/pdf/7-01-an-overview-of-failure-assessment-methods-in-codes-and-3bd1axp1wl.pdf

7.01 – An Overview of Failure Assessment Methods in Codes and Standards

Railway axles are designed for infinite life, but occasional failures have been and are observed in service. The failures, which are usually due to fatigue crack propagation, are typically positioned at the press fits which correspond to the wheels, gears, brakes, or they appear at the axle body close to the notches and transitions. The way to addressing this problem is to adopt the concept of “damage tolerance” in order to determine the inspection intervals of the axle depending on the NDT method. The issue open to discussion is the choice of the correct algorithm for simulating crack growth at R=−1 at variable amplitude loading especially when considering mild steels such as A1N. The aim of the present research is to discuss the application of state-of-the-art algorithms to estimate the effect of block loading at R=−1 (derived from real load spectra experienced by the axle) upon constant crack growth rate. More specifically the current research addresses: (i) crack growth experiments at R=−1 under constant amplitude loading on two novel types of small-scale specimens; (ii) crack growth experiments under block loading on small-scale specimens; and (iii) the prediction of the experimental evidences by well-known and wide-spread analytical tools.

Analysis of Crack Growth at R =−1 under Variable Amplitude Loading on a Steel for Railway Axles

Abstract The comparative assessments and an overview of mechanical, chemical, and physical properties of rail axles are presented. This review focused on the effects of compositions and microstructure on fatigue, fretting and corrosion fatigue of rail axles. The two main steel grades: low carbon steels for commuter trains and high strength low alloy steels for high-speed trains have ferrite-pearlite microstructures with 20–40 µm ferrite grain sizes. Minimum allowable yield and ultimate tensile strengths are 330 MPa and 600 MPa, and the minimum longitudinal and transverse toughnesses are 35 J and 22 J. Most axle failures are associated with surface and sub-surface defects with micro-cracks nucleating from ballast (small-sized pebbles in rail tracks), minute oscillatory movement leading to fretting, microstructural inclusions, and corrosion pits. The implications for structural integrity are highlighted and areas for future research directions are highlighted.

Steels for rail axles - an overview

Stress Analysis and Fracture Mechanics

Nondestructive Evaluation and Life Assessment

The Practice of Damage Tolerance Analysis

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The Practice of Damage Tolerance Analysis