CN115488483A - Method for improving bonding strength of steel rail flash butt joint - Google Patents
Method for improving bonding strength of steel rail flash butt joint Download PDFInfo
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- CN115488483A CN115488483A CN202211368275.1A CN202211368275A CN115488483A CN 115488483 A CN115488483 A CN 115488483A CN 202211368275 A CN202211368275 A CN 202211368275A CN 115488483 A CN115488483 A CN 115488483A
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- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 102
- 239000010959 steel Substances 0.000 title claims abstract description 102
- 238000000034 method Methods 0.000 title claims abstract description 63
- 210000001503 joint Anatomy 0.000 title claims abstract description 9
- 238000003466 welding Methods 0.000 claims abstract description 104
- 238000005242 forging Methods 0.000 claims abstract description 40
- 230000008569 process Effects 0.000 claims abstract description 15
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 23
- 229910052799 carbon Inorganic materials 0.000 claims description 23
- 230000001133 acceleration Effects 0.000 claims description 8
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 6
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 claims description 6
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 claims description 6
- 229910052804 chromium Inorganic materials 0.000 claims description 6
- 239000011651 chromium Substances 0.000 claims description 6
- 229910052698 phosphorus Inorganic materials 0.000 claims description 6
- 239000011574 phosphorus Substances 0.000 claims description 6
- 229910052710 silicon Inorganic materials 0.000 claims description 6
- 239000010703 silicon Substances 0.000 claims description 6
- 229910052717 sulfur Inorganic materials 0.000 claims description 6
- 239000011593 sulfur Substances 0.000 claims description 6
- 229910052720 vanadium Inorganic materials 0.000 claims description 6
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 claims description 6
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 claims description 4
- 229910052748 manganese Inorganic materials 0.000 claims description 4
- 239000011572 manganese Substances 0.000 claims description 4
- 238000010304 firing Methods 0.000 claims 1
- 239000000203 mixture Substances 0.000 claims 1
- 238000005452 bending Methods 0.000 abstract description 29
- 230000003068 static effect Effects 0.000 abstract description 29
- 230000007547 defect Effects 0.000 abstract description 9
- 238000012360 testing method Methods 0.000 description 12
- 239000000126 substance Substances 0.000 description 9
- 239000000463 material Substances 0.000 description 8
- 229910001562 pearlite Inorganic materials 0.000 description 7
- 239000007787 solid Substances 0.000 description 7
- 238000010438 heat treatment Methods 0.000 description 5
- 229910000734 martensite Inorganic materials 0.000 description 5
- 238000005422 blasting Methods 0.000 description 4
- 230000000052 comparative effect Effects 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 239000000428 dust Substances 0.000 description 2
- 230000002349 favourable effect Effects 0.000 description 2
- 230000004927 fusion Effects 0.000 description 2
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 2
- 150000001247 metal acetylides Chemical class 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000003287 optical effect Effects 0.000 description 2
- 230000002159 abnormal effect Effects 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 229910001563 bainite Inorganic materials 0.000 description 1
- 239000010953 base metal Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 229910001567 cementite Inorganic materials 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- KSOKAHYVTMZFBJ-UHFFFAOYSA-N iron;methane Chemical compound C.[Fe].[Fe].[Fe] KSOKAHYVTMZFBJ-UHFFFAOYSA-N 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 238000009721 upset forging Methods 0.000 description 1
- 229910000859 α-Fe Inorganic materials 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/04—Flash butt welding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/36—Auxiliary equipment
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/04—Ferrous alloys, e.g. steel alloys containing manganese
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/24—Ferrous alloys, e.g. steel alloys containing chromium with vanadium
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Heat Treatment Of Articles (AREA)
- Machines For Laying And Maintaining Railways (AREA)
- Pressure Welding/Diffusion-Bonding (AREA)
Abstract
The invention discloses a method for improving the bonding strength of a steel rail flash butt joint, which adopts a mobile flash welding machine to realize a welding process, wherein the welding process comprises pre-flashing, accelerated burning, upsetting and forging; after the welding process is finished, the joint is placed in the air and naturally cooled to the room temperature; wherein the upsetting amount in the upsetting stage is 5.0-18.0 mm; the forging pressure in the forging stage is 60 t-80 t. The invention also discloses a steel rail welded by the method. According to the method for improving the bonding strength of the steel rail flash butt welding joint, the steel rail welded by the method has no welding defects such as gray spots, unwelded welding, overburning and the like, the steel rail fracture is rough, and the static bending performance of the steel rail flash butt welding joint can be effectively improved greatly.
Description
Technical Field
The invention belongs to the technical field of steel rail welding, and particularly relates to a method for improving the bonding strength of a steel rail flash butt welding joint.
Background
With the development of global rail lines towards high speed and heavy load, rail welding is also becoming a focus of more and more attention. At present, the mainstream rail flash butt welding at home and abroad is a welding method which clamps rails on two sides by clamping devices such as conductive electrodes, contacts the end faces of the rails after electrification, generates resistance heat at the contact points by conducting current, quickly melts the contact points to form flash with strong splashing, applies a certain upsetting force after a certain flash allowance, and accordingly recrystallizes and forms the rails at high temperature. Mainly comprises two types of fixed flash welding and movable flash welding. The movable flash welding is usually used for construction welding on a track laying site due to the characteristics of small equipment, convenient movement and the like, and the fixed flash welding of the steel rail usually fixes welding equipment in a factory building, so the fixed flash welding is also commonly called as factory welding or base welding. The two differ most greatly in the way the rail is heated, except in the application scenario. The movable flash welding heats the steel rail by intermittent pulse flash blasting or continuous flash blasting, so the movable flash welding can be divided into pulse flash and continuous flash. Stationary flash welding is generally performed by directly short-circuiting the rail and heating the rail by means of resistance heating, which is not (or only slightly) accompanied by flash, and is also commonly referred to as short-circuit preheat flash welding.
At present, the mainstream rail flash welding standard in the world mainly comprises the standard series standard TB/T1632.2-2014 in the Chinese railway industry, part2 of rail welding: flash Welding, american society OF Railway ENGINEERING handbook, american Rail ENGINEERING AND MAINTENANCE-OF-WAY ASSOCIATION (AREMA), european Standard BS EN 14587-3, tail WAY applications-Track-Flash building Welding OF rails.part 3: welding in ASSOCIATION with cracking control AND Australian Standard AS1085.20-2012, rail Track Material Part20: welding of steel rail. All the existing flash welding standards and enterprise technical conditions suitable for pearlitic steel rails make specific provisions on the microstructure of the flash welding joint of the steel rail. The microstructure of a welding seam and a heat affected zone of a steel rail joint specified in TB/T1632.2 is pearlite, a small amount of ferrite can appear, and harmful structures such as martensite or bainite should not be contained; AMEMA specifies that the weld and the heat affected zone of the steel rail joint are expected to be 100% of pearlite structures, and once the joint generates untempered martensite structures, the results of the static bending test can be influenced; the european standard BS EN14587 specifies that, when observed under an optical microscope at a magnification of 100 × using an optical microscope, acicular carbides and intergranular continuous network carbides with signs of embrittlement do not appear, allowing the appearance of a granular martensitic structure; the steel rail joint microstructure specified in the australian standard AS1085.20 should be a pearlitic structure substantially free of intergranular cementite and untempered martensite, allowing for a small amount of martensite if the requirements of the other tests are met. The hardness of the longitudinal section of the flash welding joint of the steel rail is that after the steel rail is cut along the longitudinal rolling direction of the steel rail, the hardness values of the steel rail are detected within the range that the distance between the two sides of a joint welding line is 3-5 mm and exceeds the width of a heat affected zone by 20mm, the Rockwell hardness is adopted in some standards, the Vickers hardness is adopted in some standards, or both the Rockwell hardness and the Vickers hardness are adopted. The hardness of a steel rail welding joint is an important factor influencing the smoothness of a high-speed railway track, and the joint can be ensured to have consistent wear resistance with a line steel rail in a service period only if the hardness level of the joint is equivalent to that of a base metal. The existing problem is that the joints have softening zones in a welding state or a heat treatment state, saddle-shaped abrasion can occur during service, and the smoothness of a line is deteriorated. The correct post-welding treatment process can improve the joint structure, reduce the softening degree and meet the requirement of the wear resistance of the joint as much as possible. The rail flash welding joint static bending test is the most widely applied rail joint overall performance evaluation method at home and abroad at present, and all rail joint inspection standards have regulations. The method mainly comprises two indexes, namely load and deflection. The static bending test is to apply load to the steel rail joint at a certain loading rate by adopting a three-point or four-point supporting method until the load reaches a standard specified value and is continuous, and the maximum deflection is greater than the standard specified value, so that the static bending performance of the joint is judged to be qualified, and different rail types correspond to different load and deflection values. European standard BS EN14587-2, 2009, requires that the minimum load and deflection of the joint is not less than 1600KN and 20mm respectively (60 kg/m rail, head compressed). European standard BS EN14587-2, 2009 requires a joint rail base minimum stress of 900MPa, and a reduced minimum load and deflection of no less than 1670KN and 20mm, respectively (60 kg/m rail, head compressed). The standard requirements of China on static bending are that the breaking load is not less than 1450kN (60 kg/m, the railhead is pressed), and no requirement is made on the deflection. The static bending load mainly reflects the indexes of the joint strength, the joint appearance and the internal defects, and the deflection mainly reflects the index of the joint toughness. If the welding process of the joint is poor, the joint is likely to break before the joint does not reach the load value specified by the standard due to defects such as grey spots, incomplete fusion or overburning, or the joint is hard or soft due to improper matching of heat input and upsetting amount of the joint and improper post-welding treatment method, so that the deflection of the joint does not reach the standard requirement.
In summary, a method for improving the bonding strength of the steel rail flash butt welding joint is needed in the field of railway engineering, so as to effectively ensure that the static bending performance of the steel rail flash butt welding joint is greatly improved.
Disclosure of Invention
Based on the above, in order to make up for the defects of the existing rail welding technology, the method for welding the pearlite rail with internal damage resistance or the pearlite rail with high strength and toughness is provided, and the method can effectively alleviate the generation of abnormal defects in the microstructure of a welded joint, thereby ensuring the running safety of the railway.
In order to realize the purpose, the following technical scheme is adopted:
the invention provides a method for improving the bonding strength of a steel rail flash butt joint, which adopts a mobile flash welding machine to realize a welding process, wherein the welding process comprises pre-flashing, accelerated burning, upsetting and forging; after the welding process is finished, the joint is placed in the air and naturally cooled to the room temperature;
wherein the upsetting amount in the upsetting stage is 5.0-18.0 mm; the forging pressure in the forging stage is 60 t-80 t.
Further, the steel rail is selected from a pearlitic steel rail with the mass fraction of carbon being 0.60wt% -0.90 wt% and a hypereutectoid steel rail with the mass fraction of carbon being 0.90wt% -1.20 wt%.
Further, the pearlitic steel rail comprises the following components: the mass fraction of carbon is between 0.60 and 0.90 percent, the mass fraction of silicon is between 0.10 and 1.00 percent, the mass fraction of manganese is between 0.60 and 1.50 percent, the mass fractions of phosphorus and sulfur are both less than 0.020 percent, the mass fraction of chromium is less than 0.3 percent, and the mass fraction of vanadium is less than 0.01 percent.
Further, the hypereutectoid steel rail comprises the following components: the mass fraction of carbon is between 0.90 and 1.20 percent, the mass fraction of silicon is between 0.10 and 1.00 percent, the mass fraction of manganese is between 0.60 and 1.50 percent, the mass fractions of phosphorus and sulfur are both less than 0.020 percent, the mass fraction of chromium is less than 0.3 percent, and the mass fraction of vanadium is less than 0.01 percent.
Further, the charged upsetting time in the upsetting stage is 0.1s to 2.0s, and the upsetting time is 1.0s to 3.0s.
Furthermore, the consumption of the steel rail in the forging stage is 2.0 mm-4.0 mm, the forging time is 1.5 s-3.0 s, and the average speed is 0.60 mm/s-2.60 mm/s.
Furthermore, the voltage of the preflash stage is 370V-440V, the voltage time is 45 s-65 s, the current value is 180A-300A, the preflash distance is 2 mm-10 mm, and the flash speed is 0.1 mm/s-0.6 mm/s.
Furthermore, the current value of the pre-flash stage is divided into three stages of setting values, wherein the current setting value 1 is 180A-250A, the current setting value 2 is 200A-270A, and the current setting value 3 is 220A-300A.
Furthermore, the voltage of the flash stage is 320V-390V, the voltage time is 80 s-140 s, the current value is 180A-300A, and the flash speed is 0.1 mm/s-0.6 mm/s.
Further, the current value in the flash period is divided into three stages of setting values, i.e., a current setting value 1 of 180A to 250A, a current setting value 2 of 200A to 270A, and a current setting value 3 of 220A to 300A.
Furthermore, the voltage in the accelerated burning stage is 380V-450V, the current is 180A-300A, and the acceleration speed is 0.5 mm/s-2.0 mm/s.
Furthermore, the current value of the accelerated oxidation stage is divided into three set values, wherein the current set value 1 is 180A-250A, the current set value 2 is 200A-270A, and the current set value 3 is 220A-300A.
The invention also provides a steel rail welded by the method.
The invention has the following beneficial technical effects:
the invention mainly provides a method for improving the bonding strength of a steel rail flash butt joint aiming at a pearlitic steel rail with the mass fraction of carbon of 0.60-0.90% and a hypereutectoid steel rail with the mass fraction of carbon of 0.90-1.20%. The rail welded by the method has no welding defects such as gray spots, incomplete welding, overburning and the like, the fracture of the rail is rough, and the static bending performance of the flash welding joint of the rail can be effectively ensured to be greatly improved.
The method for improving the bonding strength of the steel rail flash butt joint comprises the steps of heating the steel rail by a flash method different from the pulse flash method in the prior art in the middle and early heating stages, removing the pressure maintaining stage in the prior art, and changing the pressure maintaining stage into the forging stage. The method for improving the bonding strength of the steel rail flash butt joint adopts hydraulic flow control in the forging stage, and the bonding strength of the joint is greatly improved by newly adding forging along with the change of displacement.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the following embodiments of the present invention are further described in detail with reference to specific embodiments.
In the invention, the joint and the welding head are regions which are obtained by welding and contain welding seams and/or heat affected zones and have the length of 80-120mm, and the center of the region is a steel rail welding seam. In the present invention, the "room temperature" is a temperature in the range of 5 to 40 ℃.
The embodiment of the invention mainly aims at a pearlitic steel rail with the mass fraction of carbon of 0.60-0.90% and a hypereutectoid steel rail with the mass fraction of carbon of 0.90-1.20%, and provides a method for improving the bonding strength of the steel rail flash butt welding joint. The steel rail welded by the method has no welding defects such as dust spots, incomplete welding, overburning and the like, the fracture of the steel rail is rough, and the static bending performance of the steel rail flash butt welding joint can be effectively and greatly improved.
In order to achieve the purpose, the method for improving the bonding strength of the steel rail flash butt welding joint is realized by adopting a steel rail movable flash welding machine, and the whole welding process comprises 5 main stages of pre-flashing, accelerated burning, upsetting, forging and the like. And after the flash welding is finished, the joint is placed in the air to be naturally cooled to the room temperature.
The mass fraction of the carbon is 0.60 to 0.90 percent of the pearlite steel rail. The pearlite steel rail comprises the main chemical components of 0.60-0.90% of carbon, 0.10-1.00% of silicon, 0.60-1.50% of manganese, 0.020% of phosphorus and sulfur, 0.3% of chromium and 0.01% of vanadium. The pearlite rail has a minimum tensile strength of 800MPa and a minimum hardness of 250HB.
The hypereutectoid steel rail with the mass fraction of carbon being 0.90-1.20%. The hypereutectoid steel rail mainly comprises the following chemical components, by mass, 0.90-1.20% of carbon, 0.10-1.00% of silicon, 0.60-1.50% of manganese, 0.020% of phosphorus and 0.3% of sulfur, 0.3% of chromium and 0.01% of vanadium. The minimum tensile strength of the steel rail is 1300MPa, and the minimum hardness of the rail head is 400HB.
The main effect of the pre-flashing stage is to enable the to-be-welded section of the steel rail to be flat and clean through flash blasting, and provide favorable conditions and basic heat for subsequent flashing, wherein the favorable conditions and the basic heat are relatively uniform and flat. In order to achieve the purpose, the control is mainly controlled by 7 variables such as high voltage time, high voltage, a current set value 1, a current set value 2, a current set value 3, a pre-flashing distance, flashing speed and the like. The high voltage of the pre-flash stage is 370V-440V and the voltage time is 45 s-65 s; the current value of the pre-flash stage is divided into set values of three stages, wherein the set value 1 of the current is 180-250A, the set value 2 of the current is 200-270A, and the set value 3 of the current is 220-300A; the pre-flashing distance is 2 mm-10 mm, and the flashing speed is 0.1 mm/s-0.6 mm/s.
The flash stage has the main effects that the steel rail is continuously and uniformly flashed continuously on the basis of the accumulated heat of the previous preflash, the steel rail is continuously heated by using the blasting of the lintel, a certain temperature gradient is formed in the longitudinal direction of the steel rail, the end face of the steel rail is heated to the sufficient temperature, and conditions are laid for the accelerated burning process. To achieve the above purpose, the control is mainly controlled by 6 variables such as low voltage time, low voltage, current set value 1, current set value 2, current set value 3, and flash speed. The low voltage of the flash stage is 320-390V and the voltage time is 80-140 s; the current value of the flash stage is divided into three stages of set values, wherein the set value of the current 1 is 180A-250A, the set value of the current 2 is 200A-270A, and the set value of the current 3 is 220A-300A; the flash speed is 0.1 mm/s-0.6 mm/s.
The main function of the accelerated burning stage is to form a protective atmosphere for preventing the end surface from being oxidized in the whole welding area, and finally form proper temperature field distribution to provide conditions for upset forging. In order to achieve the above purpose, the control is mainly controlled by 5 variables such as accelerated burning voltage, current set value 1, current set value 2, current set value 3, acceleration speed and the like. The accelerated burning voltage of the accelerated burning stage is 380V-450V, the current value of the accelerated burning stage is divided into set values of three stages, wherein the set value of the current is 180A-250A, the set value of the current is 2A-270A, and the set value of the current is 3A-220A; the acceleration speed is 0.5 mm/s-2.0 mm/s.
The charged upsetting time in the upsetting stage is 0.1s to 2.0s, the upsetting time is 1.0s to 3.0s, and the upsetting amount is 5.0mm to 18.0mm.
The forging stage mainly has the effect of continuously applying load to the steel rail joint in the process of crystallizing the joint metal after the steel rail is upset, so that the joint bonding strength is enhanced. In order to achieve the aim, the consumption of the steel rail in the forging stage is 2.0-4.0 mm, the forging time is 1.5-3.0 s, the average speed is 0.60-2.60 mm/s, and the forging pressure is 60-80 t.
The method for processing the joint after the flash welding is finished. The method is characterized in that the welded joint is not required to be treated, and the joint is directly placed in the air and naturally cooled to the room temperature.
Example 1
The test material of this example was a 60E1 profile pearlitic rail as specified in the BS EN 13674-1 standard. The carbon content of the steel rail solid chemical component is measured to be 0.75 percent. The welding method in the invention is adopted for welding. The high-voltage time of the preflash stage is 45s, the high voltage is 370V, the current set value 1 is 180A, the current set value 2 is 200A, the current set value 3 is 220A, the preflash distance is 2mm, and the flash speed is 0.1mm/s; the low-voltage time of the flash stage is 80s, the low voltage is 320V, the current set value 1 is 180A, the current set value 2 is 200A, the current set value 3 is 220A, and the flash speed is 0.1mm/s; the accelerated burning voltage in the accelerated burning stage is 380V, the current set value 1 is 180A, the current set value 2 is 200A, the current set value 3 is 220A, and the accelerated speed is 0.5mm/s; the electrified upsetting time in the upsetting stage is 0.1s, the upsetting time is 1.0s, and the upsetting amount is 5.0mm; the steel rail consumption in the forging stage is 2.0mm, the forging time is 1.5s, the average speed is 0.60mm/s, and the forging pressure is 60t. In the embodiment, the maximum deflection of the steel rail flash welding head is 23.5mm when the three-point static bending load is 2000kN, no fracture occurs, and the requirement of far exceeding the standard is met.
Example 2
The test material of this example was a 60kg profile pearlitic rail specified in AS 1085-1 standard. The actual carbon content fraction of the steel rail solid chemical component is 0.65%. The welding method is adopted for welding. The high-voltage time of the preflash stage is 56s, the high voltage is 400V, the current set value 1 is 220A, the current set value 2 is 240A, the current set value 3 is 260A, the preflash distance is 6mm, and the flash speed is 0.3mm/s; the low-voltage time of the flash stage is 110s, the low voltage is 350V, the current set value 1 is 220A, the current set value 2 is 240A, the current set value 3 is 260A, and the flash speed is 0.3mm/s; the accelerated burning voltage in the accelerated burning stage is 405V, the current set value 1 is 220A, the current set value 2 is 240A, the current set value 3 is 260A, and the accelerated speed is 1.1mm/s; the electrified upsetting time in the upsetting stage is 0.5s, the upsetting time is 2.0s, and the upsetting amount is 12.0mm; the steel rail consumption in the forging stage is 3.8mm, the forging time is 2.0s, the average speed is 1.90mm/s, and the forging pressure is 70t. In the embodiment, the maximum deflection of the steel rail flash welding head is 27.4mm when the three-point static bending load is 2200kN, no fracture occurs, and the requirement of exceeding the standard is far met.
Example 3
The test material of this example was a pearlitic rail of 115RE profile specified in the AREMA standard. The carbon content of the steel rail solid chemical component is measured to be 0.81 percent. The welding method in the invention is adopted for welding. The high voltage time of the pre-flashing stage is 53s, the high voltage is 390V, the current set value 1 is 200A, the current set value 2 is 230A, the current set value 3 is 250A, the pre-flashing distance is 5mm, and the flashing speed is 0.2mm/s; the low-voltage time of the flash stage is 100s, the low voltage is 345V, the current set value 1 is 200A, the current set value 2 is 230A, the current set value 3 is 250A, and the flash speed is 0.2mm/s; the accelerated burning voltage in the accelerated burning stage is 400V, the current set value 1 is 200A, the current set value 2 is 230A, the current set value 3 is 250A, and the acceleration speed is 0.9mm/s; the electrified upsetting time in the upsetting stage is 0.7s, the upsetting time is 1.3s, and the upsetting amount is 10.0mm; the steel rail consumption in the forging stage is 3.4mm, the forging time is 1.7s, the average speed is 2.00mm/s, and the forging pressure is 70t. In the embodiment, the maximum deflection of the steel rail flash welding head is 26.2mm when the three-point static bending load is 2500kN, no fracture occurs, and the requirement of exceeding the standard is far met.
Example 4
The test material of this example was a pearlitic rail of 136RE profile specified in the AREMA standard. The actual carbon content fraction of the steel rail solid chemical component is 0.78%. The welding method is adopted for welding. The high voltage time of the pre-flashing stage is 61s, the high voltage is 420V, the current set value 1 is 230A, the current set value 2 is 250A, the current set value 3 is 295A, the pre-flashing distance is 8mm, and the flashing speed is 0.5mm/s; the low-voltage time of the flash stage is 135s, the low voltage is 380V, the current set value 1 is 230A, the current set value 2 is 250A, the current set value 3 is 295A, and the flash speed is 0.5mm/s; the accelerated burning voltage in the accelerated burning stage is 430V, the current set value 1 is 230A, the current set value 2 is 250A, the current set value 3 is 295A, and the acceleration speed is 1.7mm/s; the electrified upsetting time in the upsetting stage is 1.2s, the upsetting time is 2.4s, and the upsetting amount is 16.0mm; the steel rail consumption in the forging stage is 2.3mm, the forging time is 1.5s, the average speed is 1.53mm/s, and the forging pressure is 60t. In the embodiment, the maximum deflection of the steel rail flash welding head is 20.1mm when the three-point static bending load is 2200kN, no fracture occurs, and the requirement of far exceeding the standard is met.
Example 5
The test material of this example was a hypereutectoid steel rail with a 136RE profile as specified in the AREMA standard. The carbon content of the steel rail solid chemical component is measured to be 0.95 percent. The welding method in the invention is adopted for welding. The high-voltage time of the pre-flashing stage is 58s, the high voltage is 410V, the current set value 1 is 220A, the current set value 2 is 260A, the current set value 3 is 285A, the pre-flashing distance is 7mm, and the flashing speed is 0.4mm/s; the low-voltage time of the flash stage is 120s, the low voltage is 371V, the current set value 1 is 220A, the current set value 2 is 260A, the current set value 3 is 285A, and the flash speed is 0.4mm/s; the voltage for accelerated burning in the accelerated burning stage is 425V, the current set value 1 is 220A, the current set value 2 is 260A, the current set value 3 is 285A, and the acceleration speed is 1.5mm/s; the electrified upsetting time in the upsetting stage is 1.5s, the upsetting time is 2.0s, and the upsetting amount is 13.0mm; the steel rail consumption in the forging stage is 3.5mm, the forging time is 2.0s, the average speed is 1.75mm/s, and the forging pressure is 75t. In the embodiment, the maximum deflection of the steel rail flash welding head is 23.4mm when the three-point static bending load is 2640kN, no fracture occurs, and the requirement of far exceeding the standard is met.
Example 6
The test material of this example was hypereutectoid steel rails of the 136RE profile specified in the AREMA standard. The actual carbon content of the steel rail solid chemical component is 1.01 percent. The welding method is adopted for welding. The high-voltage time of the pre-flashing stage is 65s, the high voltage is 440V, the current set value 1 is 250A, the current set value 2 is 270A, the current set value 3 is 300A, the pre-flashing distance is 10mm, and the flashing speed is 0.6mm/s; the low-voltage time of the flash stage is 140s, the low voltage is 390V, the current set value 1 is 250A, the current set value 2 is 270A, the current set value 3 is 300A, and the flash speed is 0.6mm/s; the accelerated burning voltage in the accelerated burning stage is 450V, the current set value 1 is 250A, the current set value 2 is 270A, the current set value 3 is 300A, and the accelerated speed is 2.0mm/s; the electrified upsetting time in the upsetting stage is 2.0s, the upsetting time is 3.0s, and the upsetting amount is 18.0mm; the consumption of the steel rail in the forging stage is 4.0mm, the forging time is 3.0s, the average speed is 2.60mm/s, and the forging pressure is 80t. In the embodiment, the maximum deflection of the steel rail flash welding head is 21.2mm when the three-point static bending load is 2610kN, no fracture occurs, and the requirement is far out of standard.
Comparative example
The test material of this comparative example was a hypereutectoid steel rail with a 136RE profile as specified in the AREMA standard. The actual carbon content of the steel rail solid chemical component is 1.01 percent. The welding method in the patent of the invention is not adopted for welding. The high-voltage time of the preflash stage is 65s, the high voltage is 445V, the current set value 1 is 240A, the current set value 2 is 260A, the current set value 3 is 275A, the preflash distance is 9.5mm, and the flash speed is 0.55mm/s; the low-voltage time of the flash stage is 138s, the low voltage is 385V, the current set value 1 is 240A, the current set value 2 is 260A, the current set value 3 is 275A, and the flash speed is 0.6mm/s; the accelerated burning voltage in the accelerated burning stage is 447V, the current set value 1 is 240A, the current set value 2 is 260A, the current set value 3 is 275A, and the acceleration speed is 2.0mm/s; the electrified upsetting time in the upsetting stage is 2.0s, the upsetting time is 2.7s, and the upsetting amount is 16.8mm; there is no forging stage. The maximum deflection of the steel rail flash welding head in the comparative example is 6.6mm when the three-point static bending load is 1557kN, and the steel rail flash welding head is broken and can not meet the standard requirement.
The static bending test is to apply load to the steel rail joint at a certain loading rate by adopting a three-point or four-point supporting method until the load reaches a standard specified value continuously and the maximum deflection is greater than the standard specified value, and then the static bending performance of the joint is judged to be qualified, and different rail types correspond to different load and deflection values. The static bending load mainly reflects the indexes of the joint strength, the joint appearance and the internal defects, and the deflection mainly reflects the indexes of the joint toughness. If the welding process of the joint is poor, the joint is likely to break before the joint does not reach the load value specified by the standard due to the defects of dust spot, incomplete fusion or overburning, or the joint is hard or soft due to improper matching of heat input and upsetting amount of the joint and improper treatment method after welding, so that the deflection of the joint does not reach the standard requirement
The maximum deflection of the flash welded joint of the steel rail in the embodiment 1 is 23.5mm when the three-point static bending load is 2000kN, and no fracture occurs; the maximum deflection of the steel rail flash welding joint of the embodiment 2 is 27.4mm when the three-point static bending load is 2200kN, and no fracture occurs; the maximum deflection of the flash welded joint of the steel rail in the embodiment 3 is 26.2mm when the three-point static bending load is 2500kN, and no fracture occurs; the maximum deflection of the steel rail flash welding joint of the embodiment 4 is 20.1mm when the three-point static bending load is 2200kN, and no fracture occurs; the maximum deflection of the steel rail flash welding head of the embodiment 5 is 23.4mm when the three-point static bending load is 2640kN, and no fracture occurs; the three-point static bending load of the flash-welded rail joint of example 6 was 2610kN, the maximum deflection was 21.2mm, and no fracture occurred.
The static bending standard in China requires that the breaking load is not less than 1450kN (60 kg/m, the railhead is pressed), and the deflection is not required; the three-point static bending load of the steel rail flash welding heads of the examples 1 to 6 is far greater than the national standard (1450 kN).
In the comparative example, the welding method in the patent is not adopted for welding, and the maximum deflection of the flash welding head of the steel rail is 6.6mm when the load of three-point static bending of the flash welding head of the steel rail is 1557kN, so that the flash welding head of the steel rail is broken. The performance gap between the rails welded by the methods of examples 1-6 is large.
The foregoing are exemplary embodiments of the present disclosure, but it should be noted that various changes and modifications could be made herein without departing from the scope of the present disclosure as defined by the appended claims. Although elements of the disclosed embodiments of the invention may be described or claimed in the singular, the plural is contemplated unless limitation to the singular is explicitly stated.
Those of ordinary skill in the art will understand that: the discussion of any embodiment above is meant only to be exemplary, and is not intended to intimate that the scope of the disclosure, including the claims, is limited to these examples; within the idea of an embodiment of the invention, also technical features in the above embodiment or in different embodiments may be combined and there are many other variations of the different aspects of the embodiments of the invention as described above, which are not provided in detail for the sake of brevity. Therefore, any omissions, modifications, substitutions, improvements and the like that may be made without departing from the spirit or scope of the embodiments of the present invention are intended to be included within the scope of the embodiments of the present invention.
Claims (10)
1. A method for improving the bonding strength of a rail flash butt joint is characterized in that a mobile flash welding machine is adopted to realize a welding process, and the welding process comprises pre-flash, accelerated burning, upsetting and forging; after the welding process is finished, the joint is placed in the air and naturally cooled to the room temperature;
wherein the upsetting amount in the upsetting stage is 5.0-18.0 mm; the forging pressure in the forging stage is 60 t-80 t.
2. The method according to claim 1, wherein the steel rail is selected from the group consisting of a pearlitic steel rail having a mass fraction of carbon in the range of 0.60 to 0.90wt% and a hypereutectoid steel rail having a mass fraction of carbon in the range of 0.90 to 1.20 wt%.
3. The method of claim 2, wherein the pearlitic rail comprises the following components: the mass fraction of carbon is between 0.60 and 0.90 percent, the mass fraction of silicon is between 0.10 and 1.00 percent, the mass fraction of manganese is between 0.60 and 1.50 percent, the mass fractions of phosphorus and sulfur are both less than 0.020 percent, the mass fraction of chromium is less than 0.3 percent, and the mass fraction of vanadium is less than 0.01 percent.
4. The method of claim 2, wherein the hypereutectoid steel rail comprises the following composition: the mass fraction of carbon is between 0.90 and 1.20 percent, the mass fraction of silicon is between 0.10 and 1.00 percent, the mass fraction of manganese is between 0.60 and 1.50 percent, the mass fractions of phosphorus and sulfur are both less than 0.020 percent, the mass fraction of chromium is less than 0.3 percent, and the mass fraction of vanadium is less than 0.01 percent.
5. The method according to claim 1, wherein the charged upsetting time in the upsetting stage is 0.1s to 2.0s, and the upsetting time is 1.0s to 3.0s.
6. The method according to claim 1, wherein the consumption of the steel rail in the forging stage is comprised between 2.0mm and 4.0mm, the forging time is comprised between 1.5s and 3.0s and the average speed is comprised between 0.60mm/s and 2.60mm/s.
7. The method of claim 1, wherein the voltage of the preflash stage is 370V to 440V and the voltage time is 45s to 65s, the current value is 180A to 300A, the preflash distance is 2mm to 10mm, and the flash speed is 0.1mm/s to 0.6mm/s.
8. The method according to claim 1, wherein the voltage of the flash stage is 320V to 390V and the voltage time is 80s to 140s, the current value is 180A to 300A, and the flash speed is 0.1mm/s to 0.6mm/s.
9. The method of claim 1, wherein the voltage in the accelerated firing stage is 380V to 450V, the current is 180A to 300A, and the acceleration rate is 0.5mm/s to 2.0mm/s.
10. A rail welded by the method of any one of claims 1 to 9.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202211368275.1A CN115488483B (en) | 2022-11-03 | 2022-11-03 | Method for improving bonding strength of steel rail flash butt welding joint |
| PCT/CN2023/093540 WO2024093184A1 (en) | 2022-11-03 | 2023-05-11 | Method for improving bonding strength of rail flash-butt welded joint |
| AU2023216810A AU2023216810A1 (en) | 2022-11-03 | 2023-05-11 | A method for increasing bonding strength of flash butt welding joint of rail |
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| CN202211368275.1A CN115488483B (en) | 2022-11-03 | 2022-11-03 | Method for improving bonding strength of steel rail flash butt welding joint |
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| CN (1) | CN115488483B (en) |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2024093184A1 (en) * | 2022-11-03 | 2024-05-10 | 攀钢集团攀枝花钢铁研究院有限公司 | Method for improving bonding strength of rail flash-butt welded joint |
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| CN115488483B (en) | 2024-04-09 |
| AU2023216810A1 (en) | 2024-05-23 |
| WO2024093184A1 (en) | 2024-05-10 |
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