ULTRASONIC METHOD

STATEMENT

GANTREX

Issuer:
G.NOWAK
Level 3 UT
Card Number: B03 - 003511 February 2015
ISO 9712 R0
 PURPOSE

The purpose of this document is to define a guideline for ultrasonic inspection of crane rail’s welds in
conformity with recommendation of tests process and recording for aluminothermic welding.
The following criteria has been defined in accordance of the 2 companies GANTREX and RAILTECH
This document is just a reference, it’s not a substitute of the inspection agency procedure.
RECOMMENDATION OF TESTS PROCESS AND
RECORDING FOR ALUMINOTHERMIC WELDING
-
LATEST REVISION
The following criteria has been defined in accordance of the 2 companies GANTREX and RAILTECH
According with the state of the art and only for NDT tests, we can refer some items from EN14730, and
consider them only as guide line.
1. Visual surface examination
1.1. As cast iron
Following stripping and grinding the as-cast weld collar surface shall be visually examined for
soundness. For the process to be accepted:
- There shall be no cracks with length of 2mm, or greater. Joints between weld collars and rail
and flashing and rail are not cracks.
- There shall be no pores with a dimension greater than 3mm nor shall there be more than
three pores in the size range 2mm to 3mm per test.
- Slag or sand inclusions shall not exceed the limits.
Surface dimension (max) in mm : 10 15 20
Depth (max) in mm: 3 2 1
No defect (exceed 1 mm) shall intrude into the rail cross section nor touch the edge of the
weld collar/rail intersection.
- The condition of the surface left by riser removal (other than that on the ground rail head)
shall conform to the requirements specified by Railtech process manual APR one shot
cresset.
1.2. Final ground weld surface
The head and the ground weld collar surface on either side of the rail head shall comply with the
following.
- There shall be no cracks.
- There shall be no defects exceed 1mm (pore, slag sand inclusions, metal beads)
1.3. Visible heat affected
The visible heat affected zones on each side of the weld shall be measured on the rail running
surface centre line. Their widths shall be equal to +/-40mm (on the head of the rail). The visible
heat affected zone shall be nominally symmetrical about the longitudinal axis of the rail and
transverse axis of the weld. A mark can be made after rail cutting but before welding, this mark
will used as reference to check any movement of the rail during the welding.
2. Internal examination by ultrasonic test
Each inspector must be certified level 2 or 3 UT (Ultrasonic testing) according to ISO EN 9712. The step
of the procedure control is given below.
- A test of the head, web, middle of the foot including fusion zone and weld (non-planar defect) Reject
level – Any defect signals > the signal 5 mm diameter side drilled hole
- A test of the head zone of the weld (planar defects)
Reject level – any defect signals> the signal from a 10mm diameter flat-bottomed hole
- A test of the web zone of the weld (planar defects)
Reject level – any defects signals> the signal from a 5mm diameter flat-bottomed hole
- A test of the middle zone of the foot of the weld (Planar defects)
Reject level – any defects signals> the signal from a 5mm diameter flat-bottomed hole
- A test of the ankle zone of the foot of the weld
Reject level – any defect signals> the signal a 5mm diameter flat-bottomed hole
- A test of the toe zone of the foot of the weld
Reject level – any defect signals> the signal a 5mm diameter flat-bottomed hole
- Planar defaults can’t exceed the limit of rejection. More than 1 acceptable vertical defect = reject of
the weld
- More than two acceptable non-planar defaults by zone (head, web and/or foot) = reject of the weld
- The calibration block must be a welded one according the drawing “UT Calibration block Based on
the Welded rail ” is proposed at the Annex 1,
The extent and depth of any defect found shall be marked on the report supplied by the
controller/inspector.
3. Validation
According the standard, the validation of the welding is under the responsibility of the controller. Those 3
kinds of tests are always considered together by welding. We consider other tests like x-ray examination
or dye penetrate examination like extra tests.
4. Calibration block (Rail)
The calibration block will be made on a same type and grade than the inspected rail.
 ISSTAF ULTRASONIC
INSPECTION METHOD
1. Types of defects

1.1 Volumetric defects

- Gas bubble and porosity

- Inclusions (sand, slag, paste)

- Shrinkage

1.2 Planar defects

- Cracks

- fatigue cracks

- Shrinkage
- Lack of fusion

2. Calibration

2.1 Detection of planar defects

- Flat bottom hole 5 or 10 mm

2.2 Detection of volumetric defects

- Side drilled hole 5 mm

3. Inspection method

3.1 Head inspection

- Type of defect detected: Gas bubble / Inclusion / Shrinkage / Fatigue cracks
- Type of defect detected: Lack of fusion

3.2 Web inspection

- Type of defect detected: Lack of fusion

- Type of defect detected: Gas bubble / Inclusion / Shrinkage

3.3 Foot inspection

- Type of defect detected: Gas bubble / Inclusion / Shrinkage / Lack of fusion
4. Tools used

3.1 Echodynamic pattern

3.2 Echostatic aspect

3.3 Evaluation defect curve (DAC)

3.4 Defect position inside the weld

- On the weld axe
- On the gap position
- In the head
- In the foot
- Single defect
- Many defects
- etc…
3.5 Defect determination method
- Defect position

- Changing of probe
ISSTAF INSPECTION
SERVICES
1. Introduction

ISSTAF can realize visual, ultrasonic, magnetoscopic and geometric inspection on site in according to
client standards and specifications.
- Realization of calibration block
- Development of inspection procedure
- Realization of inspection on site
- Determination of welds status
- Development of inspection report

2. ISSTAF Inspection services

2.1 Ultrasonic inspection of rails

 Purpose: Ultrasonic research of internal defects inside rails
 Equipment:

2.2 Ultrasonic inspection of welds

 Purpose: Ultrasonic research of internal defects inside welds
 Equipment:
2.3 weld acceptance inspection
 Purpose: Visual inspection of welds, Welded rail alignment inspection and geometrical inspection of
collar
 Equipment:

2.4 Track geometry inspection

 Purpose: Track spread, cant and rail corrugation measurements
 Equipment:

2.5 Eddy current inspection

 Purpose: Detection of defects near the surface of the head, corrugation, skid marks, burning,
reloading and weld bead
 Equipment:

2.6 Laser rail profiles measurement

 Purpose: Identify height and lateral deterioration of rails
 Equipment:
2.7 Various non-destructive testing

 Penetrant testing :
 Purpose: Research of internal defects with intense magnetic flux
 Equipment:

 Magnetic particle testing :

 Purpose: Research of emerging defects
 Equipment:

3. Contact us

ISSTAF
 ZI du bas pré – BP 9 – 59590 RAISMES (FRANCE)
 [email protected]
 +33-3-27-22-84-92

ISSTAF Director Director’s assistant

Mr. NOWAK Gérard Mrs TELLE Laetitia

 +33-3-27-22-26-24  +33-3-27-22-26-03
 [email protected]  [email protected]
4. Customers references

References in France:
Paris (RER, TRAM, Métro), TGV EST, conventional track, Port of Le Havre (bridge crane rails), the
Chunnel, Brest Arsenal (bridge crane rails), Brest tramway, Rennes VAL (metro rails), Reuil VAL (special
rails), Tunnels des Montets (Chamonix), Ariane rocket launching pad (Kourou), Martinique (port – bridge
crane rails) , Construction site APR-AREVA, Havre tramway, Toulouse tramway, Dijon tramway, Reims
tramway, Val d’ Orly, Val de Roissy, Lille tramway, Lyon tramway, Le Mans tramway…

References abroad:
China (Vignoles rails and bridge crane rails), Tibet, Guinea, Sweden, Morocco, Germany, England,
Venezuela, Luxembourg, Belgium, Switzerland, Amsterdam, Athens metro, Barcelona metro, Algers
tramway, USA (bridge cranes), Senegal, Italia, Spain, Bruxelles Tramway, Dubaï Tramway, Santo-
Domingo, Saudi Arabia, Tunisia, Turkey, Thailand