Steel Railway Research Articles

Study on the Degradation Model of Service Performance in Railway Steel–Concrete Composite Beams Considering the Cumulative Fatigue of Steel Beams and Studs Based on Vehicle–Bridge Coupling Theory

The steel–concrete composite beam, as a structural form that combines the advantages of steel and concrete, has been applied in railway engineering. However, with the increase in railway operation time, the degradation pattern of the service performance of steel–concrete composite bridges remains unclear. This paper proposes a method for calculating the long-term service performance of railway steel–concrete composite beams, considering the cumulative fatigue damage of steel beams and studs, based on the vehicle–bridge coupling theory and Miner’s linear cumulative damage criterion. The proposed method is validated using measured data from an in-service steel–concrete composite railway bridge with spans of 40 + 50 + 40 m. The calculated mid-span vertical displacement and the first two natural frequencies of the composite beam deviated from the measured results by only 2.1%, 7.7%, and 9.5%, respectively. The research results can provide a basis for extending the service life of composite beams and preventing the occurrence of safety accidents.

Synchrotron X-ray radiation study of retained austenite stability and the effect on fatigue behavior of bainitic railway steels

The effect of retained austenite stability on the fatigue performance was studied in bainitic rail steel subjected to different heat treatments, including normalizing at 900 °C and normalizing at 900 °C combined with tempering at 320 °C. The normalized steel had yield strength of 851 MPa, tensile strength of 1131 MPa, uniform elongation 7.0 %, and total elongation 17.5 %. Tempering the steel at 320 °C resulted in similar strength and plasticity compared to the normalized condition. However, the fatigue performance of steel was improved significantly after tempering. The ultimate fatigue stress (endurance limit) after 1 × 107 cycles was 671 MPa, which was 38 MPa greater than the normalized steel. Microstructural analysis revealed similarities between normalized and tempered matrices at crystallographic interfaces and grain boundaries. Synchrotron X-ray radiation indicated that the initial retained austenite content was ∼15.5 % in both normalized and tempered conditions. However, at tensile stress of 800 MPa, the amount of retained austenite transformed in the normalized steel was ∼4 %, which was twice that of the tempered steel. The enhancement of retained austenite stability was an important aspect in improving the fatigue performance. The analysis of interphase spacing showed that the strain in the normalized matrix synchronized with the retained austenite, and the stress was concentrated in the retained austenite, which promoted transformation of retained austenite. The matrix of tempered steel was strained first, which prevented stress concentration in the retained austenite and rendered the retained austenite stable.

Deflections and frequencies of long-span steel railroad truss bridges under passenger train excitation using laser Doppler vibrometer

ABSTRACT Given the critical challenge of aging infrastructure, it is imperative to adopt novel techniques that utilize modern technology to assess the structural integrity of existing bridges. This study presents a methodology to estimate the loading frequency of the train passing over the bridge and bridge dynamic responses, such as the acceleration and displacement response of long-span open-deck steel railroad truss-type bridge under the passenger train excitation using a Laser Doppler Vibrometer. The selected bridges for this study were the Cos Cob and Devon Railroad bridges in southern Connecticut, both in the Northeast Corridor. The structural response of the bridge floor system was collected during the field test using a single-point laser Doppler vibrometer and uniaxial accelerometers for reference under passenger trains, such as Metro-North M8, Amtrak Regional, and Amtrak Acela. The recorded data were analyzed using the moving load theory, interpreted, and discussed in the time and frequency domain. The study findings indicate that the bridge response and displacement align with the theoretical and vehicle axle loads. Also, it should provide valuable information about the behavior of the considered bridges under typical operating conditions.

Monitoring of a fatigue test on a full-size railway steel bridge with acoustic emission

Within the frame of the Rail4Future project (https://www.rail4future.com) co-funded by the Austrian Research Promotion Agency, a railway steel bridge was removed from the track and transported to a workshop in one piece. Artificial defects were introduced at different sections of the bridge structure as per advice of the scientific project partners in order to initiate fatigue cracks in the course of the subsequent fatigue test. One objective of the fatigue test was to identify suitable measurement and testing techniques for monitoring of fatigue crack growth. Among other techniques utilised by different project partners, acoustic emission monitoring was applied by TÜV AUSTRIA. This contribution describes the preparation as well as the performance of the acoustic emission monitoring and the results obtained. It is shown that this non-destructive testing technique is suitable for fatigue crack monitoring.

Supporting the infrastructure operators with customer specific AE-monitoring solutions

Cost-effective and efficient monitoring of infrastructure is crucial for planning maintenance and repairs while ensuring the safety of the structure. Acoustic emission is a method particularly suitable for long-term monitoring. However, the necessary extended monitoring period incurs high costs for the operator, primarily due to the exceptionally high costs of measuring equipment. The need for a tailored monitoring system for infrastructure applications is evident. TÜV AUSTRIA is developing a monitoring system called RISE, which represents a customized solution for steel bridge monitoring. The innovative online monitoring solution RISE assists experts with structural monitoring. Due to its compact design, low power consumption, and easy installation, the measuring system is specifically designed for continuous monitoring. Specifically, RISE is introduced for the hotspot monitoring of railway steel bridges. The passage of trains triggers a material response that can be recorded by the measuring system. This is used to perform crack monitoring on bridges and to have a tool for assessing crack activity and the degree of damage. This enables targeted planning of repairs and maintenance activities. Reducing the operating costs of the structure and ensures it save operation. The system is being developed to function robustly and provide a high level of automation. A demonstration of AE-monitoring of active cracks on a main bridge girder was done during a fatigue test in cooperation with the TU Graz. The girder was removed from a deconstructed bridge.

Development of a rating model for assessing the condition of steel railway bridges

Steel railway bridges play a crucial role in global transportation networks, yet their operational lifespan is often compromised by factors such as corrosion, aging, exposure conditions, and environmental challenges. Structural Health Monitoring (SHM) systems are widely employed to extend the longevity of these bridges. However, existing SHM models typically have limitations, as they tend to focus on a limited set of parameters, and their reliance on qualitative definitions introduces subjectivity into the evaluation process. To address these shortcomings, this research aims to develop an innovative priority weight-based condition rating model. Casual Factors (CF), laboratory and Non-Destructive Tests (NDT), Visual Inspection (VI), Environmental Conditions (EC), and Type of Element (TOE), were identified as main parameters to the condition assessment. Then, the research gathered opinions from 100 experts to establish the importance of these parameters. By averaging expert opinions and ensuring a high level of consistency (i.e. below 10%), the study aimed to minimize subjectivity. Numerical definitions were introduced to the model to enhance objectivity. The Fuzzy Analytical Hierarchy Process (FAHP) was employed to calculate appropriate weightings for the identified parameters, resulting in a comprehensive equation that encapsulates the main factors influencing the condition of steel railway bridges.To validate the developed rating model, a case study was conducted, analyzing seventeen railway bridges located in various regions of Sri Lanka. Notably, the model takes into account physical, geographical, and environmental conditions, making it applicable to diverse locations worldwide. This innovative approach contributes to the enhancement of steel railway bridge maintenance strategies, promoting their sustained and reliable operation on a global scale.

Prediction of fatigue life of a bolted joint in railway steel arch bridge using multiaxial fatigue criteria

Fatigue represents a critical condition for infrastructure subjected to repeated cyclic loads, such as steel railway bridges. The literature offers several methods to estimate fatigue life, consisting of three main phases: cycle counting, fatigue damage criterion, and damage accumulation criterion. Applying S-N curves might not be conservative in the case of railway bridges subjected to traffic because the stress-time history is complex and cannot be reduced to a sinusoidal history. Additionally, the presence of a multiaxial stress state must be considered. Therefore, this work compares eight multiaxial fatigue damage criteria for evaluating fatigue life in a scenario between high and low-cycle fatigue. Specifically, the authors considered four low-cycle fatigue criteria, namely Smith–Watson–Topper (SWT), Kandil, Brown and Miller (KBM), Glinka, Fatemi and Socie (FS), and four high-cycle fatigue criteria, Crossland, Basquin and the methods recommended by Eurocode 3 and British Standard. The rainflow counting method in ASTM E1049-85 (2011) and Miner’s rule for damage accumulation were used. The Polcevera railway steel bridge was selected as a case study. A 3D numerical model was developed for this purpose using Midas Civil software, taking into account the material non-linearity of the bridge’s elements. Once the area with the highest stress concentration was identified, a detailed analysis was conducted to estimate the stress and strain time histories induced by train traffic. A sensitivity analysis was conducted after critically comparing the eight methods for predicting fatigue life to assess the impact of traffic parameters, train velocity, axle load, and convoy length on fatigue life. It has been found that the criteria considering axial stress tend to overestimate the number of fatigue cycles to failure compared to the criteria, including the effect of shear stress components.

“Modernization of Railway Track Pardubice –Stéblová: New steel bridge over Labe river”

AbstractThe construction of a new double‐track steel railway arch bridge over the Elbe river, which replaced the original single‐track bridge from 1966, has significantly increased the capacity, speed, and smoothness of railway traffic in Pardubice. This 140‐meter‐long, three‐span bridge was realized as part of the modernization and double‐tracking of the Pardubice ‐ Hradec Králové line between 2021‐2024. Its construction, coupled with the provisional use of the original bridge, represents a remarkable engineering feat

Lessons Learned From Inspecting Steel Railway Bridges In Egypt

Lessons Learned From Inspecting Steel Railway Bridges In Egypt

Study on Vibration and Noise of Railway Steel–Concrete Composite Box Girder Bridge Considering Vehicle–Bridge Coupling Effect

A steel–concrete composite beam bridge fully exploits the mechanical advantages of the concrete structure and steel structure, and has the advantages of a fast construction speed and large stiffness. It is of certain research value to explore the application of this bridge type in the field of railway bridges. However, with the rapid development of domestic high-speed railway construction, the problem of vibration and noise radiation of high-speed railway bridges caused by train loads is becoming more and more serious. A steel–concrete composite beam bridge combines the tensile characteristics of steel and the compressive characteristics of concrete perfectly. At the same time, it also has the characteristics of a steel bridge and concrete bridge in terms of vibration and noise radiation. This feature makes the study of the vibration and noise of the bridge type more complicated. Therefore, in this paper, the characteristics of vibration and noise radiation of a high-speed railway steel–concrete composite box girder bridge are studied in detail from two aspects: the theoretical basis and a numerical simulation. The main results obtained are as follows: Relying on the idea of vehicle–rail–bridge coupling dynamics, a structural dynamics analysis model of a steel–concrete combined girder bridge for a high-speed railroad was established, and numerical program simulation of the vibration of the vehicle–rail–bridge coupling system was carried out based on the parametric design language of ANSYS 18.0 and the language of MATLAB R2021a, and the structural vibration results were analyzed in both the time domain and frequency domain. By using different time-step loading for the vehicle–rail–bridge coupling vibration analysis, the computational efficiency can be effectively improved under the condition of guaranteeing the accuracy of the result analysis within 100 Hz. Based on the power flow equilibrium equation, a statistical energy method of calculating the high-frequency noise radiation is theoretically derived. Based on the theoretical basis of the statistical energy method, the high-frequency noise in the structure is numerically simulated in the VAONE 2021 software, and the average contribution of the concrete roof plate to the three acoustic field points constructed in this paper is as high as 50%, which is of great significance in the study of noise reduction in steel–concrete composite girders.

Thermo-mechanical response of near-pearlitic steel heated under restriction of thermal expansion

Railway wheels experience high temperatures during operation, especially during severe block braking. The thermal expansion of wheel rim material due to frictional heating is limited by the wheel's geometry and size. This study investigated the impact of this combined mechanical and thermal loading on the mechanical properties and microstructure in the tread surface of an ER7T steel railway wheel.The material response below the austenitisation temperature is comprehensively evaluated through thermal cycling at peak temperatures of 300, 400, 600, and 650 °C, simulating severe block braking cycles with varying degrees of thermal dilatation (25 %, 50 %, 75 %, and 100 %). An initial plastic deformation was observed during the first heating cycle for the two lower temperatures at lower restrictions, followed by a predominantly elastic response. However, at higher restrictions, the material showed time-dependent relaxation during heating, and some plastic deformation was observed during cooling. Notably, even at the lowest level of restriction, similar observations were made at higher peak temperatures. Increasing the restriction resulted in large strains and a wider hysteresis loop. The test bars exposed to the two higher temperatures retained large tensile stresses after cooling. This indicates a risk of a significantly altered residual stress state in the rim of an overheated railway wheel, which could adversely affect its fatigue properties. The study's outcomes will aid in designing and calibrating constitutive material models for severe block braking. Furthermore, it will significantly contribute to research into the thermo-mechanical behaviour of pearlitic/near-pearlitic materials during railway operations and maintenance.

Performance Evaluation of High Speed Pearlite Railway Steel Joint by 3-Wire Electroslag Welding

Performance Evaluation of High Speed Pearlite Railway Steel Joint by 3-Wire Electroslag Welding

Destructive Testing of the Pinkabach Railway Bridge – Large scale Testing of Sensor Systems for Fatigue Crack Monitoring and System Identification

The work presents experiments carried out on an out-of-service steel railway bridge, the so called Pinkabach bridge. The objective was to test advanced and novel sensor systems, i.e. Distributed Fiber Optic Sensing (DFOS) and Acoustic Emission (AE), for the monitoring of fatigue cracks, both for crack initiation and subsequent crack growth, in steel railway bridges. Also, sensor systems for overall system identification, i.e. Tiny Motion (TM), Distributed Acoustic Sensing (DAS) and dynamic response analysis, have been tested. The Pinkabach bridge was a single span plate girder railway bridge with a span width of 21,5m that was taken out of service and transported to a secure environment that allowed for destructive testing with permanent access to the structure itself under controlled conditions. By harmonic excitation of the structure at its first resonance frequency, cyclic stress levels comparable to the stress levels during train passage were generated and it was possible to emulate the fatigue load from decades of train traffic within the limited period of the experiments. Crack initiation and growth happened at two locations of the flanges and crack growth was monitored till the crack length was half of the flange width of the main girder. To end the experiments a static load test showed the remaining capacity of the damaged structure. A conventional sensor system was used for validation and comparison with calculated predictions based on linear fracture mechanics, used for the design of the experiments. An overview over the whole set of experiments as well as (intermediate) results and findings on the applicability of the novel sensor systems are presented in this paper. The experiments are a collaborative work of multiple scientific and industrial partners and have been carried out as part of Area 3.1 of the COMET Project Rail4Future, funded by the Austrian Research Promotion Agency FFG.

Structural Health Monitoring for Dębica Railway Steel Arch Bridge in Poland

The study presents the vibration-based SHM system for the Dębica railway bridge located in Poland. The railway bridge owner was concerned about the excessive and self-excited vibrations of the hangers, the vibration measurement of 8 hangers per span in a total of two spans being monitored. The dynamic responses in both the transverse and longitudinal directions for each hanger under different load events over a nine-month period were recorded and introduced in this paper. The tension force and stress on each hanger are estimated through the natural frequency of the experimental vibration analysis. The proposed approaches could be used to develop a smart alarm system integrated into a vibration-based data-driven SHM system for heavy railway bridges.

Vibration-based SHM of railway steel arch bridge with orbit-shaped image and wavelet-integrated CNN classification

The study presents the data-driven applications of continuous wavelet transforms (CWT), orbit-shaped analysis and convolutional neural networks (CNN) using GoogLeNet for Dębica railway bridge health monitoring in Poland. Training and validation data sets are the dynamic behavior of the bridge deck recorded through an IEPE vibration sensor with a sampling frequency of 128 Hz from vibration-based structural health monitoring (SHM) system over a nine-month period from December 2019 to September 2020. Utilizing Morse, Morlet, and Bump wavelet, the vibration signal scalogram images are produced in the frequency–time domain as the input for CNN classification models, while the output is to predict health states based on the experimental tension force of eight hangers using label thresholds developed by calibrated finite element model. Moreover, the vibration-based orbit-shaped image patterns, acquired through a bidirectional sensor on each hanger are processed with CNN classification models for automated hanger health diagnostic. The accuracies and weighted F1-scores of the wavelet-assisted and orbit-shaped CNN models are more than 83% on imbalanced validation images. The results show that the proposed CNN approaches can classify the potential structural problems.

Investigation on laser cladding Fe-based gradient coatings with hierarchical enhanced wear resistance on U75V railway steel

This study focused on the multilayer laser cladding of 15–5 precipitation hardening (PH) steel coating on U75V railway steel for improved surface performance. The effect of pearlitic substrate dilution action with high carbon content on microstructures and wear performance of PH steel coating with four deposited layers was investigated. Results showed that each cladding layer consisted of a similar multiphase mixture of martensite, retained austenite, and NbC carbides in the case of stepwise changes in chemical compositions induced by dilution effects. The wear resistance of the multilayered PH steel coating is closely related to the deposited layer number, reflected in a gradient increase in the wear rate with the increasing cladding layers. A comparative analysis against the U75V substrate showed substantial wear rate reductions of approximately 95 % and 4.5 % in the first and fourth layers, respectively. Besides, the cross-sectional microstructures were analyzed in detail to reveal the underlying friction-induced microstructural evolution of the gradient coating. The refinement of martensite laths controlled by dislocation reaction and the friction-induced austenite to martensite transformation was responsible for the superior wear resistance. The current experimental results could provide a new strategy for designing hierarchical enhanced wearable gradient coating for surface modification in railway components.

Mode tracking for a steel railway bridge in presence of changing support conditions

Mode tracking for a steel railway bridge in presence of changing support conditions

Crystal plasticity modeling of grain boundary softening and fatigue in U75V pearlite steel under low strain conditions: A study of cyclic rolling contact fatigue

Grain boundaries (GBs) exhibit fatigue-induced softening under low strain conditions, making them the weakest and most vulnerable regions within the material. This phenomenon significantly influences plastic deformation, plastic strengthening, and the initiation and propagation of microcracks, leading to material fatigue failure. This investigation presents a comprehensive model for the rolling contact fatigue (RCF) damage mechanism of U75V railway steel. Leveraging data from Electron Backscatter Diffraction (EBSD) and employing the Crystal Plasticity Finite Element Method (CPFEM), intragranular mechanical responses are elucidated. A modified bilinear Traction Separation Law (TSL) Cohesive Zone Model (CZM) is developed to capture the impact of GBs fatigue. Integrating this CZM with CPFEM, mechanical properties, scalar stiffness degradation (SDEG), fatigue damage factors, and crack evolution patterns are analyzed to explore the effects of grain morphology, orientation, GB angle, and area on GB fatigue damage and crack initiation. Results indicate a significant increase in GBs damage with increasing GBs angle or decreasing GBs area, highlighting the potential for reducing RCF damage through deliberate grain morphology design. Additionally, GBs are found to impede crack propagation, suggesting that grain refinement can mitigate crack propagation rates. This study enhances our understanding of intergranular fracture, mechanical responses, and microstructure evolution in U75V rail steel under cyclic rolling contact loading, offering novel methodologies for investigating metallic materials' deformation behavior concerning GB fatigue.

The role of microstructure on the wear and rolling contact fatigue of railway steels: The performance of bainite

This study aims to describe the wear and rolling contact fatigue (RCF) behavior of microalloyed forged railway wheel steel Class D (7NbMo), with microstructures of upper bainite (UB - 350 HV0.5), lower bainite (LB - 450 HV0.5), and pearlite (PE - 350 HV0.5), against 7C steel with a tempered martensite microstructure (660 HV0.5) in a twin-disc tribometer. The results showed that bainite (LB and UB) exhibited greater wear resistance compared to pearlite (PE). The primary wear mechanism for all three microstructures was the fatigue wear. An analysis of the PE disc revealed continuous (single-layer) RCF cracks, which were relatively large and deep. In contrast, UB and LB cracks were discontinuous (multiple layers), thin, and smaller but more numerous (higher crack density). These characteristics indicated that bainitic microstructures also had greater resistance to RCF than pearlite did. Therefore, the combination of mechanical properties and the morphological arrangement of the microstructure led bainite to develop a shallower depth of deformed layer with a higher capacity for plastic deformation per unit volume. The greater wear and RCF performance of bainite compared to those of pearlite may be associated with how they release the accumulated deformation energy after reaching saturation in relation to volume deformation absorption: regarding bainite, the material releases energy by opening crack surfaces; conversely, regarding pearlite, it is through the detachment of large and wide cracks.

Rotary compression test for determination of critical value of hybrid damage criterion for railway steel EA1T

The article presents and discusses the problem of determining and characterizing the cracking limits of cross-rolled specimens. The limit values were determined in accordance with the hybrid Pater criterion. For the study, the author’s test method was used, which allows the determination of the cracking moment, formed as a result of the Mannesmann effect during the compression of specimens in the channel. In order to determine the values needed to describe the cracking criterion, it was necessary to perform laboratory tests and numerical simulations of the process of compression in the channel of discs made of EA1T steel under hot forming conditions. Experimental tests were carried out for forming processes at 950 °C, 1050 °C and 1150 °C. The tested material had a disc shape with a diameter of 40 mm and a length of 20 mm, during the pressing process the diameter of the disc was reduced to a diameter of 38 mm. The increase in forming temperature caused a significant increase in the forming path until cracking occurred. Numerical tests were carried out in the finite element calculation environment Simufact.Forming 2021. The stress and strain distributions in the specimen axis were analysed during the tests, which were then used to calculate the hybrid cracking criterion limit according to Pater. After calculations according to the Pater criterion and after statistical analysis, the cracking criterion limits were obtained.