Abstract
Abstract A failure analysis was performed to determine the causes of a crack on a high-speed train bolster, which was observed after an accelerated corrosion-fatigue test. The nominal stress method was used to evaluate the crack initiation life. The crack is not the result of a deficient design or geometry defects, for the theoretical lifetime of the bolster is more than 1 × 107 load cycles. The fracture surface was observed by the scanning electron microscope, and the crack source was determined to be the micro-holes caused by welding defects. The fracture mechanics method was employed to examine the crack propagation life, and it only occupied about 0.55% of the whole test time. Thus, after operating for 10 years, this bolster could provide safe service for another 20 years. Meanwhile, advanced welding technology or more welding inspection is suggested to prevent and detect the similar cracks.
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