Simulation-based failure analysis of faulty and regulatory railhead repair welding procedures
Uloženo v:
| Název: | Simulation-based failure analysis of faulty and regulatory railhead repair welding procedures |
|---|---|
| Autoři: | Andersson, Björn, 1989, Josefson, Lennart, 1954 |
| Zdroj: | Engineering Failure Analysis. 182 |
| Témata: | Phase transformation, Residual stress, Rail defect repair, Welding simulation, Numerical simulations, Over-rolling simulation |
| Popis: | Advancements in railway technology have significantly reduced wheel and axle failures, yet rail failures, particularly in welded regions, remain a major concern. Up to 60% of recorded rail failures occur in these areas, with accident reports frequently attributing incidents to improperly executed repair welds. Using thermo-metallurgical-mechanical finite element simulations, this study investigates the mechanical performance of regulatory and faulty in-situ railhead repair welds, where only part of the railhead is removed. The multi-pass welding simulations employ a multi-phase homogenization-based material model, incorporating non-linear isotropic and kinematic hardening, phase transformation kinetics, and virgin material state recovery. Mechanical performance of the railhead repairs is evaluated through wheel-rail contact over-rolling simulations and fatigue analysis using novel multi-phase Dang Van criterion. The comparison, based on quantitative data, reveals an increased risk of fatigue crack initiation when deviations from the regulatory procedure occur. The regulatory repair produces a ferritic-pearlitic microstructure and a more favorable residual stress state, characterized by compressive stresses in the weld region and tensile stresses deeper below the rail surface where the microstructure is more favorable. In contrast, the faulty repair exhibits rapid cooling rates, leading to brittle martensitic phases and high tensile residual stresses near the rail surface, significantly increasing fatigue crack initiation risk. Operational over-rolling simulations further demonstrate that tensile stresses in the faulty repair persist near the surface, failing to redistribute as effectively as in the regulatory repair. These findings underscore the importance of strict adherence to repair welding standards to prevent premature rail failures and costly maintenance interventions. |
| Popis souboru: | electronic |
| Přístupová URL adresa: | https://research.chalmers.se/publication/548694 https://research.chalmers.se/publication/548694/file/548694_Fulltext.pdf |
| Databáze: | SwePub |
Full Text Finder 
Nájsť tento článok vo Web of Science | FullText | Text: Availability: 0 CustomLinks: – Url: https://research.chalmers.se/publication/548694# Name: EDS - SwePub (s4221598) Category: fullText Text: View record in SwePub – Url: https://resolver.ebscohost.com/openurl?sid=EBSCO:edsswe&genre=article&issn=13506307&ISBN=&volume=182&issue=&date=20250101&spage=&pages=&title=Engineering Failure Analysis&atitle=Simulation-based%20failure%20analysis%20of%20faulty%20and%20regulatory%20railhead%20repair%20welding%20procedures&aulast=Andersson%2C%20Bj%C3%B6rn&id=DOI:10.1016/j.engfailanal.2025.110185 Name: Full Text Finder Category: fullText Text: Full Text Finder Icon: https://imageserver.ebscohost.com/branding/images/FTF.gif MouseOverText: Full Text Finder – Url: https://www.webofscience.com/api/gateway?GWVersion=2&SrcApp=EBSCO&SrcAuth=EBSCO&DestApp=WOS&ServiceName=TransferToWoS&DestLinkType=GeneralSearchSummary&Func=Links&author=Andersson%20B Name: ISI Category: fullText Text: Nájsť tento článok vo Web of Science Icon: https://imagesrvr.epnet.com/ls/20docs.gif MouseOverText: Nájsť tento článok vo Web of Science |
|---|---|
| Header | DbId: edsswe DbLabel: SwePub An: edsswe.oai.research.chalmers.se.f17fff80.0971.40c1.be09.d3c49cf06853 RelevancyScore: 1065 AccessLevel: 6 PubType: Academic Journal PubTypeId: academicJournal PreciseRelevancyScore: 1064.736328125 |
| IllustrationInfo | |
| Items | – Name: Title Label: Title Group: Ti Data: Simulation-based failure analysis of faulty and regulatory railhead repair welding procedures – Name: Author Label: Authors Group: Au Data: <searchLink fieldCode="AR" term="%22Andersson%2C+Björn%22">Andersson, Björn</searchLink>, 1989<br /><searchLink fieldCode="AR" term="%22Josefson%2C+Lennart%22">Josefson, Lennart</searchLink>, 1954 – Name: TitleSource Label: Source Group: Src Data: <i>Engineering Failure Analysis</i>. 182 – Name: Subject Label: Subject Terms Group: Su Data: <searchLink fieldCode="DE" term="%22Phase+transformation%22">Phase transformation</searchLink><br /><searchLink fieldCode="DE" term="%22Residual+stress%22">Residual stress</searchLink><br /><searchLink fieldCode="DE" term="%22Rail+defect+repair%22">Rail defect repair</searchLink><br /><searchLink fieldCode="DE" term="%22Welding+simulation%22">Welding simulation</searchLink><br /><searchLink fieldCode="DE" term="%22Numerical+simulations%22">Numerical simulations</searchLink><br /><searchLink fieldCode="DE" term="%22Over-rolling+simulation%22">Over-rolling simulation</searchLink> – Name: Abstract Label: Description Group: Ab Data: Advancements in railway technology have significantly reduced wheel and axle failures, yet rail failures, particularly in welded regions, remain a major concern. Up to 60% of recorded rail failures occur in these areas, with accident reports frequently attributing incidents to improperly executed repair welds. Using thermo-metallurgical-mechanical finite element simulations, this study investigates the mechanical performance of regulatory and faulty in-situ railhead repair welds, where only part of the railhead is removed. The multi-pass welding simulations employ a multi-phase homogenization-based material model, incorporating non-linear isotropic and kinematic hardening, phase transformation kinetics, and virgin material state recovery. Mechanical performance of the railhead repairs is evaluated through wheel-rail contact over-rolling simulations and fatigue analysis using novel multi-phase Dang Van criterion. The comparison, based on quantitative data, reveals an increased risk of fatigue crack initiation when deviations from the regulatory procedure occur. The regulatory repair produces a ferritic-pearlitic microstructure and a more favorable residual stress state, characterized by compressive stresses in the weld region and tensile stresses deeper below the rail surface where the microstructure is more favorable. In contrast, the faulty repair exhibits rapid cooling rates, leading to brittle martensitic phases and high tensile residual stresses near the rail surface, significantly increasing fatigue crack initiation risk. Operational over-rolling simulations further demonstrate that tensile stresses in the faulty repair persist near the surface, failing to redistribute as effectively as in the regulatory repair. These findings underscore the importance of strict adherence to repair welding standards to prevent premature rail failures and costly maintenance interventions. – Name: Format Label: File Description Group: SrcInfo Data: electronic – Name: URL Label: Access URL Group: URL Data: <link linkTarget="URL" linkTerm="https://research.chalmers.se/publication/548694" linkWindow="_blank">https://research.chalmers.se/publication/548694</link><br /><link linkTarget="URL" linkTerm="https://research.chalmers.se/publication/548694/file/548694_Fulltext.pdf" linkWindow="_blank">https://research.chalmers.se/publication/548694/file/548694_Fulltext.pdf</link> |
| PLink | https://erproxy.cvtisr.sk/sfx/access?url=https://search.ebscohost.com/login.aspx?direct=true&site=eds-live&db=edsswe&AN=edsswe.oai.research.chalmers.se.f17fff80.0971.40c1.be09.d3c49cf06853 |
| RecordInfo | BibRecord: BibEntity: Identifiers: – Type: doi Value: 10.1016/j.engfailanal.2025.110185 Languages: – Text: English Subjects: – SubjectFull: Phase transformation Type: general – SubjectFull: Residual stress Type: general – SubjectFull: Rail defect repair Type: general – SubjectFull: Welding simulation Type: general – SubjectFull: Numerical simulations Type: general – SubjectFull: Over-rolling simulation Type: general Titles: – TitleFull: Simulation-based failure analysis of faulty and regulatory railhead repair welding procedures Type: main BibRelationships: HasContributorRelationships: – PersonEntity: Name: NameFull: Andersson, Björn – PersonEntity: Name: NameFull: Josefson, Lennart IsPartOfRelationships: – BibEntity: Dates: – D: 01 M: 01 Type: published Y: 2025 Identifiers: – Type: issn-print Value: 13506307 – Type: issn-locals Value: SWEPUB_FREE – Type: issn-locals Value: CTH_SWEPUB Numbering: – Type: volume Value: 182 Titles: – TitleFull: Engineering Failure Analysis Type: main |
| ResultId | 1 |