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Innovative Welding Processes for New Rail Infrastructures

Deliverables

Document justifying the selection of rail steel grades for the assessment of the weld quality achieved with the proposed welding technologies. Collated material property data will be included

Document justifying the selection of rail steel grades for the assessment of the weld quality achieved with the proposed welding technologies. Collated material property data will be included.

Report containing metallographic examinations of the OFW welds, comparison with FBW, for grades R260 and B360

Report containing metallographic examinations of the OFW welds, comparison with FBW, for grades R260 and B360

Report containing results of destructive and non-destructive testing for forged AT welding, including approval tests according to EN14730, for grades R260 and R350HT

Report containing results of destructive and non-destructive testing for forged AT welding, including approval tests according to EN14730, for grades R260 and R350HT

Report with simulation results

Report with : - Simulation results (deformations during process, final deformation, temperature evolution,…). - Comparison simulation - experiment : model accuracy assessment.

Report with The measured joint properties and the materials & dimensions of the intermediate component

Report with : - A description of D5.1 and D5.2. - The measured joint properties. - Guidelines for the determination of the shape and dimensions of the intermediate component, as a function of the dimensions and material properties of the rails to be welded. - Suitable materials for the intermediate component for welding conventional and bainitic rail steels.

Report containing metallographic examinations of the forged AT welds, for grades R260 and R350HT

Report containing metallographic examinations of the forged AT welds, for grades R260 and R350HT

Report feasibility and performance of forged AT welds in rail infrastructure, for grades R260 and R350HT,

Report feasibility and performance of forged AT welds in rail infrastructure, for grades R260 and R350HT,

Draft quality standard

Draft quality standard.

Final event

Final event.

Project website

Project website.

Newsletter 2

Newsletter 2.

Final dissemination activities foreseen in the dissemination plan

Final dissemination activities foreseen in the dissemination plan

Newsletter 4

Newsletter 4

Newsletter 3

Newsletter 3.

Mid-term dissemination activities foreseen in the dissemination plan

Mid-term dissemination activities foreseen in the dissemination plan.

Newsletter 1

Newsletter 1.

Newsletter 5

Newsletter 5.

Draft requirements for operator training and on-site operational procedures

Draft requirements for operator training and on-site operational procedures.

Development of a prototype weld finishing tool (for aluminothermic welding)

Development of a prototype weld finishing tool (for aluminothermic welding).

Prototype device for joint alignment, additional forging and enhanced cooling, with performance specifications and concept drawings (for aluminothermic welding)

Prototype device for joint alignment, additional forging and enhanced cooling, with performance specifications and concept drawings (for aluminothermic welding).

Design and construction of a clamping mechanism for the intermediate component, providing sufficient grip and with the smallest possible over-thickness (for orbital friction welding)

Design and construction of a clamping mechanism for the intermediate component, providing sufficient grip and with the smallest possible over-thickness (for orbital friction welding).

Instrumentation to record process parameters

Instrumentation to record process parameters.

Test equipment capable of creating orbital friction welds of rails with a range of process parameters

Test equipment capable of creating orbital friction welds of rails with a range of process parameters.

Realisation of the joined rails (one conventional and one bainitic rail steel)

Realisation of the joined rails (one conventional and one bainitic rail steel)

Orbital friction welds of conventional and bainitic rail steels using an intermediate component made of a suitable material and with optimised geometry and dimensions

Orbital friction welds of conventional and bainitic rail steels using an intermediate component made of a suitable material and with optimised geometry and dimensions.

Online weld quality control and data analysis system (for aluminothermic welding)

Online weld quality control and data analysis system (for aluminothermic welding).

Clamping device for the rails and intermediate welding part (for orbital friction welding)

Clamping device for the rails and intermediate welding part (for orbital friction welding).

In-process control package linked to a web-based data management system (for aluminothermic welding)

In-process control package linked to a web-based data management system (for aluminothermic welding).

Calculated microstructure, residual deformations and stress fields for the aluminothermic welding process serving the weld quality optimisation

Calculated microstructure, residual deformations and stress fields for the aluminothermic welding process serving the weld quality optimisation

Calculated microstructure in the weld zone, residual deformations and stress fields for the orbital friction welding process serving the weld quality optimisation

Calculated microstructure in the weld zone, residual deformations and stress fields for the orbital friction welding process serving the weld quality optimisation

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Publications

Longitudinal rail weld geometry control and assessment criteria

Author(s): Ilaria Grossoni, Philip Shackleton, Yann Bezin, Jay Jaiswal
Published in: Engineering Failure Analysis, Issue 80, 2017, Page(s) 352-367, ISSN 1350-6307
DOI: 10.1016/j.engfailanal.2017.07.008

Differential wear modelling – Effect of weld-induced material inhomogeneity on rail surface quality

Author(s): Matin Sh. Sichani, Yann Bezin
Published in: Wear, Issue 406-407, 2018, Page(s) 43-52, ISSN 0043-1648
DOI: 10.1016/j.wear.2018.03.019

Rail weld geometry: the influence on Vehicle/track dynamics and assessment Criteria

Author(s): I. Grossoni, P. Shackleton, Y. Bezin
Published in: Dynamics of Vehicles on Roads and Tracks: Proceedings of the 25th International Symposium on Dynamics of Vehicles on Roads and Tracks, Issue 14-18 August 2017, 2018