E.4 E.5 E.6, E.7 E.8 E.8 E.9 E.11 E.11 E.10

Figure E.2 — Datum references for decision

93

prEN 13674-1:2002 (E)

+

Figure E.3 – Height of rail

94

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11

8

3

1

b+2

R

b'

3

2

1 2/2

2/2 1/2

b

1/2

2

R1

b

b'

1

R2

2

3

Class A

9,4

20

4

1,5

20

10,3

Class B

10,6

9,4

4

Key 1 2

Maximum width of rail head tolerance Theoretical profile

3 4

Step gauge to check the table shape Thickness 10

Figure E.4 — Crown profile

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_

_

_

Figure E.5 — Width of rail head

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1:n

1:n

R5

90º X

b

X

1:n

+

t

12

12

2 WF/6 2 WF/3 WF

Figure E.6 — Rail asymmetry

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t

X t

b

90º

1:n

5

1:n

X

12

12

2 WF/6 2 WF/3 WF

Figure E.7 — Rail asymmetry

98

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Key 1 and 2 Marks engraved 14 mm apart to indicate measuring points 3 h3 = theoretical 4 HF = theoretical X1, X2, X3, X4: gap between rail and gauge measured with a feeler gauge Points X1 and X2, maximum difference 0,35 mm Points X3 and X4, maximum difference 0,35 mm Maximum total difference when added together - 0,35 mm

Figure E.8 — Fishing height and inclination

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+

_

Figure E.9 — Web thickness

100

I

I

I

prEN 13674-1:2002 (E)

Figure E.10 — Width of rail foot

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1

14

1:n1 t"

4

t'' = t x s in (90 - arctan (1: n1))

t'

t'' = t x n1

2

14

1:n1

3

Key 1 2

Maximum Minimum

3 4

Width of foot/2 Tolerance

Figure E.11 — Foot toe thickness

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W + V1

Z

2WT

WT

WT

W

V2

V1

W

W

V1

V2

Key WT

Web thickness

Figure E.12 — Gauge for checking distance between holes and rail end and hole diameter

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Z

WT

2 WF/6 2 WF/3 WF

Key WT Z

Web thickness Distance between centre of the hole and base of the rail

Figure E.13 — Gauge for checking distance between holes and base of rail

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Annex F (informative) Comparison of steel designations referred to in this standard compared to those in EN 10027-1 and EN 10027-2

Steel grade in this standard R200 R220 R260 R260Mn R320Cr R350HT R350LHT

Steel name according to EN 10027-1 R200 R220 R260 R260Mn R320Cr R350G1HT R350G2HT

Steel number according to EN 10027-2 1.0521 1.0524 1.0623 1.0624 1.0915 1.0631 1.0632

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Annex ZA (informative) Clauses of this European Standard addressing essential requirements or other provisions of EU Directives.

This European Standard has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association and supports essential requirements of EU Directive. Council Directive 96/48/EC of 23 July 1996 on the Interoperability of the trans-European high speed rail system Compliance with this Standard provides one means of conforming with the specific essential requirements of the Directives concerned and associated EFTA Regulations WARNING: Other requirements and other EU Directives may be applicable to the products falling within the scope of this Standard

Correspondence between this European Standard and EU Directive Clauses/sub-clauses of

Chapter/§/points

Corresponding text,

This European Standard

of TSI Infrastructure

§/annex of the Directive 96/48/EU

Chapter 4 – Characterisation of the subsystem § 4.3 – Specified performance § 5 – Steel grades Table 1: Steel grades

Point 4.3.3

Comments

Chapter II Article 5 Points 3a; 3b Annex II point 3 Annex III Clauses 1.1; 1.5

and Annex K1

Only the following points: - hardness of the rail - profile of the rail

§ 9 – Acceptance tests

- linear mass of the rail are

9.1.7 Hardness

considered as relevant to satisfy the essential requirements of the Directive 96/48/EC

§ 9.2 Dimension tolerances

Chapter 5 – Interoperability

Chapter II Article 5

9.2.1 Profile

Constituents

Point 3e, 3f

§ 5.2 – Description of the Interoperability Constituents of the Infrastructure Subsystem Annex A: Rail profiles

106

| Point 5.2.1 – The rail and | Annex K2

Chapter III Article 8

prEN 13674-1:2002 (E)

Bibliograhy

[1]

EN ISO 9001, Quality management systems – Requirements (ISO 9001:2000).

[2]

EN 10027-1, Designation systems for steel – Part 1: Steel names, principal symbols.

[3]

EN 10027-2, Designation systems for steel – Part 2: Numerical systems.

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