钢轨加工开裂原因分析

60kg/m型钢轨在改制异型轨的过程中其轨腰处出现纵向裂纹.采用JSM-5600LV扫描电镜、INCA能谱仪和光学显微镜等对开裂钢轨进行了分析.结果表明,由于加热不均,造成钢轨局部区域温度过高,在钢轨腰部出现过烧、氧化和晶界熔化,并在该区域的组织中出现魏氏体组织,导致在轧制过程中轨腰处出现纵向裂纹.     

贝氏体钢轨矫直断裂失效分析

采用宏观及微观断口分析、化学成分分析、硬度测试及金相检验等方法,对某贝氏体钢轨在矫直时发生断裂的原因进行了分析。结果表明:造成该贝氏体钢轨矫直断裂的主要原因是其显微组织中存在大量的针状马氏体晶间脆性组织,当钢轨受到矫直外力作用时,便从马氏体脆性相应力集中部位的夹杂物处开始起裂,裂纹沿脆性晶界迅速扩展最终导致断裂。     

75kg/m热处理钢轨断裂原因分析

某线路发生一起PD3 75Kg／m热处理钢轨横向断裂。采用光学和电子显微镜及能谱仪对断裂钢轨进行了宏、微观分析。结果表明,钢轨轨头踏面表层为厚约2～3mm、硬度为498HV的马氏体组织;次表层为厚约3mm、硬度为312HV的回火索氏体组织;里层是硬度为380HV的细珠光体组织(即钢轨的正常组织)。钢轨轨头踏面表层的马氏体是用KD286焊条对钢轨进行堆焊所形成,次表层的回火索氏体是堆焊时热影响造成。在车轮力的作用下,表层与次表层的交界处产生裂纹,随后裂纹不断扩展而导致钢轨断裂。     

U75V焊接钢轨线路铺设时的断裂原因分析

某铁道线路进行大修换轨铺设新轨时,一支采用闪光焊接工艺焊接的长500m的钢轨在中部位置的焊缝附近发生横向断裂,采用宏观检验、化学成分分析,断口分析及微观组织分析等方法对钢轨断裂的原因进行了分析。结果表明：钢轨的冶金质量良好,钢轨发生断裂主要是因为其轨头踏面表层形成的马氏体组织在铺轨时的弯曲拉应力作用下,产生裂纹并快速扩展,导致钢轨发生脆性断裂;钢轨焊接时出现了高接头,为保证焊接钢轨的平直度对其进行了打磨,但打磨工艺控制不良,从而导致钢轨轨头踏面局部产生高温,发生马氏体组织转变。     

某大桥钢轨断裂原因分析

某大桥钢轨发生横向断裂。经对钢轨断口的宏观分析、显微组织观察、电子显微镜的微观分析和能谱的微区成分测定。结果表明，在轨底面中部的横截面上有一半径约7mm半圆形的疲劳裂纹区，疲劳裂纹起源于轨底面的小凹坑处，产生原因是钢轨在潮湿环境中受腐蚀而形成。在车轮应力的重复作用下，疲劳裂纹扩展而导致钢轨断裂。     

U71Mn钢轨矫直断裂原因分析

针对U71Mn钢轨在矫直过程中出现断裂的现象,对钢轨断口部位的宏观形貌、显微组织、化学成分、力学性能和显微硬度等进行了观察和分析。结果表明:钢轨角部的外来夹杂物、网状渗碳体、针状渗碳体魏氏组织,以及钢轨角部由于擦伤出现的隐针马氏体和微裂纹,是造成钢轨矫直断裂的主要原因。最后探讨了解决措施。     

线路钢轨断裂分析

湘桂线发生一起PD3钢轨横向断裂。经对钢轨断口的宏观分析，以及用光学显微镜进行金相分析、电子显微镜的断口微观分析和能谱微区成分测定。结果表明，钢轨轨底下表面中部有一沿钢轨纵向长17mm、宽12mm、深约3mm的外伤凹坑缺陷，凹坑底部有一层厚度不均的、最厚约1．0mm的铜铁合金熔融层，再往里是厚度达1．0mm的马氏体组织层。凹坑缺陷及其凹坑底部的铜铁合金熔融层的产生，是由于钢轨进行接触焊时在电极板与钢轨底面之间接触不良所产生的电打火造成。裂纹就起源于铜铁合金熔融层，然后裂纹快速向轨腰和轨头方向扩展造成钢轨横向断梨．     

挤压道岔轨断裂原因分析

针对在挤压加工道岔轨时出现挤压爆裂和矫直断裂的情况,对断裂钢轨进行了化学成分分析、低倍及金相检验,并采用X-650扫描电镜及EDAX电子探针对断口进行了分析。分析结果表明,断裂钢轨化学成分满足标准要求,低倍组织和显微组织正常,断口呈脆性断裂解理特征,断口处氧化严重。由此认为,造成挤压时道岔轨爆裂和矫直断裂的原因是挤压前加热工艺不当所致。     

钢轨腰部裂纹原因分析

115RE钢轨在线路上仅使用了6个月就在钢轨轨腰处出现长220mm的纵向裂纹。采用宏观分析以及扫描电镜和光学显微镜进行微观分析和相关的力学性能检验等方法对裂纹出现原因进行了分析。结果表明：钢轨的材质与力学性能无问题,钢轨上的裂纹是由于在轨腰处标识炉号“2”字痕的底部形成较大的应力集中造成的。     

某高速铁路钢轨伤损原因分析

某城际高速铁路开通运营仅约半年,使用的U71MnG60kg／m热轧钢轨在某车站列车进站端的半径为600m的一曲线路段上随机出现多处严重轨头踏面掉块伤损。经对钢轨伤损状态的分析以及化学成分分析、拉伸性能测试和金相检验对掉块伤损的原因进行了分析。结果表明：钢轨轨头踏面的掉块伤损是由其表层的马氏体组织造成,而马氏体组织的产生则是因列车车轮对钢轨的严重摩擦所引起的。     

轴重对轮轨材料滚动磨损与损伤行为影响

利用WR-1轮轨滚动磨损实验机研究不同轴重下轮轨材料滚动磨损与损伤性能。结果表明:轮轨试样磨损率均随轴重增加呈现线性增加趋势,且钢轨试样磨损率大于车轮试样磨损率。轮轨试样硬化率均随时间呈现先增加后趋于稳定的变化趋势,轮轨试样塑变层厚度和硬化率均随轴重增加而增大,且车轮试样硬化率大于钢轨。车轮试样和钢轨试样表面损伤形貌不同,车轮试样表面表现为垂直于滚动方向的疲劳裂纹,钢轨试样表面表现为裂纹和块状剥落,轮轨试样表面损伤均随轴重增加而更加严重;车轮试样表面裂纹疲劳断裂和钢轨试样表面块状剥落形成磨屑,成分主要为Fe2O3和马氏体,随轴重增加,磨屑尺寸呈现增大趋势,但成分与含量无明显变化。     

THE GROWTH OF SMALL FATIGUE CRACKS IN A LOW CARBON STEEL; THE EFFECT OF MICROSTRUCTURE AND LIMITATIONS OF LINEAR ELASTIC FRACTURE MECHANICS

The growth characteristics of small fatigue cracks were studied under rotary bending in a low carbon steel prepared with two ferrite grain sizes of 24 and 84 μm, and were compared with the growth characteristics of large through cracks in fracture mechanics type specimens. The effect of microstructure on crack growth rates and the interaction in growth behaviour between two neighboring small cracks were examined experimentally, and also the critical crack lengths above which linear elastic fracture mechanics (LEFM) is applicable were evaluated for small crack growth and for fatigue crack thresholds. It is found that small cracks grow much faster than large ones and also show growth rate perturbations due to grain boundaries. It is indicated that the critical crack lengths for fatigue crack thresholds are significantly shorter than those for small crack growth.     

钢轨高速打磨试验台的切向磨削力修正方法研究

进行钢轨高速打磨试验是研究钢轨高速打磨机理的重要手段。而钢轨高速打磨试验台与打磨列车现场打磨作业的主要差别是试验台的钢轨沿纵向方向具有有限曲率半径,而现场钢轨沿纵向的曲率半径接近无限大。这一现象使得试验台上测得的砂轮与钢轨间的切向磨削力与现场打磨过程中的实际磨削力有差别。该文根据砂轮磨削原理建立了一种可考虑钢轨沿纵向曲率半径的砂轮切向磨削力计算方法。通过与试验数据的对比,表明该方法计算得到的磨削切向力与试验数据有较好的吻合。该文利用所建立的方法给出了将试验台切向磨削力修正到现场切向磨削力的修正系数k,并分析了打磨过程中的法向加载力以及圆盘曲率半径对k值的影响。     

THE GROWTH OF SMALL CORROSION FATIGUE CRACKS IN ALLOY 2024

Abstract— The corrosion fatigue crack growth characteristics of small surface and corner cracks in aluminium alloy 2024 is established. The damaging effect of salt water on the early stages of small crack growth is characterized by: (1) crack initiation at constituent particle pits, (2) intergranular microcracking for a≤100μm, and (3) transgranular small crack growth for a≥100μm. In aqueous 1% NaCl and at a constant anodic potential of −700 mV_SCE, small cracks exhibit a factor of three increase in fatigue crack growth rates compared to laboratory air. Small cracks exhibit accelerated corrosion fatigue crack growth rates at low levels of Δ K (< 1 MPa√m) below the long crack Δ K _th value. When exposed to Paris regime levels of crack tip stress intensity, small corrosion fatigue cracks exhibit growth rates similar to that observed for long cracks. Similar small and long crack growth behavior at various levels of R suggest that crack closure effects influence the corrosion fatigue crack growth rates of small cracks for a≥100 μm. Contrary to the corrosion fatigue characteristics of small cracks in high strength steels, no pronounced chemical crack length effect is observed for alloy 2024 exposed to salt water.     

U75V重轨钢弯曲疲劳裂纹扩展行为EI北大核心

为明确珠光体钢轨的疲劳裂纹扩展行为,测定U75V重轨钢轧态和热处理态两种条件下的三点弯曲疲劳裂纹扩展速率,采用光学显微镜、扫描电镜、EBSD对钢轨的微观组织、片层、断口形貌及裂纹扩展轨迹进行观察。结果表明:轧态和热处理态钢轨的疲劳辉纹平均间距分别为253,215 nm,轧态钢轨的疲劳断口呈现解理台阶与河流花样形貌,且河流花样趋于合并,而热处理态钢轨的疲劳断口呈现大量的解理台阶及较多的微裂纹和撕裂棱,河流花样以支流为主;热处理态钢轨的疲劳裂纹扩展速率远低于轧态,到达裂纹失稳阶段也较滞后;轧态和热处理态钢轨的疲劳裂纹扩展都是以穿晶断裂为主的穿晶断裂和沿晶断裂混合扩展方式进行,轧态和热处理态钢轨的珠光体片层间距分别为272,148 nm,其中热处理态钢轨的珠光体片层细密且方向多样,存在显著的珠光体团簇,裂纹扩展轨迹中出现较多的分支裂纹和裂纹桥接现象,对扩展起到阻碍作用,是热处理态钢轨抗疲劳裂纹扩展能力优于轧态的重要原因。     

Interaction between cracks and microstructure in three dimensions for rolling contact fatigue in railway rails

The rail–wheel contact generates plastic deformation and cracks in the top layer of a rail. Rolling contact fatigue (RCF) cracks in rail samples from track and from a full scale test rig were examined. Due to the shear forces arising in the wheel rail contact, the microstructure close to the surface becomes aligned in the shear direction. Thereby, the pearlite becomes anisotropic, and resistance to cracks is lower in certain directions. RCF cracks follow the weakest direction of the microstructure, which in pearlitic railway rails is the aligned pearlite structure or singular weaknesses such as pro‐eutectoid ferrites or slags. The deformation of the microstructure is different depending on loading situation and original microstructure (rail grade). Once the plastic deformation is present, the cracks follow the path of the weakest crack resistance. Cracks close to each other can interact or shield each other; it is unclear, however, to what extent. In this paper, a new method is described that allows the presentation of RCF cracks in three dimensions.     

Failure Analysis of Connecting Plate Between Indication Rod and Switch Rail in a Turnout System

Failure analysis was conducted on a connecting plate of indication rod and switch rail in the switch system of rail. The cracking of connecting plate was detected during the periodic routing inspection after one year of service. Detailed fracture morphology examinations on the fractured connecting plate were conducted combining with the actual working condition analysis. Typical morphology of brittle fracture like cleavage and quasi-cleavage morphology was observed in the fractured surface. The results indicated that the bending stress, resulted from the lateral force during the train passing the switch rail, is the key reason leading to the cracks initiation and propagation of the connecting plate.     

Fracture Mechanics Determinations of Allowable Crack Size in Railroad Rails

An evaluation of fatigue behavior of rail steel is necessary to ensure rail transportation safety. Fatigue in these steels was studied with fracture mechanics techniques. The goal of these studies was to find out the appropriate way of preventing a crack from reaching its critical size in the rail. Tests were conducted on rail head, and transverse head cracks were analyzed through damage tolerance concepts. Critical crack size and crack growth characteristics for the rail were determined, and the residual service life was calculated for defective segments of the rails. Additionally, the allowable crack size for different nondestructive testing intervals was determined.