Journal ArticleDOI
Temperature Field Evolution during Flash Butt Welding of Railway Rails
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In this paper, a finite element (FE) model of the flash-butt welding of railway rails was developed and implemented with the help of ESI's FE-software SYSWELD.Abstract:
Flash butt welding (FBW) of railway rails was investigated in this work. For this purpose samples of R260 rail steel and 60E1 profile were instrumented and subsequently welded on a Schlatter GAA 100 welding machine under industrial conditions. The intention is to gain in depth process knowledge by more accurately depicting thermal cycles for an entire welding sequence in the immediate proximity of the weld as well as in the heat affected zone (HAZ). A detailed characterization of the single stages of the heat up phase of the process is important. Additionally, the secondary welding voltage was measured simultaneously during the experiments to characterize the transient heat input. Moreover, these data were used in the analysis of the temperature signals to better cope with electrical interferences. Additionally, a finite element (FE) model of this FBW process was developed in the present work. Its implementation and solution is realized with the help of ESI’s FE-software SYSWELD. A strong coupled thermo-electrokinetical and metallurgical calculation routine was used. The model comprises the transition resistance at the welding surfaces as the main heat source to the process. Temperature dependent material properties and a corresponding metallurgical model based on an experimental CCT diagram of the rail steel R350HT are implemented in the simulation as well.read more
Citations
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Journal ArticleDOI
Microstructure and mechanical properties of a flash butt welded pearlitic rail
Rodrigo Rangel Porcaro,Geraldo Lúcio de Faria,Leonardo Barbosa Godefroid,Gabriela Ribeiro Apolonio,Luiz Cláudio Cândido,Elisângela Silva Pinto +5 more
TL;DR: In this article, the microstructural evolution of the heat affected zone is clarified with the aid of dilatometry, and a dilatometric based methodology is proposed to define a process window and control the post-weld cooling rate at the rail head in order to improve the weld performance due to a better hardness profile, without increasing costs or welding time.
Journal ArticleDOI
Ratcheting behaviour of flash butt welds in heat-treated hypereutectoid steel rails under uniaxial and biaxial cyclic loadings
TL;DR: In this article, the authors investigated the ratcheting behavior of new flash butt welds in a heat-treated hypereutectoid steel rail used in Australian heavy haul railways.
Journal ArticleDOI
Experimental and numerical investigation of the characteristics of flash-butt joints used in continuously welded rails:
TL;DR: In this article, a thermal model of the flash-butt welding process was used to accurately model the process of train construction in Iran's railway network, which is used for continuous welded rails.
Journal ArticleDOI
Thermo-metallurgically coupled numerical simulation and validation of multi-layer gas metal arc welding of high strength pearlitic rails
TL;DR: A 3D transient thermo-metallurgical finite element simulation of a narrow gap multi-layer gas metal arc welding of the first ten layers of a 60E1 profile and R350HT steel rail was implemented in SYSWELD® to study the evolution of the temperature field, phase fractions, and the hardness in the heat-affected zone.
Journal ArticleDOI
Development of a new technology of welding of high speed movement rails
TL;DR: In this article, a method of contact joint welding, protected by a RF patent, was developed, enabling to obtain a welding connection of parts made of rail steel with uniform hardness distribution and small zone of thermal influence, meeting the elaborated by JSC EVRAZ ZSMK technical specifications for perspective welded joint connection of R65 rails of DT350 category.
References
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Journal ArticleDOI
Rolling contact fatigue of three pearlitic rail steels
TL;DR: In this paper, the effects of varying contact pressure and creepage on the early stages of rolling contact fatigue in three pearlitic rail steels have been investigated in the laboratory under water lubricated conditions.
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Microstructure-property relationships in pearlitic eutectoid and hypereutectoid carbon steels
TL;DR: In this paper, the effects of micro-structural features on the yield strength and toughness of fully pearlitic steels, and the importance of hypereutectoid alloy compositions for increasing the strength of full pearlite steels are discussed.
Journal ArticleDOI
Characterization and morphological analysis of pearlite in a eutectoid steel
Francisca García Caballero,Francisca García Caballero,C. García de Andrés,Carlos Capdevila,Carlos Capdevila +4 more
TL;DR: In this paper, three different morphologies of pearlite have been formed isothermally at three temperatures in a eutectoid steel and the interlamellar spacings of these morphologies have been measured by scanning and transmission electron microscopy.
Journal ArticleDOI
Effects of microstructural parameters on the mechanical properties of eutectoid rail steels
Maria das Graças Mendes da Fonseca Gomes,Luiz Henrique de Almeida,Luiz Claudio F.C. Gomes,Iain Le May +3 more
TL;DR: In this paper, the effects of microstructural variations, as produced by differences in heat treatment and the addition of Nb, on the mechanical properties of eutectoid pearlitic carbon steels were made.
Journal ArticleDOI
Modeling surface rolling contact fatigue crack initiation taking severe plastic shear deformation into account
TL;DR: In this article, a new model for the prediction of rolling contact fatigue crack initiation at the surface of railway rails and wheels has been developed, which takes contact-related plasticity effects into account.