Gas Metal Arc Root Welding of Pearlitic Rails Using Magnetic Arc Deflection

Leonhard Andreas Weingrill, Martin Schwald, Clemens Faustmann, David Frühstück, N Enzinger

Research output: Contribution to journalArticleResearchpeer-review

Abstract

Magnetic arc deflection was applied to improve gas metal arc root welds on R260 pearlitic rail steel foot samples. During laboratory welding trials parameter optimization was carried out which comprised the welding current, voltage and speed, layer sequence, filler wire diameter, and the external magnetic field. Results were evaluated by visual inspection, and the lateral and diagonal penetration in cross-sections, as well as the microstructure and the hardness in the HAZ. Additionally, the influence of the external magnetic field on the
process was studied using a high-speed camera. Overall best results were finally obtained in high welding current spray arc mode (380-400A) with the 1,6mm solid wire and at high welding speed (65cm/min) and two pass per layer sequence, in combination with maximum 30mT magnetic flux density and increased welding voltage (30-31V) for longer arc. A continuously well-formed root with sufficient lateral penetration was achieved and a smooth transition from base metal to weld metal at the lower edges could be achieved. Inside base metal HAZ the
microstructure was fully pearlitic and no soft zone occurred. Furthermore, the size of the HAZ was in comparison
to aluminothermic weld reduced by more than 75% in comparison to an AT rail weld.
Translated title of the contributionMetal-Aktivgasschweißen der Wurzel an perlitischen Schienen unter Zuhilfenahme magnetischer Lichtbogenablenkung
Original languageEnglish
Article number02001
Number of pages8
JournalMATEC Web of Conferences
Volume269
DOIs
Publication statusPublished - Jan 2019
Event2018 International Conference on Advanced Welding and Smart Fabrication Technologies - Bali, Indonesia
Duration: 15 Jul 201820 Jul 2018

Keywords

    Fields of Expertise

    • Mobility & Production

    Cite this

    Gas Metal Arc Root Welding of Pearlitic Rails Using Magnetic Arc Deflection. / Weingrill, Leonhard Andreas; Schwald, Martin; Faustmann, Clemens; Frühstück, David; Enzinger, N.

    In: MATEC Web of Conferences, Vol. 269, 02001, 01.2019.

    Research output: Contribution to journalArticleResearchpeer-review

    Weingrill, Leonhard Andreas ; Schwald, Martin ; Faustmann, Clemens ; Frühstück, David ; Enzinger, N. / Gas Metal Arc Root Welding of Pearlitic Rails Using Magnetic Arc Deflection. In: MATEC Web of Conferences. 2019 ; Vol. 269.
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    abstract = "Magnetic arc deflection was applied to improve gas metal arc root welds on R260 pearlitic rail steel foot samples. During laboratory welding trials parameter optimization was carried out which comprised the welding current, voltage and speed, layer sequence, filler wire diameter, and the external magnetic field. Results were evaluated by visual inspection, and the lateral and diagonal penetration in cross-sections, as well as the microstructure and the hardness in the HAZ. Additionally, the influence of the external magnetic field on theprocess was studied using a high-speed camera. Overall best results were finally obtained in high welding current spray arc mode (380-400A) with the 1,6mm solid wire and at high welding speed (65cm/min) and two pass per layer sequence, in combination with maximum 30mT magnetic flux density and increased welding voltage (30-31V) for longer arc. A continuously well-formed root with sufficient lateral penetration was achieved and a smooth transition from base metal to weld metal at the lower edges could be achieved. Inside base metal HAZ themicrostructure was fully pearlitic and no soft zone occurred. Furthermore, the size of the HAZ was in comparisonto aluminothermic weld reduced by more than 75{\%} in comparison to an AT rail weld.",
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    AU - Weingrill, Leonhard Andreas

    AU - Schwald, Martin

    AU - Faustmann, Clemens

    AU - Frühstück, David

    AU - Enzinger, N

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    N2 - Magnetic arc deflection was applied to improve gas metal arc root welds on R260 pearlitic rail steel foot samples. During laboratory welding trials parameter optimization was carried out which comprised the welding current, voltage and speed, layer sequence, filler wire diameter, and the external magnetic field. Results were evaluated by visual inspection, and the lateral and diagonal penetration in cross-sections, as well as the microstructure and the hardness in the HAZ. Additionally, the influence of the external magnetic field on theprocess was studied using a high-speed camera. Overall best results were finally obtained in high welding current spray arc mode (380-400A) with the 1,6mm solid wire and at high welding speed (65cm/min) and two pass per layer sequence, in combination with maximum 30mT magnetic flux density and increased welding voltage (30-31V) for longer arc. A continuously well-formed root with sufficient lateral penetration was achieved and a smooth transition from base metal to weld metal at the lower edges could be achieved. Inside base metal HAZ themicrostructure was fully pearlitic and no soft zone occurred. Furthermore, the size of the HAZ was in comparisonto aluminothermic weld reduced by more than 75% in comparison to an AT rail weld.

    AB - Magnetic arc deflection was applied to improve gas metal arc root welds on R260 pearlitic rail steel foot samples. During laboratory welding trials parameter optimization was carried out which comprised the welding current, voltage and speed, layer sequence, filler wire diameter, and the external magnetic field. Results were evaluated by visual inspection, and the lateral and diagonal penetration in cross-sections, as well as the microstructure and the hardness in the HAZ. Additionally, the influence of the external magnetic field on theprocess was studied using a high-speed camera. Overall best results were finally obtained in high welding current spray arc mode (380-400A) with the 1,6mm solid wire and at high welding speed (65cm/min) and two pass per layer sequence, in combination with maximum 30mT magnetic flux density and increased welding voltage (30-31V) for longer arc. A continuously well-formed root with sufficient lateral penetration was achieved and a smooth transition from base metal to weld metal at the lower edges could be achieved. Inside base metal HAZ themicrostructure was fully pearlitic and no soft zone occurred. Furthermore, the size of the HAZ was in comparisonto aluminothermic weld reduced by more than 75% in comparison to an AT rail weld.

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