METRODE PRODUCTS LTD
HANWORTH LANE, CHERTSEY
SURREY, KT16 9LL
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+44(0)1932 569449 Technical DATA SHEET A-80
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RAILROD
Product description for depositing the root can utilise a copper backing plate
or wire-reinforced window glass. Before and during
MMA electrode for rail welding utilising basic low
welding it is important to use a sufficient preheat-interpass
hydrogen flux coating with low moisture absorption
range, and to retard cooling.
characteristics. Recovery is about 110% with respect to
core wire, 65% with respect to whole electrode. Composition (weld metal wt %)
Specifications C Mn Si S P Cr Ni Mo
min 0.06 0.7 0.2 -- -- 2.0 -- --
None strictly applicable, nearest AWS E12016-G and max 0.12 1.5 0.8 0.020 0.025 2.6 0.5 0.5
nearest BS EN E69 Z Z B. typ 0.09 1 0.5 0.008 0.012 2.3 0.2 0.2
ASME IX Qualification All-weld mechanical properties
QW432 F-No -, QW442 A-No -. As welded typical
Tensile strength MPa 900
Materials to be welded 0.2% Proof stress MPa 700
Elongation on 4d % 17
Rail steels with up to 0.8% carbon and nominal tensile Impact energy * + 20°C J 18-48
strength of > 700 MPa. 0°C J 14-43
Hardness HV 280
Applications * For comparison, typical thermit rail weld: 8J @ 20°C, 5J @ 0°C.
This electrode is especially designed for the butt welding Parameters
of rails with square preparation. It can also be used for
welding similar cross-sections such as bars, thick plates, DC +ve or AC (OCV: 70V min)
flanges, etc. The electrode is specially designed to enable
good fusion to the side walls to take place without ø mm 3.2 5.0 6.0
min A 100 200 240
excessive slag interference. max A 160 280 360
Weld metal has good resistance to collapse under
compression by rolling loads. Packaging data
Applications include rails for rolling stock and crane ø mm 3.2 * 5.0 6.0 *
rails in dockyards, mines, steelworks and length mm 380 450 450
petrochemical plants. kg/carton 15.0 17.7 18.3 * supplied to order
pieces/carton 447 183 135
Note that this technique has not been generally accepted
as an alternative to the thermit process for in-situ welding Storage
of passenger track. 3 hermetically sealed ring-pull metal tins per carton, with
unlimited shelf life. Direct use from tin will give hydrogen
Microstructure
<5ml/100g weld metal during 8h working shift.
Mainly auto-tempered bainitic ferrite. For electrodes that have been exposed:
Redry 250-300°C/1-2h to ensure H2 <10ml/100g, 300-
Welding guidelines 350°C/1-2h to ensure H2 <5ml/100g. Maximum 420°C, 3
Preheat typically 200°C for >0.5%C rail steel, increasing cycles, 10h total.
Storage of redried electrodes at 100-200°C in holding oven
to 300°C for >0.7%C rail steel. It is important to maintain
or 50-150°C in heated quiver: no limit, but maximum 6
these minimum temperatures during welding. Maximum
weeks recommended. Recommended ambient storage
suggested interpass temperature 400oC. Slow cool under
conditions for opened tins (using plastic lid): < 60% RH,
insulation after welding. >18°C.
This electrode is normally used in the downhand (flat)
position with a slag-over-slag technique. Rail ends are Fume data
square butt welded by setting 15-20mm apart with a Fume composition, wt % typical:
prepared 4-6mm thick steel insert at the weld root, then
Fe Mn Ni Cr Cu Pb F OES (mg/m3)
copper shims are stacked to form an enclosure for the 15 5 < 0.2 0.8 < 0.2 < 0.1 18 5
weld pool whilst allowing excess slag to run free.
Good surface profile underneath the weld root area will
maximise fatigue resistance of the joint. Initial support
Rev 00 01/01 DS: A-80 (pg 1 of 1)
