Residual Stress Measurement Techniques for Metal Joints, Metallic Coatings and Components in the Railway Industry: A Review

Abstract

Manufacturing and maintenance procedures in the railway industry regularly implement welding and metal deposition operations to produce joints, coatings and repair structures. During these processes, residual stresses arise through the generation of heat affected zones and plastic deformation. This makes accurate measurements of the internal stresses a critical aspect of manufacturing, monitoring, repair and model validation in the develop new metallic coating and joining technologies. Selection of an appropriate residual stress measurement method has many important factors including component size, resolution and the magnitude and location of internal stresses, often resulting in a combination of techniques required to obtain complete assessment of the stress state. This paper offers a review of residual stress measurement techniques for railway components including rail joints and coatings through comparison of destructive and non-destructive approaches, their measurement capabilities, benefits and limitations. A comprehensive discussion of different applications is provided with a summary of facilities available to both research and industry.

Cold Spray Coatings of Complex Concentrated Alloys: Critical Assessment of Milestones, Challenges, and Opportunities

“…Thermal stresses are due to differences in the coefficient of thermal expansion (CTE) of the substrate and coating materials. Based on the magnitude of the CTE mismatch of the coating and substrate, tensile or compressive residual stresses can be induced [38,45]. Typical compressive residual stresses are observed in the coatings and tensile stresses in the substrate when CTE substrate > CTE coating [29].…”

Optical Analysis of the Impact Transmission in Steel Sheet Arrays with Bolted-Type Joints

“…Additionally, bolts were studied under reverse fault loadings [25] for the design of truss joints analyzing the stress and strain of plates [26], evidencing the importance of joints in precast concrete structures [27], to determine experimentally and numerically the mixed-mode fracture properties of adhesive structures [28]. A review of measurement techniques for residual stress was written, in which the authors expose the importance of internal stresses as a critical aspect of manufacturing, monitoring, repair, and model validation in the development of new metallic coating and joining technologies [29].…”