The worldwide preferred method for rail joining is welding; flash butt welding (FBW) and thermite welding (TW) are the two main welding methods used for joining continuous welded rail (CWR) tracks. However, the welds still represent a discontinuity in the track structure due to variations in microstructure, mechanical properties and residual stress levels with respect to the parent rail. These variations can play significant roles in increasing the risk of weld failure under service conditions. In order to better understand how FBW parameters affect these variations, the two main parameters; number of preheating cycles and upsetting forces were varied in three 56E1 rail welds, welded by a stationary FBW machine. Besides, these variations were systematically compared with those that occur in a standard thermite 60E2 rail weld. The thermite weld showed a heat affected zone (HAZ) extent much greater than those measured in the flash butt welds. The flash butt rail weld with a greater upsetting force (Standard Crushed) showed a HAZ extent larger than those in the other two welds (Standard Uncrushed and Narrow-HAZ Crushed), while the weld with fewer preheating cycles (Narrow-HAZ Crushed) showed a smaller extent of the HAZ.All welds showed pearlite colonies with proeutectoid ferrite at the prior austenite grain boundaries in the weld centre, and in the thermite weld zone. The rest zones across the welds exhibited almost fully pearlitic microstructures, but the pearlite at nearly the visible HAZ extents was partially spheroidised. The partially spheroidization zone had the minimum hardness across each of the thermite and flash butt welds. The Narrow-HAZ Crushed weld showed hardness in the weld centre, on average, higher than that of the parent metal. Moreover, the averaged hardness levels in this weld were significantly higher than those in the other two welds. However, these levels in the Standard Crushed weld were slightly lower than those in the Standard Uncrushed weld. Although the visible HAZ extent coincided with the point of minimum hardness, the residual stresses arising from the welds seem to extend much further. Contour Method and laboratory X-ray diffraction techniques were used together to measure the residual stress components across the thermite and flash butt rail welds. The longitudinal residual stress distribution showed tension in the web region along with compression in the head and foot regions of the rail welds. The vertical stress distribution across the flash butt welds was generally similar, and the maximum tensile stress values were comparable to those in the longitudinal direction. While the maximum values of the longitudinal tensile stress increased with decreasing the HAZ widths, these values in the vertical direction were significantly unaffected. However, the longitudinal and vertical tensile residual stresses typically promote the vertical straight-break and horizontal split web failure modes respectively.

Pipe and ring blanks can be produced in several different ways. Today's focus on environmental effects motivates companies to develop processes that are as efficient as possible in their production. Ringsvets AB is a company that produces pipe and ring blanks from a flat stock by rolling and welding the piece to make it stay in its desired form. The direct benefit of the method is the minimizing of material loss, and it has thereby both environmental and economical advantages. The downside of the method is that the processes involved changes the mechanical behavior of the ring, locally around the weld zone. The focus of this master thesis is the processes and how they affect the material, both microstructure and behavior. The processes involved are; rolling, welding, shaping, brushing, forging, heat treatment, and calibration. The purpose of this work was to elevate the knowledge and understanding of the processes at Ringsvets. The goals were to give a theoretical description of them along with practical test results and explanations of how and why they function in reality. A literature study has been conducted which provided a theoretical basis on how the material reacts on certain processes. Practical examination of samples from current production has been done to get evidence of how well the processes are used, and how well they function, in today's production. Lastly, the main focus of the thesis, an evaluation has been made; do theory and practice correlate, and should anything be changed to correlate better? The results showed that the first operations do not alter the material behavior to an unacceptable extent. Forging, on the other hand, gives the material a very high hardness in the weld zone, and that needs to be corrected. The following heat treatment should compensate for that in a perfect world, but does not in reality. The finished ring shows good properties in general but with places where the heat treatment has failed to correct the uneven behavior induced by earlier operations. The heat treatment requires some adjustments before it functions as intended. Some grainshas not been recrystallized which makes them very hard and non-ductile. Future tests using a higher temperature or a longer heat treatment time would reveal the best way to adjust the heat treatment to obtain the desired properties. Other changes in the processes could also be benecial. Interesting things to try and change would, for example, be the degree of deformation in the forging, which affects the recrystallization temperature. Notes should be taken that this examination is done on just one sample of just one size. Analyses of different samples of different sizes should be done to ensure of the accuracy of the examination.

Šiame baigiamajame magistro darbe tiriama R65 tipo bėgio kontaktinio suvirinimo jungtis. Supažindinama su pagrindiniais mokslininkų parašytais straipsniais, bėgių kontaktinio suvirinimo tematika. Pateikiama tyrimų metodika, kurią sudaro šios dalys: apžiūrimasis paviršiaus tyrimas, ultragarsinės kontrolės tyrimas, važiuojamasis paviršiaus kiečio bandymas, sulydimo zonos nustatymas, termiškai suminkštintos zonos kiečio matavimas, mikrokietumo matavimas, mikroskopinis jungties matomosios terminio poveikio ir sulydymo zonų tyrimas, smūginio tąsumo bandymas, cheminė analizė, aširačio bandažo ir bėgio sąveikos tyrimas baigtinių elementų metodu (BEM). Išanalizuoti gauti tyrimo rezultatai, kurie įvertina suvirinimo siūlės kokybę. Pateiktos tiriamojo darbo išvados. / In the final thesis of masters degree I analyze the R65 type rail joint that were welded flash butt. Introducing with scientific articles about flash butt welding of rails. Survey methodology of the research, which consists of the following parts: visual surface review of welded joint, ultrasonic rail inspection, hardness test of upper part of the rail, fusion area research, the measurement test hardness of heat-softened area, the measurement test microhardness, microstructure research of the welded joint, impact strenght experiments, chemical analysis of welded joint, wheel-rail interaction research of the finite element method (FEM). Analyzes the results of the research, who assess the quality of weld. The conclusion is based on the results of this research.

As amarras de correntes de aço para aplicação naval utilizadas na indústria de óleo e gás são fabricadas para atender elevadas exigências operacionais. Com a prospecção de petróleo em águas profundas e ultraprofundas o conhecimento de suas propriedades torna-se relevante. Frente a essa necessidade foi realizado o estudo das propriedades mecânicas e metalúrgicas de um elo de corrente de amarra naval na indústria do petróleo proveniente de operação. Esse estudo teve como objetivo principal identificar e avaliar as propriedades mecânicas e metalúrgicas das regiões resultante do processo de soldagem por centelhamento frente ao material de base. Como objetivo secundário foi classificado o material de acordo com algumas propriedades mecânicas recomendadas pela IACS UR W22. Para isso foram realizados ensaios de tração, microdureza, tenacidade ao impacto Charpy e à fratura CTOD, com avaliações metalúrgicas no material de base e região de união por centelhamento. Como resultado foi verificado que o processo de soldagem por centelhamento produziu zonas de extensões reduzidas e com menores valores de tenacidade à fratura e ao impacto. O processo de centelhamento produziu união com espessura de 0,375 mm, com uma zona de solda revelada por ataque químico e duas zonas afetadas pelo calor caracterizadas apenas por perfil de microdureza, com 0,150 mm e 0,300 mm, respectivamente. Os menores valores de tenacidade ao impacto Charpy e à fratura CTOD foram medidos nos corpos de prova posicionados na zona afetada pelo calor. Os resultados obtidos em todos os ensaios foram comparados com as recomendações técnicas IACS UR W22, onde caracterizou o elo como grau R4. / Mooring chains of offshore systems anchors are design to be used under extreme environment operation. New fields of exploration have been operated in deep water and ultra-deep water, wherefore, require more knowledge of the mechanical and metallurgical properties. Hence a study of a studless link of offshore chain from the operating service component was carried out. The main goal of this work was to determine and evaluate the properties of the base material and the zones produced by Flash Butt Welding Process. Furthermore, the material was characterized by the IACS UR W22 standard recommendation. In this study tests of tensile test, microhardness, Charpy and CTOD toughness, mechanical and metallurgical evaluation were performed in the base material and welding zones. The results showed small welding zones with reduced impact and fracture toughness. The lowest values were seen in specimens from the heat affect zone. The weld zone thickness observed by chemical etching extend 0,375 mm and the microhardness profile indicated a Heat Affected Zone (HAZ) with 0,150 and 0,300 mm. The lowest Charpy and CTOD toughness tests were measured in the HAZ specimens. These results were compared with IACS UR W22 standard recommendation and the link chain was characterized as R4 grade.

As amarras de correntes de aço para aplicação naval utilizadas na indústria de óleo e gás são fabricadas para atender elevadas exigências operacionais. Com a prospecção de petróleo em águas profundas e ultraprofundas o conhecimento de suas propriedades torna-se relevante. Frente a essa necessidade foi realizado o estudo das propriedades mecânicas e metalúrgicas de um elo de corrente de amarra naval na indústria do petróleo proveniente de operação. Esse estudo teve como objetivo principal identificar e avaliar as propriedades mecânicas e metalúrgicas das regiões resultante do processo de soldagem por centelhamento frente ao material de base. Como objetivo secundário foi classificado o material de acordo com algumas propriedades mecânicas recomendadas pela IACS UR W22. Para isso foram realizados ensaios de tração, microdureza, tenacidade ao impacto Charpy e à fratura CTOD, com avaliações metalúrgicas no material de base e região de união por centelhamento. Como resultado foi verificado que o processo de soldagem por centelhamento produziu zonas de extensões reduzidas e com menores valores de tenacidade à fratura e ao impacto. O processo de centelhamento produziu união com espessura de 0,375 mm, com uma zona de solda revelada por ataque químico e duas zonas afetadas pelo calor caracterizadas apenas por perfil de microdureza, com 0,150 mm e 0,300 mm, respectivamente. Os menores valores de tenacidade ao impacto Charpy e à fratura CTOD foram medidos nos corpos de prova posicionados na zona afetada pelo calor. Os resultados obtidos em todos os ensaios foram comparados com as recomendações técnicas IACS UR W22, onde caracterizou o elo como grau R4. / Mooring chains of offshore systems anchors are design to be used under extreme environment operation. New fields of exploration have been operated in deep water and ultra-deep water, wherefore, require more knowledge of the mechanical and metallurgical properties. Hence a study of a studless link of offshore chain from the operating service component was carried out. The main goal of this work was to determine and evaluate the properties of the base material and the zones produced by Flash Butt Welding Process. Furthermore, the material was characterized by the IACS UR W22 standard recommendation. In this study tests of tensile test, microhardness, Charpy and CTOD toughness, mechanical and metallurgical evaluation were performed in the base material and welding zones. The results showed small welding zones with reduced impact and fracture toughness. The lowest values were seen in specimens from the heat affect zone. The weld zone thickness observed by chemical etching extend 0,375 mm and the microhardness profile indicated a Heat Affected Zone (HAZ) with 0,150 and 0,300 mm. The lowest Charpy and CTOD toughness tests were measured in the HAZ specimens. These results were compared with IACS UR W22 standard recommendation and the link chain was characterized as R4 grade.

As amarras de correntes de aço para aplicação naval utilizadas na indústria de óleo e gás são fabricadas para atender elevadas exigências operacionais. Com a prospecção de petróleo em águas profundas e ultraprofundas o conhecimento de suas propriedades torna-se relevante. Frente a essa necessidade foi realizado o estudo das propriedades mecânicas e metalúrgicas de um elo de corrente de amarra naval na indústria do petróleo proveniente de operação. Esse estudo teve como objetivo principal identificar e avaliar as propriedades mecânicas e metalúrgicas das regiões resultante do processo de soldagem por centelhamento frente ao material de base. Como objetivo secundário foi classificado o material de acordo com algumas propriedades mecânicas recomendadas pela IACS UR W22. Para isso foram realizados ensaios de tração, microdureza, tenacidade ao impacto Charpy e à fratura CTOD, com avaliações metalúrgicas no material de base e região de união por centelhamento. Como resultado foi verificado que o processo de soldagem por centelhamento produziu zonas de extensões reduzidas e com menores valores de tenacidade à fratura e ao impacto. O processo de centelhamento produziu união com espessura de 0,375 mm, com uma zona de solda revelada por ataque químico e duas zonas afetadas pelo calor caracterizadas apenas por perfil de microdureza, com 0,150 mm e 0,300 mm, respectivamente. Os menores valores de tenacidade ao impacto Charpy e à fratura CTOD foram medidos nos corpos de prova posicionados na zona afetada pelo calor. Os resultados obtidos em todos os ensaios foram comparados com as recomendações técnicas IACS UR W22, onde caracterizou o elo como grau R4. / Mooring chains of offshore systems anchors are design to be used under extreme environment operation. New fields of exploration have been operated in deep water and ultra-deep water, wherefore, require more knowledge of the mechanical and metallurgical properties. Hence a study of a studless link of offshore chain from the operating service component was carried out. The main goal of this work was to determine and evaluate the properties of the base material and the zones produced by Flash Butt Welding Process. Furthermore, the material was characterized by the IACS UR W22 standard recommendation. In this study tests of tensile test, microhardness, Charpy and CTOD toughness, mechanical and metallurgical evaluation were performed in the base material and welding zones. The results showed small welding zones with reduced impact and fracture toughness. The lowest values were seen in specimens from the heat affect zone. The weld zone thickness observed by chemical etching extend 0,375 mm and the microhardness profile indicated a Heat Affected Zone (HAZ) with 0,150 and 0,300 mm. The lowest Charpy and CTOD toughness tests were measured in the HAZ specimens. These results were compared with IACS UR W22 standard recommendation and the link chain was characterized as R4 grade.