Rail Welding Technology: Processes and Welding Quality

Patel, Trushil Alpeshkumar; Badheka, Vishvesh J.

doi:10.1007/978-981-16-7660-4_33

Cited by 4 publications

(1 citation statement)

References 12 publications

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“…Nevertheless, given that rail welding is the principal method to realize seamless railway which can greatly improves the running speed, stability and riding comfort of trains [19], the service performance of welded joints of bainitic rails as the weak area of the whole track structure remains a challenge. Compared to the commonly used rail welding technologies [20][21][22], flash-butt welding (FBW) has the advantage of reliable welding quality and high productivity over thermite and gas pressure welding, and hence has become the mainstream method to produce seamless railways. However, upon welding, the microstructure of joint will differ from the parent microstructure due to the formation of heat affected zone (HAZ), which will degrade the mechanical properties of joint.…”

Section: Introductionmentioning

confidence: 99%

Microstructural evolutions and impact toughness in simulated welding heat affected zones for a high-strength carbide-free bainitic rail steel

Bai

Liu

et al. 2023

Materials Science and Engineering: A

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Section: Introductionmentioning

confidence: 99%

Microstructural evolutions and impact toughness in simulated welding heat affected zones for a high-strength carbide-free bainitic rail steel

Bai

Liu

et al. 2023

Materials Science and Engineering: A

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Performance Evaluation of High Speed Pearlite Railway Steel Joint by 3-Wire Electroslag Welding

Khan,

Shengfu

2024

J. of Materi Eng and Perform

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Simulation-based assessment of railhead repair welding process parameters

Andersson,

Steyn,

Ekh

et al. 2024

Weld World

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This study uses a finite element method based simulation methodology for in-situ railhead repair welding to investigate how welding process parameters impact the repaired rail quality. The methodology includes material modeling with cyclic plasticity, phase transformations, transformation-induced plasticity, and multi-phase homogenization. The weld process modeling includes a 3D heat transfer analysis and a 2D Generalized Plane Strain (GPS) mechanical analysis. The Heat source model used in the thermal simulation is calibrated using measurements from a repair welding experiment. To assess the performance of the repaired rail, mechanical rolling contact simulations are performed to estimate the risk of fatigue crack initiation. The process parameter study is based on the Swedish stick-welding railhead repair procedure and focuses on factors affecting the repair quality, such as preheating and operation temperature conditions as well as variations in repair geometry. Significant findings highlight both the inherent robustness of the process and regions susceptible to parameter variations. Specifically, the powerful final zig-zag weld passes provide effective resilience against variations in additional heating, and the start and end stretches of the repair welding are the most susceptible to parameter variations. Chamfered and deeper cutout repair geometries are found to be effective in mitigating adverse effects. In agreement with field observations, the simulations identify the fusion zone of the base and weld filler material as the critical region of the repaired rail in operation. This is attributed to the integrated effects of unfavorable microstructures, longitudinal tensile residual stresses from repair welding, and tensile stresses during operational traffic loads.

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Rail Welding Technology: Processes and Welding Quality

Cited by 4 publications

References 12 publications

Microstructural evolutions and impact toughness in simulated welding heat affected zones for a high-strength carbide-free bainitic rail steel

Microstructural evolutions and impact toughness in simulated welding heat affected zones for a high-strength carbide-free bainitic rail steel

Performance Evaluation of High Speed Pearlite Railway Steel Joint by 3-Wire Electroslag Welding

Simulation-based assessment of railhead repair welding process parameters

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