Aluminothermisches Schweißen

Head Wash Repair-Schienenschweißung

Pandrol ist weltweit führend im Head Wash Repair-Schweißen, einer kostengünstigen und effizienten Lösung zur Reparatur von Schienenkopfdefekten und zur erheblichen Senkung der Wartungskosten moderner Schienennetze. Das Verfahren ist in den USA und Kanada seit 2008, im Vereinigten Königreich seit 2013 und in Frankreich ab 2015 gut etabliert und wird dort eingesetzt, mit spezifischen Verfeinerungen des Verfahrens für lokale Schienenprofile und Netzstandards.

 

Head Wash Repair-Schienenschweißung

Das Verfahren ist für die Reparatur von Defekten mit einer Breite zwischen 25 mm und 90 mm und einer Tiefe von 25 mm (je nach Schienenprofil) ausgelegt. Es kann auch zur Reparatur von Abbrennstumpfschweißnähten verwendet werden, die oft unter Breitenverformung leiden.

  • Das HWR-Verfahren ist im Vergleich zur Verwendung von Steckschienen sehr effizient, da es die Anzahl der Schweißnähte von zwei auf eine reduziert, was zu erheblicher Reduzierung von Zeit und Wartungskosten führt.
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Advantages of the Pandrol Head Wash Repair Rail Welds

01

Simplicity

Repair head wash welds with just one weld and no need for rail destressing. The Pandrol head wash rail repair process is simple and efficient, bypassing the need for rail section replacement involved in the plug rail repair process.

02

Time savings

Save time compared to plug rail repair. The familiar mould design enables the welding crew to do the repair weld quickly and easily. Head wash repair welding takes just one hour rather than three or four, reducing rail system downtime and labour costs.

03

Safety

Promote a safer rail environment by choosing head wash repair rail welding. The process uses the same parameters and hardware as Pandrol’s signature aluminothermic welding process, which is known for its safety.

04

Equipment cost savings

Save the money you’d otherwise invest in training and hardware for alternative weld repair processes. The head wash weld repair process uses standard hardware and a one-shot crucible, making it easy for any welding expert to complete.

05

Compliance

Easily meet the compliance requirements of modern railway networks. Pandrol head wash repair welding is available for all rail grades and suitable for all environments.

Technical Capabilities of Head Wash Repair Rail Welding

01

Cutting and grinding

Adapt the head wash repair rail welding process to your project and equipment requirements. The slot can be created by oxy-propane cutting or grinding, as per your preference.

02

Optimum fusion area

Ensure total removal of the rail defect with head wash rail repair welding’s optimum size fusion area. The width is approximately 120mm with the oxy-propane cutting method, and 80mm with the grinding method. Fusion depth reaches 30mm below the slot.

03

Tensile stress management

Strengthen fatigue resistance while also avoiding flashing under the rail head for a cleaner weld. When using head wash repair rail welding, the felt protects this crucial location of the highest tensile stress.

04

Hardware

Choose a weld repair process that welding crews are already familiar with. The Pandrol head wash rail repair process uses standard hardware and a one-shot crucible, and its specially designed moulds are based on products that crews use often.

05

Versatility

Repair squats, transversal defects, shelling and corner gauge defects between 25mm and 90mm wide and 25 mm deep with the same process. Head wash repair is even compatible with the parent rail and electric flash butt welds.

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