Custom-Forged Rail Fishplates

Custom-forged rail fishplates (joint bars) are heavy-duty metal plates used to bolt the ends of two rails together. They are typically hot-forged from high-carbon or alloy steel to withstand intense dynamic loads. Custom forging is required for transition joints, heavy-haul lines, and industrial crane rails. 

Signum Rail Fastening has the capability to forge many types of rail fishplates to suit types of rail sections, such as UIC 60, UIC 54, U33, BS 80A, BS 90A, IRS 52 KG, IRS 90 Lbs, 115 RE, 136 RE, TJ 45, TJ 37, RN 45, etc.

Key Features of Custom Forged Fishplates

• Perfect Alignment: Custom forged to match specific rail profiles (e.g., UIC 60, AREMA, CRANE) to prevent sagging.

• Compromise Joints: Used to securely connect two different rail sizes or weights.

• Joggled Designs: Specially forged to temporarily repair cracked continuous welded rails.

• Material Integrity: Forging aligns the steel's grain structure, offering higher tensile strength and fatigue resistance compared to cast alternatives. 

Signum Rail Fastening are able to supplying rail fishplates according to international standards such as BS, ASTM,AREMA,DIN, and others. We have equipment for rolling, forging, machining, and drilling and punching to customize rail fish plates for drawings supplied by customer.

Production Of Custom-Forged Rail Fishplates

The production of custom-forged rail fishplates involves precise metallurgical manufacturing designed to withstand heavy dynamic loads. The process transitions from initial CAD design and stress analysis to material selection, hot forging, precision machining, heat treatment, and rigorous quality control. 

1. Co-Engineering and Design

• CAD and FEA: Custom manufacturing begins by matching the exact rail profile (e.g., UIC60, AREMA, BS113A). Signum uses CAD design and Finite Element Analysis (FEA) to simulate stress distribution and determine the optimal thickness, bolt-hole pattern, and taper for the plate.

2. Material Selection and Preparation

• Steel Selection: High-strength carbon or alloy steel (such as 45# steel or medium-manganese) is selected based on required tensile strength, hardness, and impact resistance. 

• Blanking: The raw steel billets or bars are cut to specific lengths matching the planned fishplate (e.g., 4-hole or 6-hole spans) using heavy-duty saws or shears. 

3. Hot Forging

• Heating: The steel blanks are heated in an induction or medium-frequency furnace to temperatures ranging from 900°C to 1100°C until the metal is highly malleable. 

• Forging: The heated blanks are pressed using power hammers or hydraulic die-forging machines to mold the metal into the specific angled profile of the rail web.

• Deburring: Excess flashing (extruded metal) is trimmed off immediately after the forging process.

4. Precision Machining

• Drilling and Milling: The forged plates are machined on automated CNC centers to create the precise bolt holes needed to connect the joint. Custom drilling allows for the exact spacing required for compromise joints or specialized expansion gaps.

• Surface Finishing: Any rough edges or imperfections that could damage the rail are smoothed out to ensure a flush, even fit.

5. Heat Treatment

• Hardening and Tempering: To enhance wear resistance and fatigue life under heavy loads, the fishplates undergo quenching (rapid cooling in oil or water) and tempering. 

6. Anti-Corrosion Finishing and Quality Control

• Coating: Finished plates are treated for weather resistance, often utilizing hot-dip galvanizing, black oxide, or specialized petroleum-based rust inhibitors. 

• Inspection: Batches are checked for dimensional tolerances, hardness, bolt hole alignment, and tensile strength to ensure compliance with global standards (e.g., UIC, AREMA, DIN).

If you are looking for custom-forged rail fishplates, please contact Signum Rail Fasteners. Forged rail joint bars, forged rail tie plates are our featured products. We will send you our offer for the forged rail fishplates and support soon.