Connection. The vital link between two components. Approximately 7.097 km of railways are connected in the Dutch railway infrastructure to offer travelers a safe and reliable way to get to their destination. The connection of rails, however, cannot be done without welds. And rail welds cannot be done without certification in order to guarantee safety and the highest quality. We recently extended our Rail Services portfolio with the flash butt weld certificate for the 400 UHC® HSH® rail quality. From now on, the 400 UHC® HSH® rails can be supplied in ultra-long lengths of up to 360 meters. (Fun fact: UHC stands for the metallurgical steel design based on Ultra High Carbon content, and HSH describes a unique heat treatment technology, so-called Head Special Hardened.)
The 400 UHC® HSH® (also known as the R400HT quality) has a higher hardness due to its compact and strengthened microstructure. Because of this new steel grade, flash butt welding of this type of rail demands a certification according European standards. In order to obtain this certification, which also serves as proof, a bend and break test takes place to check on the weld’s quality. Because of the growing interest for this type of rail abroad, we recently obtained our certification in accordance with European standards. We adjusted our machines and processes accordingly. For this certification, thirteen test welds were produced out of 140 meters of rail for this certification and endure a bend and break test. Because we passed this test with flying colors, we are now able to give our 100% welding guarantee on the continuous welded 400 UHC® HSH® rail.
The Super Premium 400 UHC® HSH® rail is developed by our sister company voestalpine Rail Technology, because of the increasing demands of modern railways. This type of rail is better resistant to against wear and tear as a result of higher axle loads, a higher frequency of train traffic and/or tight curves. The compact pearlite microstructure consists of both soft ferrite and harder cementite lamellas. This combination gives the rail the special ability to resist high contact pressure points and is therefore better equipped against wear and tear. In addition, this combination contributes to the lifecycle of the rail. It also offers the perfect solution for tight curves (especially up to +/-700 meters in radius) and other particular areas in the network that are more susceptible to wear and tear due to the severe loading.
The compact microstructure offers more advantages. It ensures the consistency in the rail profile, prevents bad rail/wheel contact when properly adjusted, and is better equipped against wear and tear and head checks in the rail infrastructure due to the high load.
This type of rail follows the exact same production process as other heat-treated rails. After production and cooling down of the blooms, the chemical quality of the rail is determined and inspected. Next, the rolling process takes place, followed by the rail being placed headfirst in a special hot bath. This process only changes the microstructure in the head of the rail, also referred to as head hardening process. The 120 meters long rail is then transported to Hilversum, the Netherlands, where we are now able to flash butt weld of up to 360 meters. The longer the rail, the less welds are needed in the tracks and therefore less potential weak spots.
In a nut shell: the 400 UHC® HSH® has a longer lifecycle, is sustainably produced due to the HSH® production process in combination with the improved steel design, having the best performance against wear, corrugation and head checks of all standardized rail grades - up to a factor of six in comparison to R260 rails. Thus, this type of rail increases the safety in the track significantly, which, in return, requires less maintenance. In our Rail Service Center on our premises in Hilversum, the Netherlands, we are able to mill stationary, coat, and weld of up to 360 meters. We can also offer in track welding services. Our sister company voestalpine Track Solutions Germany, for example, has welding teams available.
Contact our international sales department if you would like more information on the 400 UHC® HSH® and how to apply this in the best way possible.