Evaluation of the Effect of Heat Input and Cooling Rate of Rail Flash-Butt Welding using Finite Element Method Simulation
Autor(a) principal: | |
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Data de Publicação: | 2022 |
Outros Autores: | , , |
Tipo de documento: | Artigo |
Idioma: | eng |
Título da fonte: | Revista soldagem & inspeção (Online) |
Texto Completo: | http://old.scielo.br/scielo.php?script=sci_arttext&pid=S0104-92242022000100200 |
Resumo: | Abstract Simulations using the finite element method (FEM) were done to understand the effects of heating/cooling rates on the distribution of residual stresses. Two material parameters from rails were used while the boundary conditions remained constant: heat-affected zone size, maximum temperature and heating extraction rate. To complement the analysis, a flash-butt weld of a Premium rail was done with welding parameters adjusted to obtain a narrow HAZ, without forced cooling, to examine the microstructure formed in the critical regions in the web and the edge of the rail foot. The results showed that there was a concentration of vertical residual stresses in the web region, while the presence of horizontal compression residual stresses was mostly superficial in the rail head region. The main result from the simulation sets was that when using two simulation parameters with similar materials (rails) substantially different results were obtained. Metallographic examinations showed that there was no presence of acicular microconstituents (martensite/bainite). In the rail web, proeutectoid ferrite was observed in the central region, cementite in a previous austenitic grain boundary, in the region that reached temperatures close to AC3, and almost complete spheroidization in the region of maximum spheroidization. In contrast, in the rail foot edge region, there was a completely pearlitic microstructure, in the central region and in the zone that reached temperatures close to AC3, and a lower volume of spheroidization in the region where maximum spheroidization is typically observed, probably due to the higher cooling rate in this region. |
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Revista soldagem & inspeção (Online) |
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Evaluation of the Effect of Heat Input and Cooling Rate of Rail Flash-Butt Welding using Finite Element Method SimulationRailWeldingFlash-buttFEMSimulationResidual stressesAbstract Simulations using the finite element method (FEM) were done to understand the effects of heating/cooling rates on the distribution of residual stresses. Two material parameters from rails were used while the boundary conditions remained constant: heat-affected zone size, maximum temperature and heating extraction rate. To complement the analysis, a flash-butt weld of a Premium rail was done with welding parameters adjusted to obtain a narrow HAZ, without forced cooling, to examine the microstructure formed in the critical regions in the web and the edge of the rail foot. The results showed that there was a concentration of vertical residual stresses in the web region, while the presence of horizontal compression residual stresses was mostly superficial in the rail head region. The main result from the simulation sets was that when using two simulation parameters with similar materials (rails) substantially different results were obtained. Metallographic examinations showed that there was no presence of acicular microconstituents (martensite/bainite). In the rail web, proeutectoid ferrite was observed in the central region, cementite in a previous austenitic grain boundary, in the region that reached temperatures close to AC3, and almost complete spheroidization in the region of maximum spheroidization. In contrast, in the rail foot edge region, there was a completely pearlitic microstructure, in the central region and in the zone that reached temperatures close to AC3, and a lower volume of spheroidization in the region where maximum spheroidization is typically observed, probably due to the higher cooling rate in this region.Associação Brasileira de Soldagem2022-01-01info:eu-repo/semantics/articleinfo:eu-repo/semantics/publishedVersiontext/htmlhttp://old.scielo.br/scielo.php?script=sci_arttext&pid=S0104-92242022000100200Soldagem & Inspeção v.27 2022reponame:Revista soldagem & inspeção (Online)instname:Associação Brasileira de Soldagem (ABS)instacron:ABS10.1590/0104-9224/si27.01info:eu-repo/semantics/openAccessPereira,Henrique BoschettiEcheverri,Edwan Anderson ArizaAlves,Luiz Henrique DiasGoldenstein,Hélioeng2022-02-09T00:00:00Zoai:scielo:S0104-92242022000100200Revistahttp://abs-soldagem.org.br/s&i/https://old.scielo.br/oai/scielo-oai.php||revista-si@abs-soldagem.org.br0104-92241980-6973opendoar:2022-02-09T00:00Revista soldagem & inspeção (Online) - Associação Brasileira de Soldagem (ABS)false |
dc.title.none.fl_str_mv |
Evaluation of the Effect of Heat Input and Cooling Rate of Rail Flash-Butt Welding using Finite Element Method Simulation |
title |
Evaluation of the Effect of Heat Input and Cooling Rate of Rail Flash-Butt Welding using Finite Element Method Simulation |
spellingShingle |
Evaluation of the Effect of Heat Input and Cooling Rate of Rail Flash-Butt Welding using Finite Element Method Simulation Pereira,Henrique Boschetti Rail Welding Flash-butt FEM Simulation Residual stresses |
title_short |
Evaluation of the Effect of Heat Input and Cooling Rate of Rail Flash-Butt Welding using Finite Element Method Simulation |
title_full |
Evaluation of the Effect of Heat Input and Cooling Rate of Rail Flash-Butt Welding using Finite Element Method Simulation |
title_fullStr |
Evaluation of the Effect of Heat Input and Cooling Rate of Rail Flash-Butt Welding using Finite Element Method Simulation |
title_full_unstemmed |
Evaluation of the Effect of Heat Input and Cooling Rate of Rail Flash-Butt Welding using Finite Element Method Simulation |
title_sort |
Evaluation of the Effect of Heat Input and Cooling Rate of Rail Flash-Butt Welding using Finite Element Method Simulation |
author |
Pereira,Henrique Boschetti |
author_facet |
Pereira,Henrique Boschetti Echeverri,Edwan Anderson Ariza Alves,Luiz Henrique Dias Goldenstein,Hélio |
author_role |
author |
author2 |
Echeverri,Edwan Anderson Ariza Alves,Luiz Henrique Dias Goldenstein,Hélio |
author2_role |
author author author |
dc.contributor.author.fl_str_mv |
Pereira,Henrique Boschetti Echeverri,Edwan Anderson Ariza Alves,Luiz Henrique Dias Goldenstein,Hélio |
dc.subject.por.fl_str_mv |
Rail Welding Flash-butt FEM Simulation Residual stresses |
topic |
Rail Welding Flash-butt FEM Simulation Residual stresses |
description |
Abstract Simulations using the finite element method (FEM) were done to understand the effects of heating/cooling rates on the distribution of residual stresses. Two material parameters from rails were used while the boundary conditions remained constant: heat-affected zone size, maximum temperature and heating extraction rate. To complement the analysis, a flash-butt weld of a Premium rail was done with welding parameters adjusted to obtain a narrow HAZ, without forced cooling, to examine the microstructure formed in the critical regions in the web and the edge of the rail foot. The results showed that there was a concentration of vertical residual stresses in the web region, while the presence of horizontal compression residual stresses was mostly superficial in the rail head region. The main result from the simulation sets was that when using two simulation parameters with similar materials (rails) substantially different results were obtained. Metallographic examinations showed that there was no presence of acicular microconstituents (martensite/bainite). In the rail web, proeutectoid ferrite was observed in the central region, cementite in a previous austenitic grain boundary, in the region that reached temperatures close to AC3, and almost complete spheroidization in the region of maximum spheroidization. In contrast, in the rail foot edge region, there was a completely pearlitic microstructure, in the central region and in the zone that reached temperatures close to AC3, and a lower volume of spheroidization in the region where maximum spheroidization is typically observed, probably due to the higher cooling rate in this region. |
publishDate |
2022 |
dc.date.none.fl_str_mv |
2022-01-01 |
dc.type.driver.fl_str_mv |
info:eu-repo/semantics/article |
dc.type.status.fl_str_mv |
info:eu-repo/semantics/publishedVersion |
format |
article |
status_str |
publishedVersion |
dc.identifier.uri.fl_str_mv |
http://old.scielo.br/scielo.php?script=sci_arttext&pid=S0104-92242022000100200 |
url |
http://old.scielo.br/scielo.php?script=sci_arttext&pid=S0104-92242022000100200 |
dc.language.iso.fl_str_mv |
eng |
language |
eng |
dc.relation.none.fl_str_mv |
10.1590/0104-9224/si27.01 |
dc.rights.driver.fl_str_mv |
info:eu-repo/semantics/openAccess |
eu_rights_str_mv |
openAccess |
dc.format.none.fl_str_mv |
text/html |
dc.publisher.none.fl_str_mv |
Associação Brasileira de Soldagem |
publisher.none.fl_str_mv |
Associação Brasileira de Soldagem |
dc.source.none.fl_str_mv |
Soldagem & Inspeção v.27 2022 reponame:Revista soldagem & inspeção (Online) instname:Associação Brasileira de Soldagem (ABS) instacron:ABS |
instname_str |
Associação Brasileira de Soldagem (ABS) |
instacron_str |
ABS |
institution |
ABS |
reponame_str |
Revista soldagem & inspeção (Online) |
collection |
Revista soldagem & inspeção (Online) |
repository.name.fl_str_mv |
Revista soldagem & inspeção (Online) - Associação Brasileira de Soldagem (ABS) |
repository.mail.fl_str_mv |
||revista-si@abs-soldagem.org.br |
_version_ |
1754213004571836416 |