Railway wheel steel behaviour upon thermo-mechanical loadings

Abstract: Optimised railway maintenance techniques such as rail grinding and milling, or rail repair welding, are vital to more sustainable rail networks. As demands on the railway increases, the need to better understand the material behaviour during local heating events occurring during maintenance is amplified. Other heating events can occur during operation, for instance during severe block braking. This thesis provides insight into thermal damage resulting from these local heating events on railway wheels, which can lead to altered mechanical properties and changed residual stresses. The material behaviour of the ferritic-pearlitic railway wheel steel ER7T was studied during severe block braking (i.e., slow heating and cooling) at peak temperatures varying between 300 °C and 650 °C. The thermal dilatation was restricted to different degrees between free expansion and full restriction. This study thus explores the combined effect of thermal and mechanical cycling on the mechanical properties and material structure. The experimental results from the thermo-mechanical testing were also used to validate a new constitutive material model for use in FE models to predict severe block braking.  The second part of the thesis explored the effect of rapid heating and cooling events on the microstructure and residual stress state of railway wheel steel. Localised heating using laser scanning with additive manufacturing equipment was compared to the heating done by scanning with laser welding equipment. This study thus investigated the similarities of different rapid heating (high temperature) processes and the effect of process parameter variations. The results can be used to provide insight into the material behaviour of railway steels during local heating events. Furthermore, it can support the development of more accurate simulations for both operation and maintenance processes.