Finite Element Modeling and Validation of Submerged Arc Welding for Repairing 136RE Heavy Rails

Abstract

The constant wear and tear experienced by rail surfaces due to continuous loading necessitates repairs for maintaining optimal performance within railway networks. Traditional repair methods are not only time-consuming but also costly, motivating the exploration of innovative alternatives. This study focuses on the development of a finite element (FE) model to simulate the submerged arc welding (SAW) process, which serves as an additive manufacturing technique for restoring 136-lb/yd (136RE) rails, commonly utilized in heavy freight and passenger rail systems across the United States. To validate the developed FE model, a series of experimental laboratory investigations was conducted. A worn section of the 136RE rail was carefully chosen for this study. After the rail’s surface underwent milling and flattening, the submerged arc welding process was employed to rebuild the rail, utilizing a 1/8-inch Lincore 40-S depositing wire. The reconstructed rail sample was then subjected to experimental tests, including tensile testing, which provided the essential mechanical properties required to validate the simulation process. The FE model encompasses all conceivable interactions, including thermal, mechanical, and phase transformations. This simulation employs an element-birth-and-kill method, examining the thermal distribution within the sample across different sections. By considering the thermal history and phase change relations, the model predicts the mechanical properties of the repaired rail. The validated model showcases substantial potential in exploring and predicting mechanical properties and thermal distribution during the SAW process for heavy rail repair.