Induction Welding of Rail. Nick Matthews C.Eng MSc MIET MPWI S&C North Alliance Nick Mountford C.Eng, MCIBSE, BEng (Hons) Mirage Managing Director

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1 Induction Welding of Rail Nick Matthews C.Eng MSc MIET MPWI S&C North Alliance Nick Mountford C.Eng, MCIBSE, BEng (Hons) Mirage Managing Director

2 Introduction The Need for Induction Welding The R&D Challenge The Road to Mirage Mirage Who are we? The Induction Welding Process Weld Testing and Validation Next Steps

3 Intellectual Property Two UK Patents in place Filed for Ten International patents including Europe North America Australia Hong Kong

4 The Need For Induction Welding

5 The R&D Challenge Network Rail buy in what they need. Expectation that product will work Immediately Product Acceptance does not allow for Prototype equipment Comparisons with other technology's Funding (Hendy Report)

6 The Road to Mirage Original design subjected to FMEA(d) FMEA(d) demonstrated that the design needed to be improved Original contractor brought in Mirage LTD to improve the design Original contractor went into liquidation Mirage contracted to build prototype welding head

(TPS) Poka-Yoke - Inadvertent Error Prevention Lean

7 Mirage who are we? Bespoke Machine Builders & Automation Specialists Clients: Automotive Manufacturers, Food, Pharmaceutical. Specialist Areas: Application of Toyota Production System (TPS) Poka-Yoke - Inadvertent Error Prevention Lean Manufacture Reduction of waste; energy, time, & resource. Green Technology Integration Intelligent Controls & Software

Objective: Target: Minimal Consumption Solid Phase Weld Bend strength as close to plain rail Equivalent properties to parent rail material in the absence of a weld Microstructure and associated

8 Objective: Target: Minimal Consumption Solid Phase Weld Bend strength as close to plain rail Equivalent properties to parent rail material in the absence of a weld Microstructure and associated hardness - fault free Clean visual appearance after forged material removal Minimal rail consumption for S&C installations Fatigue resistance as plain rail Light Weight Mobile Welding Head Deployment from various RRV s

9 Development: Test Bench Development to establish the variables affecting the weld integrity Heat Applied Forge Distance, Forces Applied Rail Consumption Sacrificial Insert Welding Prototype Welding Head Development Operational Railway Trials from an RRV

10 Video

Results: Bend strength In excess of 1330kN minimum. Nom.

absence of a weld Microstructure: As parent rail with slight

11 Results: Bend strength In excess of 1330kN minimum. Nom. 1660kN Bend test properties similar to parent rail material in the absence of a weld Microstructure: As parent rail with slight increase in hardness Microstructure: Heat affected zone without oxidation & flaws. Visual appearance after forged material removal clean & linear Zero/minimal consumption for S&C installation Fatigue resistance to be established

12 Bend Test Results: Bend Test Results FORCE kn DISTANCE 0.1 mm BEND Induction Weld RAIL Plain Rail 1330 kn Pass

13 Metallurgical Results: HEAD WEB FOOT HEAD WEB FOOT

14 Mobile Welding Head: Production Prototype: Deployable from lightweight RRV Automatic Peaking Stressing Capabilities Automatic Shearing Compact for S&C installations Poka-Yoke error proof welds Sub 5 Minute weld process (CEN 56)

15 Benefits: Significant safety benefits, which include; no transportation of gas cylinders, no heavy lifting and reduced staff on track. Substantial environmental benefits, which include; reduction in power, no flames, no fumes and less noise. The established contract allows for a potential revenue stream to be realised from sales outside of Network Rail. Fully endorsed by the Professional Head of Track Engineering in both Network Rail and London Underground. Modular design so the system can be multi modal.

16 The Next Steps Manufacture Prototype Head Manufacture Interface Skid Integrate systems Produce test weld for fatigue and macro testing Operational testing

Underground Applications Lightweight Rapid Response RRV Tunnel & Tube Lines Emission Free

17 Next Steps for Induction Welding: Coming Soon: HS2 High Integrity Welding Twin Head applications for rapid panel laying Integrated Rail Stressing Induction Stressing Underground Applications Lightweight Rapid Response RRV Tunnel & Tube Lines Emission Free Welding Fixed Plant Welding Mobile Maintenance Train Unit. MMT. GPS positional weld data archiving with traceability

18 Acknowledgements John Hempshall: Network Rail Senior Welding Engineer Lisa Scholes: S&C North Alliance Project Manager Sue Millington: Programme Manager Rob MacDonald Project Engineer Lynsey O Neil Senior Commercial Manager Chris Holmes: Network Rail Project Manager David Marr: Network Rail Project Manager Colin Cassidy Network Rail Project Manager R&D Fund Investor LNE Route Investor LNW Route Investor Pablo Forteza Network Rail Director of Engineering and Innovation GOS Engineering Interface Skid Manufacturer

Bob Scholfield. Senior Consultant. Expertise. Experience. BEng(Hons) MEng CEng FIMechE PhD. Structural, Stress, Vibration and Design Analysis

Bob Scholfield. Senior Consultant. Expertise. Experience. BEng(Hons) MEng CEng FIMechE PhD. Structural, Stress, Vibration and Design Analysis Dr Senior Consultant BEng(Hons) MEng CEng FIMechE PhD Expertise Structural, Stress, Vibration and Design Analysis Automotive Component Design Tunnelling and Mining Equipment Steel Making and Process Improvement