AWS D15.2/D15.2M:2013

An American National Standard

Recommended Practices for the Welding of

Rails and Related Rail Components for Use by Rail Vehicles

AWS D15.2/D15.2M:2013

An American National Standard

Approved by the American National Standards Institute

October 30, 2012

Recommended Practices for the Welding of Rails and Related

Rail Components for Use by Rail Vehicles

3rd Edition

Supersedes AWS D15.2:2003

Prepared by the American Welding Society (AWS) D15 Committee on Railroad Welding

Under the Direction of the AWS Technical Activities Committee

Approved by the AWS Board of Directors

Abstract

This document recommends the minimum standards for the welding of rails and related rail components used by rail vehicles. Repair procedures for rails and austenitic manganese steel components are covered. Thermite welding and electric flash welding guidelines are discussed. Procedure qualification, welder qualification, and general welding safety procedures are addressed.

International Standard Book Number: 978-0-87171-829-7

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All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the American Welding Society (AWS) are voluntary consensus standards that have been developed in accordance with the rules of the American National Standards Institute (ANSI). When AWS American National Standards are either incorporated in, or made part of, documents that are included in federal or state laws and regulations, or the regulations of other governmen- tal bodies, their provisions carry the full legal authority of the statute. In such cases, any changes in those AWS standards must be approved by the governmental body having statutory jurisdiction before they can become a part of those laws and regulations. In all cases, these standards carry the full legal authority of the contract or other document that invokes the AWS standards. Where this contractual relationship exists, changes in or deviations from requirements of an AWS stan- dard must be by agreement between the contracting parties.

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This standard may be superseded by new editions. This standard may also be corrected through publication of amend- ments or errata, or supplemented by publication of addenda. Information on the latest editions of AWS standards includ- ing amendments, errata, and addenda is posted on the AWS web page (www.aws.org). Users should ensure that they have the latest edition, amendments, errata, and addenda.

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Official interpretations of any of the technical requirements of this standard may only be obtained by sending a request, in writing, to the appropriate technical committee. Such requests should be addressed to the American Welding Society, Attention: Managing Director, Technical Services Division, 8669 Doral Blvd., Suite 130, Doral, FL 33166 (see Annex F). With regard to technical inquiries made concerning AWS standards, oral opinions on AWS standards may be ren- dered. These opinions are offered solely as a convenience to users of this standard, and they do not constitute professional advice. Such opinions represent only the personal opinions of the particular individuals giving them. These individuals do not speak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or interpretations of AWS. In addition, oral opinions are informal and should not be used as a substitute for an official interpretation.

This standard is subject to revision at any time by the AWS D15 Committee on Railroad Welding. It must be reviewed every five years, and if not revised, it must be either reaffirmed or withdrawn. Comments (recommendations, additions, or deletions) and any pertinent data that may be of use in improving this standard are required and should be addressed to AWS Headquarters. Such comments will receive careful consideration by the AWS D15 Committee on Railroad Welding and the author of the comments will be informed of the Committee’s response to the comments. Guests are invited to attend all meetings of the AWS D15 Committee on Railroad Welding to express their comments verbally. Procedures for appeal of an adverse decision concerning all such comments are provided in the Rules of Operation of the Technical Activities Committee. A copy of these Rules can be obtained from the American Welding Society, 8669 Doral Blvd., Suite 130, Doral, FL 33166.

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Personnel

AWS D15 Committee on Railroad Welding

M. R. Untermeyer, Chair Union Tank Car Company

R. A. Wolbert, Vice Chair Progress Rail Services Corporation

1. B. Pearson, Jr., 2nd Vice Chair LTK Engineering Services

   S. N. Borrero, Secretary American Welding Society

   D. M. Allbritten GE Equipment Services-Rail

   R. C. Bly TTX Company – Hamburg Division

   C. Boulden TrinityRail Group

   1. B. Broadway American Railcar Industries

      N. S. Brown Canadian Pacific Railway

      1. A. Conrad Hobart Brothers

      2. A. Coughlin Consultant

   2. R. Desjardins National Steel Car Limited

   1. A. Forsstrom Greenbrier Rail Services

      1. J. Gamblin ALLTRANSTEK, LLC

         J. Haacke Motive Power

      2. S. Lassen Greenbrier Rail Services

   T. M. Nelson LTK Engineering Services

   B. W. Siebold BNSF Railway Company

   T. D. Spry Electro Motive Diesel, Incorporated

   L. H. Strouse Federal Railroad Administration

   1. Willaredt American Railcar Industries

      
      

      Advisors to the AWS D15 Committee on Railroad Welding

   2. C. Blackwell Standard Car Truck Company

   W. Blamire Norfolk Southern Corporation

   J. L. Cooley JC and Associates, Incorporated

   W. Jaxa-Rozen Bombardier Transportation

   M. MacGillivray Hobart Brothers of Canada, LTD

   J. R. Murray TTX Company

   R. D. Stiffler PA

   D. A. Wright Wright Welding Technologies

   
   

   AWS D15C Subcommittee on Track Welding

   R. L. Bell, Chair BNSF Railway Company

   1. Hernandez, Vice Chair Union Pacific Railroad Company

      1. N. Borrero, Secretary American Welding Society

         R. E. Adler BNSF Railway Company

         D. A. Bjork Canadian National Railway Company

         W. M. Blamire Norfolk Southern Corporation

         D. N. Blowatt Canadian National Railway Company

         M. J. Boos Union Pacific Railroad

         W. C. Bragg Orgo-Thermit, Incorporated

         N. S. Brown Canadian Pacific Railway

         C. J. Bunzendahl J.B. Railroad Services, LLC

         G. K. Clem GKC Consulting Company

         T. Y. Gehr, Jr. Esco Equipment Service Company

         D. I. Gregory Track-Weld

         J. R. Hansen Railworks

         F. C. Hefer Orgo-Thermit, Incorporated

         R. Kral Holland Company

         1. A. Kruckenberg Canadian National Railway Company

            P. J. Lawless BNSF Railway Company

            S. E. Markis Norfolk Southern Corporation

            B. A. Meade The Lincoln Electric Company

            T. A. Nelson LTK Engineering Services

            1. B. Pearson, Jr. LTK Engineering Services

               1. Pierson Norfolk Southern Corporation

R. P Roper CSX Transportation

T. L. Swalboski Railworks

S. W. Tribble Track-Weld Industries, Incorporated

M. K. Wilson CSX Transportation

B. E. Wylie Orgo-Thermit, Incorporated

Advisors to the AWS D15C Subcommittee on Track Welding

T. L. Baxley Norfolk Southern Corporation

K. K. Hamik BNSF Railway Company

1. S. Koblinski METRA

2. O. Scharnweber Cold Railroad Builders

J. Sun Association of American Railroads

M. R. Untermeyer Union Tank Car Company

J. S. Wiederholt BNSF Railway Company

Foreword

This foreword is not part of AWS D15.2/D15.2M:2013, Recommended Practices for the Welding of Rails and Related Rail Components for Use by Rail Vehicles, but is included for informational purposes only.

This recommended practice establishes standards for the joining, repair, maintenance and inspection of rail welds, and the welding of related rail components. It was developed and is maintained by the Subcommittee on Track Welding within the AWS Committee on Railroad Welding.

The welding of rails and related rail components for use by rail vehicles is vital to the safe and economical operation of American railroads. This subcommittee has endeavored to develop these recommended practices to serve as a guideline for the railroad and related industries in the establishment of track welding specifications. The subcommittee is made up of individuals from all segments of the railroad industry, both users and suppliers, and representatives of both the Association of American Railroads and the American Railway Engineering and Maintenance-of-Way Association.

The purpose of this document is to provide a single comprehensive source of information that will be used throughout the railroad industry. It should act as a guideline towards improving welding quality through the economical joining and repair of rail and rail components.

The evolution of AWS D15.2, Recommended Practices for the Welding of Rails and Related Rail Components for Use by Rail Vehicles, is shown below:

ANSI/AWS D15.2–94, Recommended Practices for the Welding of Rails and Related Rail Components for Use by Rail Vehicles

AWS D15.2:2003, Recommended Practices for the Welding of Rails and Related Rail Components for Use by Rail Vehicles

Comments and suggestions for the improvement of this standard are welcome. They should be sent to the Secretary, AWS D15 Committee on Railroad Welding, American Welding Society, 8669 Doral Blvd., Suite 130, Doral, FL 33166.

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Table of Contents

Page No.

Personnel v

Foreword vii

List of Tables xi

List of Figures xi

List of Forms xi

1. General Requirements 1

   1. Scope 1

   2. Units of Measurement 1

   3. Safety 1

2. Normative References 2

3. Terms and Definitions 2

4. Rail, Rail Components Manufactured from Rail, and Their Repair 3

   1. Specific Items 3

   2. Welding and Joining Processes 3

   3. Railroad Rail Welding 3

   4. Repair of Battered Rail Ends and Wheel Burns (Carbon Steel or Premium Carbon Steel Rail) 3

   5. Repair of Rail-Type Switch Points and Switch Point Protectors 5

   6. Frogs, Crossings, and Other Components Made From Rail Steel 5

   7. Miscellaneous Carbon Steel and Premium Carbon Steel Components 5

5. Repair or Fabrication of Components Manufactured from Austenitic Manganese Steel 6

   1. Metallurgical Background 6

   2. Components 6

   3. Welding Processes 6

   4. Filler Metals 6

   5. Preparation for Welding 6

   6. General Welding Recommendations for Austenitic Manganese Steel 7

   7. Welding Recommendations—Frogs and Crossings in Track 8

6. Recommended Practices for Joining of Rails by Thermite Welding (TW) 8

   1. General Description 9

   2. Application 9

   3. Preparation of Final Gap for Welding 9

   4. Welding Procedure 9

   5. Care of Thermite Materials 9

   6. Procedure Qualification 10

   7. Welder Qualification 10

   8. Thermite Welding Safety Precautions 11

7. Recommended Practices for Joining of Rails by Flash Welding (FW) 12

   1. General Process Description 12

   2. Rail Preparation 12

   3. Rail Welding 12

   4. Finishing Operations 13

   5. Continuous Welded Rail Storage 13

8. Application of Rail Bonds Using External Heat 13

   1. General Process Description 13

   2. Rail Preparation 13

   3. Rail Preheating. 13

   4. Bond Wire Application 13

   5. Controlled Cooling 13

9. Track Welder Qualification—Arc Welding Processes 14

   1. General Information for Austenitic Manganese (Hadfield) Steel 14

   2. Qualification by Standard Test for Austenitic Manganese Steel 15

   3. Qualification by Workmanship Test for Austenitic Manganese Steel 15

   4. Test Weldments for Austenitic Manganese Steel 15

   5. Examination Procedures and Acceptance Criteria for Austenitic Manganese Steel 16

   6. Performance Qualification Variables for Austenitic Manganese Steel 20

   7. General Information for Rail Steel 20

   8. Qualification by Standard Test for Rail Steel 21

   9. Qualification by Workmanship Test for Rail Steel 21

   10. Test Weldments for Rail Steel 23

   11. Examination Procedures and Acceptance Criteria for Rail Steel 24

   12. Performance Qualification Variables for Rail Steel 26

10. Testing 26

    1. Nondestructive Testing 26

    2. Other Testing 26

Annex A (Informative)—Welding Processes 31

Annex B (Informative)—Welding of Austenitic Manganese Steel 37

Annex C (Informative)—Flash Welding Guidance 41

Annex D (Informative)—AREMA Tests for Continuous Welded Rail. 43

Annex E (Informative)—Sample Forms 47

Annex F (Informative)—Guidelines for the Preparation of Technical Inquiries 49

List of AWS Documents on Railroad Welding 51

List of Tables

Table Page No.

4.1 Welding Processes for Carbon and Premium Carbon Steel Rail Components 3

1. Examination Requirements for Performance Qualification 15

2. Position Limitations for Performance Tests 17

3. Examination Requirements for Performance Qualification 21

4. Position Limitations for Performance Tests 25

10.1 Minimum Performance Specifications for New Flash and Thermite Welded Rail 27

D.1 Wheel Loads for Rolling Load Test 44

List of Figures

Figure Page No.

4.1 Typical Weld Pattern for Rail End Repair 4

5.1 Typical Skip Welding Repair 8

9.1(a) Typical Test Plates 16

9.1(b) Typical Weld Bead Sequence for Test Weldments 17

9.1(c) Typical Weld Bead Sequence for Test Weldments 17

1. Typical Test Weldments 18

2. Dimensions for Inspection 19

9.4(a) Typical Weld Bead Sequence for Test Weldments 22

9.4(b) Typical Weld Bead Sequence for Test Weldments 23

9.4(c) Typical Weld Bead Sequence for Test Weldments 23

1. Typical Test Plates 24

2. Dimensions for Inspection 25

1. Layout of Hardness Survey on Rail Head 28

2. Layout of Transverse Hardness Survey 29

1. Shielded Metal Arc Welding (SMAW) 31

2. Gas Metal Arc Welding (GMAW) 32

3. Flux Cored Arc Welding (FCAW) 33

4. Section Through a Thermite Mold and Crucible 34

5. Automatic Hydraulically Operated Flash Welding Machine with Horizontal Clamping 34

6. Rail Welding Production Line 35

7. Oxyfuel Gas Welding (OFW) 35

1. Loading Arrangement for the 12 in [305 mm] Stroke Rolling Load Machine 43

2. Load Arrangement for the Slow Bend Test and Formula for Deriving the Modulus of Rupture 45

List of Forms

Form Page No.

E–1 Typical Welding Procedure Qualification Test Record 47

E–2 Typical Welder Performance Qualification Test Record 48

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Recommended Practices for the Welding of Rails and Related Rail Components for Use by Rail Vehicles

1. General Requirements

   1. Scope. This document recommends standards for joining, repair, maintenance, inspection of rail welds, and related rail components. For the purposes of this document, rails include railroad rails, crane rails, guard rails, electrical contact rails, girder rails, and retarder rails. Classification of rails is based on the American Railway Engineering and Maintenance-of-Way Association (AREMA) specifications governing the manufacture of rails.

      Related rail components include rail crossings and turnouts which further include switch points, stock rails, switch point guards, spacer blocks, connecting rods, switch rods, plates, frogs, and frog components.

      The use of track components reconditioned by welding is a decision of the rail owner outside the scope of this document. This document does not include road bed maintenance except where it affects the expected life of the repair.

      Welding processes addressed in this document include shielded metal arc welding (SMAW), gas metal arc welding (GMAW), flux cored arc welding (FCAW), flash welding (FW), and thermite welding (TW). See Annex A and the Welding Handbook, Volumes 2 and 3, Ninth Edition for details on these processes.

   2. Units of Measurement. This standard makes use of both U.S. Customary Units and the International System of Units (SI). The latter are shown within brackets [ ], or in appropriate columns in tables and figures. The measurements may not be exact equivalents; therefore, each system must be used independently.

   3. Safety. Safety and health issues and concerns are beyond the scope of this standard; some safety and health information is provided, but such issues are not fully addressed herein.

      Safety and health information is available from the following sources:

      American Welding Society

      1. ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes

      2. AWS Safety and Health Fact Sheets

      3. Other safety and health information on the AWS website Material or Equipment Manufacturers:

         1. Material Safety Data Sheets supplied by materials manufacturers

         2. Operating Manuals supplied by equipment manufacturers Applicable Regulatory Agencies

         (1) Code of Federal Regulations (CFR), Title 49, Part 214, Railroad Workplace Safety.

         Work performed in accordance with this standard may involve the use of materials that have been deemed hazardous and may involve operations or equipment that may cause injury or death. This standard does not purport to address all safety and health risks that may be encountered. The user of this standard should establish an appropriate safety program to address such risks as well as to meet applicable regulatory requirements. ANSI Z49.1 should be considered when developing the safety program.

2. Normative References

   The standards listed below contain provisions that, through reference in this text, constitute mandatory provisions of this AWS standard. For undated references, the latest edition of the referenced standard shall apply. For dated references, sub- sequent amendments to, or revisions of, any of these publications do not apply.

   American Welding Society (AWS) documents:1

   AWS A2.4, Standard Symbols for Welding, Brazing, and Nondestructive Examination; AWS A3.0M/A3.0, Standard Welding Terms and Definitions;

   AWS A5.13/A5.13M, Specification for Surfacing Electrodes for Shielded Metal Arc Welding; AWS A5.21/A5.21M, Specification for Composite Surfacing Welding Rods and Electrodes; AWS B1.10M/B1.10, Guide for the Nondestructive Examination of Welds;

   AWS B2.1/B2.1M, Specification for Welding Procedure and Performance Qualification; AWS D15.1/D15.1M, Railroad Welding Specification for Cars and Locomotives; and AWS Welding Handbook, Volumes 2 and 3, Ninth Edition.

   American National Standards Institute (ANSI) document:2

   ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes

   American Railway Engineering and Maintenance-of-Way Association (AREMA) document:3

   AREMA Manual for Railway Engineering, Chapter 4, Rail.

   ASTM International documents:4

   ASTM A36/A36M, Standard Specification for Carbon Structural Steel;

   ASTM E140, Standard Hardness Conversion for Metals (Relationship Among Brinell Hardness, Vickers Hardness, Rockwell Hardness, Superficial Hardness, Knoop Hardness, and Scleroscope Hardness);

   ASTM E164, Standard Practice for Contact Ultrasonic Testing of Weldments; ASTM E1417, Standard Practice for Liquid Penetrant Testing; and

   ASTM E709, Standard Guide for Magnetic Particle Testing.

   Code of Federal Regulations (CFR) document:5

   Code of Federal Regulation, Title 49 (Transportation), Volume 4, Chapter 2, Parts 200–299.

   
   

3. Terms and Definitions

AWS A3.0M/A3.0, Standard Welding Terms and Definitions, Including Terms for Adhesive Bonding, Brazing, Soldering, Thermal Cutting, and Thermal Spraying, provides the basis for terminology used herein.

1 AWS documents are published by the American Welding Society, 8669 Doral Blvd., Suite 130, Doral, FL 33166.

2 This ANSI standard is published by the American Welding Society, 8669 Doral Blvd., Suite 130, Doral, FL 33166.

3 AREMA documents are published by the American Railway Engineering and Maintenance-of-Way Association, 10003 Derekwood Lane, Suite 210, Lanham, MD 20706–4875.

4 ASTM International standards are published by ASTM International, 100 Barr Harbor Drive, West Conshohocken, PA 19428–2959.

5 Federal regulations are published by the U.S. Government Bookstore, Wells Fargo Building, 201 West 8th, Pueblo, CO 81003, or https://www.gpo.gov/.