24UTP Railway GB

Your reliable partner for railway systems

UTP Railway120908.qxd:UTP 13.09.2008 12:22 Uhr Seite 1

RAILWAY SYSTEMS

efficiency.Therefore the competence of UTP is indispensable whenit comes to LCC (Life Cycle Costs), optimized approach and to thespecific strengths of high speed, heavy haul or light rail applications.Each case can be solved according to customers needs with aco-coordinated flow of know how all over the world with the UTPbrand

Crossings and rail maintenance as well as repair works represent asubstantial cost factor for railway systems.The right refurbishingpolicy will save costs. Repairing rails and crossings by weldingaccording to UTP procedures worked out together withrenowned track and crossings producers likeVoestalpine SchienenGmbH i.e. VAE GmbH as well as with railway systems worldwidewill lead to cost savings of at least 80% compared to replacementcosts.For the reconditioning work UTP has a special range of adaptedwelding consumables, starting from shielded manual metal arcwelding electrodes which are still unbeatable considering on siteworks, to flux cored wires with stable quality and total cost

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Maintenance of crossings and rails with UTP welding consumables

From the raw material to the rail, to the switch


UTP-TypeDIN 8555

Weldmetalanalysis

Hardness of the pure weldingdeposit

SMAW FCAW Approvals Application field

UTP DUR 250E 1-UM-250

C 0,15Si 0,11Mn 1,2Cr 0,8

After welding: appr. 270 HB1 layer on stell withC = 0,5 %appr. 320 HB

• DB Basic coated electrode for tough, easily machinablebuildups.

UTP AF DUR 250MF 1-GF-250

C 0,1Si 0,2Mn 1,6Cr 1,7

After welding: appr. 280 HB • - Flux-cored wire used for buildups on parts mainlysubject to rolling and gliding abrasive wear


C 0,1Si 0,2Mn 1,2Cr 1,3

After welding: appr. 300 HB1 layer on steel withC = 0,5 %appr. 350 HB

• ÖBB,DB

Basic coated welding electrode for wear resistantsurfaces on Mn-Cr-V-alloyed parts.


C 0,2Si 1,2Mn 1,4Cr 1,8


• DB Basic coated welding electrode for wear resistantsurfaces on Mn-Cr-V-alloyed parts.

UTP AF DUR 350MF 1-GF-350

C 0,12Si 0,12Mn 1,5Cr 2,7


• DB Flux-cored wire suited for wear resistant buildups onparts subject to high pressure in combination withrolling and gliding wear.

UTP CHRONOSE 7-UM-200-KP

C 0,9Si 0,8Mn 13Fe Rest

As-weldid:approx. 220 HBAfter work hardening:utp to 550 HV

• DB Welding consumables suitable for buildups on highMn-steel of the same and of similar nature and onC-steels.

UTP 7200 SE 7-UM-250-KP

C 0,7Mn 13Cr 4,5Ni 4,0Fe Rest

After welding:appr. 200 - 250 HBAfter work hardening:up to 400 - 450 HB

• DB Basic coated, CrNi alloyed Mn hard-steel electrodefor joining and surfacing against extreme impact,compression and shock.

UTPAF BMCMF 7-GF-250-KP

C 0,5Mn 17Cr 13Fe Rest

After welding:appr. 0260 HBAfter work hardening:up to 550 HB

• - Welding consumables used for buildups onparts made of high Mn-steel subjected to highestcompression and impact in combination withabrasion.

UTP BMCE 7-G-UM-250-KPR

C 0,6Si 0,8Mn 16,5Cr 13,5Fe Rest


• SEPROZ Welding consumables used for buildups on partsmade of high Mn-steel subject to highest compressionand impact in combination with abrasion.

UTP 630BÖHLER FOX A 7-AE 8-UM-200-KRZ

C 0,1Si 1,0Mn 4,0Cr 19,5Ni 8,5Fe Rest


• SEPROZTÜV

Austenitic welding electrode for joining of stainlesssteels and Mn-Steels.

Maintenance of crossings and railways with UTP welding consumables

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RAILWAY SYSTEMS

UTP-TypeDIN 8555

Weldmetalanalysis

Hardness of the purewelding deposit

SMAW FCAW Approvals Application field

UTP 614 Kb

BÖHLER FOX EV 50

BÖHLER FOX EV 63

C 0,06 Si 0,7Mn 0,9C 0,07 Si 0,5Mn 1,1C 0,08 Si 0,7Mn 1,7

- • TÜVDBÖBB

Basich coated electrode for highly stressed joints.Particculary suited for rail conection welds.

UTP AF A 7BÖHLER A 7-FDMF 8-GF-200-ZRKN

C 0,1Mn 6,5Cr 19,0Ni 8,5Fe Rest


• - Fully austenitic CrNiMn open arc wire for bufferlayers and crack resistant joints.


HSHL Head Special Hardened Low CarbonHSHM Head Special Hardened Medium CarbonHSH Head Special Hardened

UHC Ultra High CarbonHT HeatTreatedLHT Low Alloyed HeatTreated

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chemical composition mechanical data PreheatingTemperatur

standard designation C [%] Si [%] Mn [%] Cr [%] P [%] S [%] Rmmin.

A5min.

hardness

min max min max min max min max max min max [MPa] [%] [BHN] °C

ASROLLED

EN 13674 R200 0,40 0,60 0,15 0,58 0,70 1,20 - 0,15 0,035 0,008 0,035 680 14 > 200 -

UIC 860 700 0,40 0,60 0,10 0,40 0,80 1,30 - - 0,050 - 0,050 680 14 - -

EN 13674 R220 0,50 0,60 0,20 0,60 1,00 1,25 - 0,15 0,025 0,008 0,025 770 12 > 220 100

EN 13674 R260 0,62 0,80 0,15 0,58 0,70 1,20 - 0,15 0,025 0,008 0,025 880 10 > 260 300

UIC 860 900A 0,60 0,80 0,10 0,50 0,80 1,30 - - 0,040 - 0,040 880 10 - 300

EN 13674 R260Mn 0,55 0,75 0,15 0,60 1,30 1,70 - 0,15 0,025 0,008 0,025 880 10 > 260 300

UIC 860 900B 0,55 0,75 0,10 0,50 1,30 1,70 - - 0,040 - 0,040 880 10 - 300 - 350

EN 13674 R320Cr 0,60 0,80 0,50 1,10 0,80 1,20 0,80 1,20 0,020 0,008 0,025 1080 9 > 320 > 500

UIC 860 1100 0,60 0,82 0,30 0,90 0,80 1,30 0,80 1,30 0,030 - 0,030 1080 9 - > 500

HEADHARDENED

VA-Spec. HSHL 0,40 0,60 0,05 0,35 0,80 1,25 - - 0,035 0,008 0,035 900 10 > 260 -

EN 14811 R260 GHT 0,40 0,60 0,15 0,58 0,70 1,20 - - 0,035 0,008 0,035 880 12 260 - 300 -

VA-Spec. HSHM 0,50 0,60 0,20 0,40 0,80 1,10 - - 0,035 0,008 0,035 980 9 > 290 -

EN 14811 R290 GHT 0,50 0,65 0,15 0,58 1,00 1,25 - - 0,025 0,008 0,025 960 10 290 - 330 -

EN 13674 R350HT 0,72 0,80 0,15 0,58 0,70 1,20 - 0,15 0,020 0,008 0,025 1175 9 > 350 300

EN 13674 R350LHT 0,72 0,80 0,15 0,58 0,70 1,20 - 0,30 0,020 0,008 0,025 1175 9 > 350 350

VA-Spec. 370LHT 0,70 0,82 0,40 1,00 0,70 1,10 0,40 0,70 0,020 0,008 0,025 1280 9 > 370 400 - 450

VA-Spec 400UHC 0,90 1,00 0,20 0,40 1,20 1,30 0,20 0,30 0,020 0,008 0,025 1280 9 > 400 400 - 450


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Name Crossings Analysis Approval TensileStrength

Rails

AUSTENITIC MANGANESEHARD STEELCast manganeseCrossings Mn 13

High-manganese steel C 0,95 - 1,3Si < 0,65Mn 11,5 - 14S < 0,03P < 0,04

1.3401 S 900 (UIC 860)260 (1.3674)S 900 A (1.3674)350 HT (1.3674)

PERLIT 1300 special heat treatmentprocess developed byVAE

C 0,75 - 0,82Si 0,15 - 0,58Mn 0,7 - 1,2P < 0,025S 0,008 - 0,035Cr < 0,15

1.3674 1200 - 1300N/mm²

Made from thefine pearlitic,head-hardened rails

COMPACT 1400 Material 51 CRV 4 C 0,47 - 0,55Si < 0,4Mn 0,7 - 1,1P < 0,035S < 0,035Cr 0,9 - 1,2V 0,1 - 0,25

1.8159 1200 - 1400N/mm²

S 900 (UIC 860)260 (1.3674)S 900 A (1.3674)350 HT (1.3674)

VARIO 1800 MaterialW720 1.6358 1700 - 1800N/mm²

S 900 (UIC 860)260 (1.3674)S 900 A (1.3674)350 HT (1.3674)



RAILWAY SYSTEMS

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General welding instructions for manganese crossingsAustenitic manganese steel is very ductile and has a strongtendancy towards strain-hardening under compressive and impactloads.If manganese steel is heated to over 300° C for a prolongedperiod this results in brittleness.Manganese steel must not be preheated, except at ambienttemperatures lower than 5° C. In this case heating of the basematerial to room temperature is sufficient.Manganese steel should only be welded using welding

consumables with high manganese content like UTP BMC, UTP7200 S or UTP CHRONOS.Coated electrodes (SMAW) are preferable.The Flux cored wire(FCAW) technique can be used.Use only electrodes from new packages, vacuum packs or re-driedelectrodes according to UTP instructions.Welding of crossings may only be carried out by approvedwelders.

General welding instructions for butt welds and built up welds of railsRail steels commonly have a perlitic microstructure.The higherthe carbon and chromium content, makes it necessary to applypre heating (see page 4)Attention also has to be paid to avoid any moisture during thewelding work. Repair welding at temperatures below 5° C shouldbe avoided. Coated electrodes (SMAW) are recommended.

The use of flux cored wire is only recommended when theworking area can be totally protected against draughts.Use only electrodes from new packages, vacuum packs or re-dried electrodes according to UTP instructions.Rail welding may only be carried out by approved welders.


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Primary material: 700 / R200 - 400 UHC* Grind out strain–hardened surface defects, nicks, flaws,etc. approx. 3 mm

* For crack tests using colour penetrant method and remove the colour* Local preheating to 250>500 degrees Celsius (see page 4)* Weld with UTP DUR 350 4.0 mm (140 - 180 A)alternative FCAW wire UTP AF DUR 350 2.4 mm(250 - 450 A; 23 - 31V)

* Interpass temperature 100-500 degrees Celsiusin the area of welding

* Weld last four layers with UTP BMC 4.0 mm (140 - 190 A)FCAW wire UTP AF BMC 2.4 mm(240 - 450 A; 25 - 32V)

* Weld temperature BMC hand-hot (~50 degrees Celsius)* Hammering each welding bead* Alternate welding onground-out surface defects that are somedistance apart from each other

* Rework to size, grinding without blue coloration

Primary material: Manganese steel* Grind out strain–hardened surface defects, cracks, nicks, flaws,etc. approx. 3 mm

* For crack tests using colour penetrant method and remove thecolour.

* Weld with UTP BMC 4.0 mm (140 - 190 A) alternativeFCAW wire UTP AF BMC 2.4 mm (240 - 450 A; 25 - 32V)

* Max. one buffer layer with UTP 630 Ø 4.0 mm (100 to 130 A)* Do not preheat; interpass temperature,maximum 50 degree Celsius

* Hammering each welding bead* Alternate welding on ground-out surfacedefects that are some distance apart from each other

* Rework to size, grinding without blue coloration

Welding procedures for crossings

for welding consumables:[email protected]

[email protected]

for railswww.voestalpine.com/[email protected]

for crossingswww.voestalpine.com/[email protected]

Contacts

Remark: For further welding details, preparation, post weld treatment please call our specialists or contact [email protected]


Sales Program

Welding consumables: Stick electrodes for welding nickel and nickel alloysStick electrodes for hardfacingSpecial stick electrodes for welding different kinds of steelStick electrodes for welding cast ironStick electrodes for chamfering and cuttingStick electrodes for welding non-ferrous metalsStick electrodes for welding stainless, acid- and heat resistant steelsSilver solders, brazing alloys, soft soldersFluxesStick electrodes for welding low- and medium-alloyed steelsMIG/MAG wires andTIG rodsFlux-cored wiresSubmerged arc welding wires and fluxes

Flame and Plasma Metal powdersspraying powders: EXOBOND powders

UNIBOND powdersHABOND powdersPTA powders (Plasma)

UTP SchweissmaterialZweigniederlassung derBöhler Schweisstechnik Deutschland GmbHElsässer Straße 10D-79189 Bad Krozingen

Fon: +49 (0) 7633 - 409 - 01 (24 h Serviceline)Fax: +49 (0) 7633 - 409 - 222Email: [email protected]: www.utp-welding.com

UTP is a certificated company.TÜV Certification according to DIN EN ISO 9001

DIN EN ISO 14001

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