Your reliable partner for railway systems

RAILWAY SYSTEMS
Crossings and rail maintenance as well as repair works represent a substantial cost factor for railway systems.The right refurbishing policy will save costs. Repairing rails and crossings by welding according to UTP procedures worked out together with renowned track and crossings producers like Voestalpine Schienen GmbH i.e. VAE GmbH as well as with railway systems worldwide will lead to cost savings of at least 80% compared to replacement costs. For the reconditioning work UTP has a special range of adapted welding consumables, starting from shielded manual metal arc welding electrodes which are still unbeatable considering on site works, to flux cored wires with stable quality and total cost

Maintenance of crossings and rails with UTP welding consumables

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

From the raw material to the rail, to the switch

Maintenance of crossings and railways with UTP welding consumables

UTP-Type DIN 8555 Weld metal analysis 0,15 0,11 1,2 0,8 0,1 0,2 1,6 1,7 0,1 0,2 1,2 1,3 0,2 1,2 1,4 1,8 0,12 0,12 1,5 2,7 0,9 0,8 13 Rest 0,7 13 4,5 4,0 Rest Hardness of the pure welding deposit SMAW FCAW Approvals UTP DUR 250 E 1-UM-250 C Si Mn Cr C Si Mn Cr C Si Mn Cr C Si Mn Cr C Si Mn Cr C Si Mn Fe C Mn Cr Ni Fe After welding: appr. 270 HB 1 layer on stell with C = 0,5 % appr. 320 HB After welding: appr. 280 HB

Application field

DB

Basic coated electrode for tough, easily machinable buildups.

UTP AF DUR 250 MF 1-GF-250

Flux-cored wire used for buildups on parts mainly subject to rolling and gliding abrasive wear

UTP DUR 300 E 1-UM-300

After welding: appr. 300 HB 1 layer on steel with C = 0,5 % appr. 350 HB After welding: appr. 300 HB 1 layer on steel with C = 0,5 % appr. 420 HB After welding: appr. 370 HB 1 layer on steel with C = 0,5 % appr. 420 HB As-weldid: approx. 220 HB After work hardening: utp to 550 HV After welding: appr. 200 - 250 HB After work hardening: up to 400 - 450 HB After welding: appr. 0260 HB After work hardening: up to 550 HB After welding: appr. 260 HB After work hardening: up to 550 HB After welding: appr. 200 HB After work hardening: up to 350 HB

BB, DB

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

UTP DUR 350 E 1-UM-300

DB

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

UTP AF DUR 350 MF 1-GF-350

DB

Flux-cored wire suited for wear resistant buildups on parts subject to high pressure in combination with rolling and gliding wear. Welding consumables suitable for buildups on high Mn-steel of the same and of similar nature and on C-steels. Basic coated, CrNi alloyed Mn hard-steel electrode for joining and surfacing against extreme impact, compression and shock.

UTP CHRONOS E 7-UM-200-KP

DB

UTP 7200 S E 7-UM-250-KP

DB

UTP AF BMC MF 7-GF-250-KP

C 0,5 Mn 17 Cr 13 Fe Rest C Si Mn Cr Fe C Si Mn Cr Ni Fe 0,6 0,8 16,5 13,5 Rest 0,1 1,0 4,0 19,5 8,5 Rest

Welding consumables used for buildups on parts made of high Mn-steel subjected to highest compression and impact in combination with abrasion. Welding consumables used for buildups on parts made of high Mn-steel subject to highest compression and impact in combination with abrasion.

UTP BMC E 7-G-UM-250-KPR

SEPROZ

UTP 630 BHLER FOX A 7-A E 8-UM-200-KRZ

SEPROZ TV

Austenitic welding electrode for joining of stainless steels and Mn-Steels.

RAILWAY SYSTEMS
Maintenance of crossings and railways with UTP welding consumables
UTP-Type DIN 8555 Weld metal analysis Si Si Si Hardness of the pure welding deposit SMAW FCAW Approvals UTP 614 Kb BHLER FOX EV 50 BHLER FOX EV 63 UTP AF A 7 BHLER A 7-FD MF 8-GF-200-ZRKN C Mn C Mn C Mn 0,06 0,9 0,07 1,1 0,08 1,7 0,7 0,5 0,7 After welding: appr. 200 HB After work hardening: up to 400 HB Application field

TV DB BB

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

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

Fully austenitic CrNiMn open arc wire for buffer layers and crack resistant joints.

chemical composition standard designation C [%] min max Si [%] min max Mn [%] min max Cr [%] min 0,80 0,80 0,40 0,20 max P [%] max S [%] min max Rm min. [MPa] 680 680 770 880 880 880 1080 1080 900 880 980 1175 1175 1280 1280 960 880

mechanical data A5 min. [%] hardness [BHN] -

Preheating Temperatur

EN 13674 UIC 860 EN 13674 AS ROLLED EN 13674 UIC 860 EN 13674 UIC 860 UIC 860 EN 13674 VA-Spec. VA-Spec.

R200 700 R220 R260 900A 900B 1100

0,40 0,40 0,50 0,62 0,60 0,55 0,55 0,60 0,60 0,40 0,40 0,50 0,50 0,72 0,72 0,70 0,90

0,60 0,60 0,60 0,80 0,80 0,75 0,75 0,80 0,82 0,60 0,60 0,60 0,65 0,80 0,80 0,82 1,00

0,15 0,10 0,20 0,15 0,10 0,15 0,10 0,50 0,30 0,05 0,15 0,20 0,15 0,15 0,15 0,40 0,20

0,58 0,40 0,60 0,58 0,50 0,60 0,50 1,10 0,90 0,35 0,58 0,40 0,58 0,58 0,58 1,00 0,40

0,70 0,80 1,00 0,70 0,80 1,30 1,30 0,80 0,80 0,80 0,70 0,80 1,00 0,70 0,70 0,70 1,20

1,20 1,30 1,25 1,20 1,30 1,70 1,70 1,20 1,30 1,25 1,20 1,10 1,25 1,20 1,20 1,10 1,30

0,15 0,15 0,15 0,15 1,20 1,30 0,15 0,30 0,70 0,30 -

0,035 0,050 0,025 0,025 0,040 0,025 0,040 0,020 0,030 0,035 0,035 0,035 0,025 0,020 0,020 0,020 0,020

0,008 0,008 0,008 0,008 0,008 0,008 0,008 0,008 0,008 0,008 0,008 0,008 0,008 -

0,035 0,050 0,025 0,025 0,040 0,025 0,040 0,025 0,035 0,035 0,035 0,025 0,025 0,025 0,025 0,025 0,030

14 14 12 10 10 10 10 9 9

> 200 > 220 > 260 > 260 > 320 > 260 > 290 > 350 > 350 > 370 > 400 -

C -

100 300 300 300 - 350 > 500 > 500 300 400 - 450 400 - 450 350 300

R260Mn R320Cr HSHL

EN 14811 HEAD HARDENED EN 14811 EN 13674 EN 13674 VA-Spec. VA-Spec

R260 GHT HSHM R290 GHT R350HT 370LHT R350LHT 400UHC

10 12 10 9 9 9 9 9

260 - 300 290 - 330

HSHL HSHM HSH 4

Head Special Hardened Low Carbon Head Special Hardened Medium Carbon Head Special Hardened

UHC HT LHT

Ultra High Carbon Heat Treated Low Alloyed Heat Treated

Maintenance of crossings and railways with UTP welding consumables

Name Crossings Analysis Approval Tensile Strength Rails AUSTENITIC MANGANESE HARD STEEL Cast manganese Crossings Mn 13 PERLIT 1300 High-manganese steel 0,95 - 1,3 C Si < 0,65 Mn 11,5 - 14 S < 0,03 P < 0,04 1.3401 S 900 (UIC 860) 260 (1.3674) S 900 A (1.3674) 350 HT (1.3674) 1200 - 1300 N/mm Made from the fine pearlitic, head-hardened rails

special heat treatment process developed by VAE

COMPACT 1400

Material 51 CR V 4

C 0,75 - 0,82 Si 0,15 - 0,58 Mn 0,7 - 1,2 P < 0,025 S 0,008 - 0,035 Cr < 0,15 C 0,47 - 0,55 Si < 0,4 Mn 0,7 - 1,1 P < 0,035 S < 0,035 Cr 0,9 - 1,2 V 0,1 - 0,25

1.3674

1.8159

1200 - 1400 N/mm

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

VARIO 1800

Material W720

1.6358

1700 - 1800 N/mm

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

RAILWAY SYSTEMS
Austenitic manganese steel is very ductile and has a strong tendancy towards strain-hardening under compressive and impact loads. If manganese steel is heated to over 300 C for a prolonged period this results in brittleness. Manganese steel must not be preheated, except at ambient temperatures lower than 5 C. In this case heating of the base material to room temperature is sufficient. Manganese steel should only be welded using welding

General welding instructions for manganese crossings

consumables with high manganese content like UTP BMC, UTP 7200 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-dried electrodes according to UTP instructions. Welding of crossings may only be carried out by approved welders.

Rail steels commonly have a perlitic microstructure.The higher the carbon and chromium content, makes it necessary to apply pre heating (see page 4) Attention also has to be paid to avoid any moisture during the welding work. Repair welding at temperatures below 5 C should be avoided. Coated electrodes (SMAW) are recommended.

General welding instructions for butt welds and built up welds of rails

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

Primary material: Manganese steel

Welding procedures for crossings

* Grind out strainhardened surface defects, cracks, nicks, flaws, etc. approx. 3 mm * For crack tests using colour penetrant method and remove the colour. * Weld with UTP BMC 4.0 mm (140 - 190 A) alternative FCAW wire UTP AF BMC 2.4 mm (240 - 450 A; 25 - 32 V) * Max. one buffer layer with UTP 630 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 surface defects that are some distance apart from each other * Rework to size, grinding without blue coloration

* Grind out strainhardened 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 - 31 V) * Interpass temperature 100-500 degrees Celsius in 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 - 32 V) * Weld temperature BMC hand-hot (~50 degrees Celsius) * Hammering each welding bead * Alternate welding onground-out surface defects that are some distance apart from each other * Rework to size, grinding without blue coloration

Primary material: 700 / R200 - 400 UHC

www.utp-welding.com info@utp-welding.com

for welding consumables:

Contacts

www.boehler-welding.com postmaster.bsga@bsga.at
for rails

www.voestalpine.com/schienen info.schienen@voestalpine.com
for crossings

www.voestalpine.com/vae info.vae@voestalpine.com

Remark: For further welding details, preparation, post weld treatment please call our specialists or contact info@utp-welding.com 7

Sales Program
Welding consumables: Stick electrodes for welding nickel and nickel alloys Stick electrodes for hardfacing Special stick electrodes for welding different kinds of steel Stick electrodes for welding cast iron Stick electrodes for chamfering and cutting Stick electrodes for welding non-ferrous metals Stick electrodes for welding stainless, acid- and heat resistant steels Silver solders, brazing alloys, soft solders Fluxes Stick electrodes for welding low- and medium-alloyed steels MIG/MAG wires and TIG rods Flux-cored wires Submerged arc welding wires and fluxes Metal powders EXOBOND powders UNIBOND powders HABOND powders PTA powders (Plasma)

Flame and Plasma spraying powders:

UTP Schweissmaterial Zweigniederlassung der Bhler Schweisstechnik Deutschland GmbH Elssser Strae 10 D-79189 Bad Krozingen Fon: Fax: Email: Web:

+49 (0) 7633 - 409 - 01 (24 h Serviceline) +49 (0) 7633 - 409 - 222 info@utp-welding.com www.utp-welding.com

UTP is a certificated company. TV Certification according to DIN EN ISO 9001 DIN EN ISO 14001