Introduction Manufacturing Process Manufacturing Process and Quality Control Standard Dimensions and Weights Chemical composition and mechanical

Transcription

1

2 C O N T E N T S Introduction Manufacturing Process Manufacturing Process and Quality Control Standard Dimensions and Weights Chemical composition and mechanical properties Sections Head Hardened Rails Quality Typical data of JFE rails Marking (Branding and Stamping) Conversion factors and tables Information to be included with order and inquiries

3 ntroduction You will find detailed information on JFE's railroad rails in this catalog, including technical and dimensional data. This information should help you select the rails best suited to your specific needs. JFE Rails are produced in the shape mill at our West Japan Works. Their high quality reflects the superior manufacturing processes and quality control systems that we have developed during more than a hundred years of steelmaking. The rails' super-clean materials are produced with a combination of desulfurizing, degassing and continuous casting processes for improving contact fatigue properties. And their quality is assured by the rigorous controls of UST, ECT and other systems. Along with the super-clean standard carbon rails, our head-hardened rails, JFE-SP and JFE-THH, which are produced by our advanced on-line heat treatment technologies, enjoy favorable reception from worldwide heavy-haul customers. JFE rail manufacturing meets the specifications of JIS, AREMA, EN, UIC, AS, IRS and other internationally recognized standards. We hope this information is helpful, and we look forward to serving you. 2 3

4 Manufacturing Process Torch cutting Desulphurizing Basic oxygen furnace Vacuum degassing Continuous casting Cooling Marking Inspection (conditioning) Blast furnace Storing Reheating furnace Breakdown mill (BD) On-line heat-treatment equipment Hot stamper Hot saw Finishing mill (F) Intermediate rolling mill (R2) Roughing mill (R1) Cold saw Hot saw Hot stamper Cooling bed Preliminary inspection Roller straightener Surface flatness measuring device Eddy current testing machine On-line ultra-sonic testing machine Sawing and drilling machine Gag press Inspection Marking and bundling Finished products 4 5

5 Manufacturing Process and Quality Control RH Type Alloy element Vacuum vessel Droplet Evacuator Ar Gaseous phase Molten steel Ladle Vacuum degassing Rail rolling Online heat-treatment equipment Forming sequence Continuous casting bloom BLoom BD R1 R2 F 6 7

6 A E C R D Standard Dimensions and Weights Specifications Profile A B mm in. mm in. AREMA 2015 Chapter 4 RAIL 115lbs 115RE (168.28) /8 (139.70) 5-1/2 136lbs 136RE (185.74) /16 (152.40) 6 141lbs 141RE (188.91) 7-7/16 (152.40) 6 EN : kg 54E kg 60E1 60E UIC kg UIC kg UIC AS kg AS kg AS JIS E kg 37A JIS E kg 40N kg 50N kg C mm in. D mm (69.06) 2-23/32 (15.88) (74.61) 2-15/16 (17.46) (77.79) 3-1/16 (17.46) Dimensions in. 5/8 11/16 11/16 E mm in. F mm (42.86) 1-11/16 (28.58) (49.21) 1-15/16 (30.16) in. 1-1/8 1-3/16 G mm (82.55) (98.43) (54.77) /32 (30.16) /16 (98.43) in. R mm in. 3-1/4 3-7/8 3-7/8 (203.2) (254.0) (203.2) (254.0) (203.2) (72.37) (85.98) (89.01) Sectional Area Weight S W cm 2 in. 2 kg/m lbs/yd F B G Moment of Inertia Ix cm 4 in Section Modulus Head Base Zx Zx cm 3 in. 3 cm 3 in Chemical composition and mechanical properties Standards AREMA 2016 Chapter 4 RAIL EN :2011 UIC860-0 AS IRS-T-12-9 JIS E JIS E High Strength Intermediate Type of Rail Standard (Carbon) (Low Alloy) (Carbon) (Low Alloy) (Carbon) (Low Alloy) R350HT R260 Grade1100 Grade900A Head-Hardened Standard 1080 HH 880 HH370 HH340 Standard (40N,50N,60) Standard (37A) C Si Mn P S Yield Strength Tensile Strength Elongation Test Piece Brinell Hardness % % % % % N/mm 2 N/mm 2 % mm HB max max max max max max max max max max max max max max max max max max max. 828 min. 1,179 min. 10 min. 370 min. 724 min. 552 min. 780 min. 420 min. 1,069 min. 1,014 min. 1,175 min. 880 min. 1,080 min ,030 1,130 min. 880 min. 1,080 min. 880 min. 1,130 min. 1,080 min. 800 min. 690 min. 10 min. 8.0 min. 511 min. 983 min. 10 min. 310 min. 9 min. 10 min. 9 min. 10 min. 9 min. 8 min min min. 8 min. 8 min. 10 min. 9 min. Diam.=12.7 GL=50.8 Diam.=10 GL=50 Diam.=10 GL=50 Diam.=10 GL=50 Diam.=10 GL=50 Diam.=10 GL= min. 325 min min. 260 min min min. 8 9

7 Sections AREMA (American Railway Engineering and Maintenance-of -Way Association) AREMA 115 RE : 4 1 : 4 NEUTRAL AXIS 1.59R R : R 76.20R R R 19.05R 44.45R 14.29R 9.53R 1.59R AS (Australian Standard) AS 60kg Bolt holes : 20 Neutral axis R R 35R 1 : 4 80R 15.5R R 30.0R 20.0R 1 : 4 Gauge point 5.0R 3R R AREMA 136 RE R 14.29R 9.53R AS 68kg R 14.3R NEUTRAL AXIS 1 : 40 1 : R R 7.94R 19.05R R R, R : R R 1 : 4 7.9R 19.1R 203.0R 203R, 508R Neutral axis Bolt holes : R R 3.18R 1.59R R 19.1R 1 : R AREMA 141 RE R 1 : R R 44.45R 14.29R 7.94R 19.05R R WEB R, R R 19.05R : R 1.59R

8 EN (European Norm) UIC (International Union of Railway) EN 54 E1 X R 508R 2 508R 80R 13R 3R 8R B A R 508R 16 X 16R 1 : R UIC R 508R 20R 13R 3R 80R 8R 2 16R R y : 20 1 : 18 3R EN 60 E B A : 20 13R 3R 80R R EN 60 E2 120R X 40R R R 120R 8R R 35R 7R 7R 16R B A R X 4R UIC (International Union of Railway) IRS (Indian Railway Standard) UIC 60 / IRS R 35R 13R 80R 3R 7R R : X 120R 40R 1 : R 120R : 20 35R 120R 35R 3R 7R 7R R X 4R R 35R 40R 75 7R R

9 Sections JIS (Japanese Industrial Standards) JIS 37kg (36.12) R 1.59R R R R NA 6.35R 7.94R 304.8R JIS 40kg N (41) 70 3R 1 : 9 1 : R R 6R 20R 15R 13R 500R 500R 15R 6 NA Approx.45 Approx JIS 50kg N JIS 60kg : R 80R 13R (49) (49) 5R 1 : 40 1 : 4 600R 13R 50R R 1 : R R6 R500 R30 500R 11 NA R 1 : R 19R R NA Approx.60 Approx

10 13

11 Head Hardened Rails (JFE-SP4, SP3, SP2, SPA, THH370N, THH370A, THH370, THH340 and IH) Designed for heavy haul railways and passenger railways, JFE head hardened rails have been developed by super clean steel making, optimal chemical composition and our advanced on-line heat treatment technologies that deliver still higher economics. Features Uniform, thicker head hardened layer. Our advanced on-line heat-treatment technologies make the head-hardened region of JFE head hardened rails. Outstanding wear-resistance. Optimal alloy designing and advanced heat-treatment technologies bring about the outstanding wear-resistance of JFE head hardened rails. Excellent weld-ability. JFE head hardened rails have excellent weld-ability in flash-butt and thermite welding. Consistent quality. JFE head hardened rails offer consistent quality accomplished by our super-clean steelmaking technology, advanced on-line heat-treatment technique and rigorous inspection systems. 5 Extremely economy. The excellent resistance to wear and rolling contact fatigue damage of JFE head hardened rails will greatly contribute to reduce the cost of maintenance and replace. 14

12 Quality 1. Hardness (for reference) JFE Grade Hardness* of head top (HB) * an approximate average 500 The hardness range of JFE grade (for reference) THH340 THH370 IH THH370N THH370A SP2 SPA SP3 SP4 JIS E Hardness of head top (HB) Standard IH THH 340 THH 370 THH 370N 370A JFE Grade SP2 SPA SP3 SP4 2. Chemical composition (for reference) wt % JFE Grade C Si Mn P S Cr Others THH340 THH370 JIS E max max V:0.03max. V:0.03max. IH THH370N THH370A SP add. SPA add. SP add. add. SP add. add. add. add. 3. Tensile properties (for reference) JFE Grade 0.2% Yield Strength N/mm 2 (Ksi) Tensile Strength N/mm 2 (Ksi) Elongation % THH340 THH370 JIS E ,228 (178) 1,240 (180) JIS Diameter=14 Gauge length=50 AREMA, others Diameter=1/2" Gauge length=2" IH 717 (104) 1,171 (170) /2" THH370N 853 (124) 1,285 (186) /2" THH370A 880 (128) 1,310 (191) 13.3 SP2 SPA 916 (133) 900 (130) 1,366 (198) 1,360 (197) Unit: mm Unit: inch SP3 967 (140) 1,413 (205) 13.0 SP4 1,002 (145) 1,457 (211)

13 Typical data of JFE rails 1. Hardness of rail head cross section (for reference) SP4 SP3 SP2 THH370N C 420 O Hardness (HB) Distance from head surface (mm) 2. JFE grade and international standards The chart of rough correlation of mechanical property between JFE rail grade and major grade of general standard. Though this chart is rough correlation of mechanical property, please use for reference of rail grade. Please contact us for the confirmation of the detailed conformability. JFE Grade JIS E1101, E1120 EN UIC IRS T-12 AREMA Chapter4 AS Standard THH340 THH370 JIS E1120 Standard HH340 HH370 R260 R350HT Gr900A Cr Standard Standard IH THH370N THH370A R320Cr R350HT R350LHT Gr HH Intermediate strength SP2 SPA SP3 SP4 - R370HT R370CrHT R400HT - High strength Head hardened 16

14 3. Properties of head-hardened layers Microstructure Grade Magnification Optical micrographs (x ) SEM image (x 15,000) Measurement point of microstructure 1mm Standard THH 370N SP3 4. Rail life comparison in the actual track Wear loss (W1) (mm) Rail life limit W1 HB370 Grade rail SP3 79% Improvement The condition of the curve Low Rail Curvature : R240 m Some lubrication and periodical grinding were conducted. 191MGT 342MGT MGT 17

15 Typical data of JFE rails 5. Hardness distribution in flash-butt welded joints 2mm (0.08in) Hardness distribution (Measurement points=2mm from surface of head top) SP3/TTCI 500 Hardness (HV) Distance from welded joint (mm) SP2/TTCI 500 Hardness (HV) Distance from welded joint (mm) THH370N/TTCI 500 Hardness (HV) Distance from welded joint (mm) 18

16 6. Residual stress Test method : Contact strain gauge method (N/mm 2 ) 250 Residual Stress in Longitudinal Direction Longitudinal residual stress Head Web Base 1 2,3 4,5 6,7 8,9 10,11 12 Measuring position Measuring position

17 Marking (Branding and Stamping) To identify case histories of manufacture, letters and numerical figures are shown in relief and hot-stamped on the web, as shown below. Japanese Industrial Standard 1 Rolled letters (Branding) Arrow mark to indicate direction of top of bloom or ingot Rail type Steelmaking furnace type Manufacturer Year rolled Month rolled 2 Hot-stamped letters (Stamping) Serial number of rail Number of strand Serial number of cast bloom Heat number Work gang identification Carbon content 20

18 American Railway Engineering and Maintenance-of-Way Association 1 Rolled letters (Branding) Weight Section Method of hydrogen elimination Manufacturer Year rolled Month rolled 2 Hot-stamped letters (Stamping) Kind of rail (SP=SP rail, SPA=SPA rail, TH=THH rail, THA=THHA rail Heat number Serial number of rail Number of strand Serial number of cast bloom 21

19 Conversion factors and tables Force Conversion Factors N Kgf kip tonf x x Stress & Pressure MPa (N/mm 2 ) kgf/mm 2 ksi Energy Curve Conversion Factors Degree of Curve 0 30, 0 35, 1 00, 0 52, 1 30, 1 10, 2 00, 1 44, 2 30, 2 11, 3 00, 2 55, 3 30, 3 30, 4 00, 4 30, 4 22, 5 00, 5 30, 6 00, 5 50, 7 00, 8 00, 9 00, 8 44, 10 00, 11 00, 12 00, Conversion Factors kip=1000 lbf kip/in 2 = ksi=1000 psi psi=lbf/in 2 J kgf. m ft. lbf Conversion Table x Radius of Curve R = HV HB Hardness HRC Rockwell Hardness HSC Shore Hardness D Vicker Hardness Brinell Hardness (Degree) Conversion Table HV HBS HRC HSC TS N/mm 2 (kgf/mm 2 ) (186) (183) (179) (174) (169) (165) (160) (156) (153) (149) (144) (140) (136) (131) (127) (123) (120) (115) (112) (109) (105) (103) (100) (97) (96) (92) (92) (91) (89) (87) (86) (84) (82) (81) (79) (78) Load 50kgf 10mm Ball Load 0kgf C-Scale Load 150kgf diamond cone D = 2 Sin R (ft) = 2 Sin R (m) 22

20 Conversion Table Temperature Fahrenheit ( F) to Celsius ( C) Celsius ( C) to Fahrenheit ( F) F F F F F F C C C C C C F = 32 + C 9 5 C = (F-32) 5 9 Conversion Table Temperature

21 Information to be included with order and inquiries Orders and inquiries should be accompanied by the following information, and by any other information that can be useful in meeting the customers requirements. Dimension and Weight Grade Specification or Standard Length and Quantity Drilling Marking and Bundling Delivery Date 24

22 25

23 Cat.No.D1E R (0304) SP