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Simulation-based assessment of railhead repair welding process parameters

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Titel: Simulation-based assessment of railhead repair welding process parameters
Autoren: Andersson, Björn, 1989, Steyn, Erika, 1990, Ekh, Magnus, 1969, Josefson, Lennart, 1954
Quelle: Welding in the World, Le Soudage Dans Le Monde. 69(1):177-197
Schlagwörter: Railhead defect repair, Phase transformation, Numerical simulations, Residual stress, Welding simulation, Over-rolling simulation
Beschreibung: 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.
Dateibeschreibung: electronic
Zugangs-URL: https://research.chalmers.se/publication/543102
https://research.chalmers.se/publication/543102/file/543102_Fulltext.pdf
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  Group: Ti
  Data: Simulation-based assessment of railhead repair welding process parameters
– Name: Author
  Label: Authors
  Group: Au
  Data: <searchLink fieldCode="AR" term="%22Andersson%2C+Björn%22">Andersson, Björn</searchLink>, 1989<br /><searchLink fieldCode="AR" term="%22Steyn%2C+Erika%22">Steyn, Erika</searchLink>, 1990<br /><searchLink fieldCode="AR" term="%22Ekh%2C+Magnus%22">Ekh, Magnus</searchLink>, 1969<br /><searchLink fieldCode="AR" term="%22Josefson%2C+Lennart%22">Josefson, Lennart</searchLink>, 1954
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  Label: Source
  Group: Src
  Data: <i>Welding in the World, Le Soudage Dans Le Monde</i>. 69(1):177-197
– Name: Subject
  Label: Subject Terms
  Group: Su
  Data: <searchLink fieldCode="DE" term="%22Railhead+defect+repair%22">Railhead defect repair</searchLink><br /><searchLink fieldCode="DE" term="%22Phase+transformation%22">Phase transformation</searchLink><br /><searchLink fieldCode="DE" term="%22Numerical+simulations%22">Numerical simulations</searchLink><br /><searchLink fieldCode="DE" term="%22Residual+stress%22">Residual stress</searchLink><br /><searchLink fieldCode="DE" term="%22Welding+simulation%22">Welding simulation</searchLink><br /><searchLink fieldCode="DE" term="%22Over-rolling+simulation%22">Over-rolling simulation</searchLink>
– Name: Abstract
  Label: Description
  Group: Ab
  Data: 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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      – Type: doi
        Value: 10.1007/s40194-024-01837-y
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      – Text: English
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      Pagination:
        PageCount: 21
        StartPage: 177
    Subjects:
      – SubjectFull: Railhead defect repair
        Type: general
      – SubjectFull: Phase transformation
        Type: general
      – SubjectFull: Numerical simulations
        Type: general
      – SubjectFull: Residual stress
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      – SubjectFull: Welding simulation
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      – SubjectFull: Over-rolling simulation
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      – TitleFull: Simulation-based assessment of railhead repair welding process parameters
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            NameFull: Andersson, Björn
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              M: 01
              Type: published
              Y: 2025
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