22nd February / Andrew J Wilson

The Technical Aspects of the Rail

Manufacturing Process
The Technical Aspects of the Rail Manufacturing
Process

• Tata Steel in the European Rail Market

• The Medium Section Mill – Scunthorpe
• Rail manufacturing
• Rail in track
• New product development

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Tata Steel Rail Business

MSM ~ 250k Tonnes Rail

~ 400k Tonnes Sections

Tata Steel Scunthorpe

• Medium Section Mill
• Steel-plant
Hayange ~ 300k Tonnes Rail

Tata Steel Hayange

• Hayange Rail Mill

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Medium Section Mill

152 x 127mm Colliery Joists

60E2 Rail

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Medium Section Mill

Configuration:
1 WBF capable of 160tph
2 reversing breakdown mill
stands
7 stand continuous universal
finishing mill

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Medium Section Mill
Rolling

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Medium Section Mill
Finishing

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Medium Section Mill

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Rail Manufacturing
Roller Straightening

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 Rolling Rails
Rail in Track
HISTORY OF RAIL ROLLING

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Rail in Track

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Rail in Track

Key Rail Developments over last 100 years

• Cleaner Steel for fewer rail breakages (defects)
• Longer ‘as rolled’ lengths for fewer welds/joints
• Higher carbon, higher hardness for greater wear resistance

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Rail in Track
Rolling Contact Fatigue

‘Head Checks’

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Rail in Track

Hatfield Rail Crash 17th October 2000

Train speed, 115mph - rail fractured due to gross RCF
4 fatalities, 70 people injured

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New Product Developments
Tata Steel ‘High Performance’ HP Rail
Metallurgically Engineered Pearlitic Rail Steel
• Increased volume fraction of pearlitic cementite
• Increased strength of pearlitic ferrite

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Tata Steel in the Rail Industry

Strong Commercial Position in the European Rail Market

World Class Manufacturing facilities
Excellent R&D

World leaders in new rail steel development

Thank you, Any Questions?

Acknowledgements:
Damian Shipton, Tata Steel Roll Design
Dr. Jay Jaiswal, Tata Steel Rail Technologies
Brian Whitney, Network Rail

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