Fatigue Crack Growth of

Imitated Heat Affected Zone

in Railroad Thermite Welding

Present by : [Link] Nimakorn

Advisor : [Link]. Dr. Ing. Patiphan Juijerm
Department : Materials Engineering
Faculty : Engineering
University : Kasetsart
Introduction
Introduction

3
Introduction

4
Introduction

5
 Introduction

[1]Alumino Thermit Welding type SkV-E , Siemens Ltd. 2014. All Rights Reserved. Only for BTS - Project internal use.
 Introduction

[1]Alumino Thermit Welding type SkV-E , Siemens Ltd. 2014. All Rights Reserved. Only for BTS - Project internal use.
 Introduction
เกิดประมาณ 10 จุด เกิดขึ้นในช่วงเวลาใกล้ๆกัน (15 ปี หลังติดตั้ง) (25 – 30 ปี )
ซ่อม 3 วัน งบประมาณซ่อมต่อจุด 75,000 บาท

[1]Alumino Thermit Welding type SkV-E , Siemens Ltd. 2014. All Rights Reserved. Only for BTS - Project internal use.
 Introduction

[1]Alumino Thermit Welding type SkV-E , Siemens Ltd. 2014. All Rights Reserved. Only for BTS - Project internal use.
 Introduction

[1]Alumino Thermit Welding type SkV-E , Siemens Ltd. 2014. All Rights Reserved. Only for BTS - Project internal use.
 Introduction

[1]Alumino Thermit Welding type SkV-E , Siemens Ltd. 2014. All Rights Reserved. Only for BTS - Project internal use.
 Introduction

[1]Alumino Thermit Welding type SkV-E , Siemens Ltd. 2014. All Rights Reserved. Only for BTS - Project internal use.
 Introduction

[1]Alumino Thermit Welding type SkV-E , Siemens Ltd. 2014. All Rights Reserved. Only for BTS - Project internal use.
 Introduction

[1]Alumino Thermit Welding type SkV-E , Siemens Ltd. 2014. All Rights Reserved. Only for BTS - Project internal use.
 Welding in railroad
25 m length rails

Welding methods
Plant welding  Flash-butt welding
 Gas pressure welding

Field welding

Welding methods
 Thermite welding
 Enclosed-arc welding
 Mobile flash-butt welding
 Gas pressure welding

17
Introduction
 Literature Review
Rail Section and Materials [1],[2]
60E1 to EN 13674-1 1999
Flat Bottom symmetrical railway rails 46 kg/m and above.

Rail steel Hardness Head hardened Remark

Grade
R260 260 HBW none All straight tract and
main line curves of
greater than 400 m
R350HT > 350 HBW Heat treatment Use in station,
switches, crossings
and main line curves
of 400 m or less

[1] Kingdom of Thailand, Ministry of Transport Mass Rapid Transit Authority of Thailand, Green Line Project (Bearing – Samutprakan)
[2] Kingdom of Thailand, Ministry of Transport Mass Rapid Transit Authority of Thailand, Blue Line Project (Hua Lamphong – Lak Song)
 Literature Review

Operational Criteria [1],[2]

• Vehicles per train up to 6

• Maximum speed in tunnels or on viaduct 80 km/hr.
• Maximum axle load 17.5 tons.
• Maximum unsprung mass 2,000 kg.
• Environmental conditions – air temperature 10 – 43 C

[1] Kingdom of Thailand, Ministry of Transport Mass Rapid Transit Authority of Thailand, Green Line Project (Bearing – Samutprakan)
[2] Kingdom of Thailand, Ministry of Transport Mass Rapid Transit Authority of Thailand, Blue Line Project (Hua Lamphong – Lak Song)
[1] P.I. Christodoulou et al. / Theoretical and Applied Fracture Mechanics 83 (2016) 51–59.
Literature Review
Literature Review
Thermite Welding
 Literature Review

Thermite Welding
 Literature Review
Welding Procedure for Thermite (Alumino Thermit Welding type SkV-E)[1]
The rail ends to be square, the weld gap, to be 25 mm ±1
Setup
The crown gap over 0.5 meter, to be 1.2 – 1.4 mm

The torch, to be in the middle of sand mould and height 40 mm

Oxygen / LPG pressure, to be 4 bar / 1.5 bar

Preheat Neutral flame in correct manner of 150 - 200 mm. long and clear bright blue color
Weld
The distressing rails temperature; 31-41 deg’s C

Preheat time, to be 4min and temperature to be 950 – 1,000 deg’s C

Moulds removal after pouring, 4 min 30 sec

Weld
Start of trimming after pouring, 6 min

Oxygen / LPG pressure, to be 5 bar / 1.5 bar

Post Weld Post heat time, to be 1 min 40 sec

Cover heated area with the insulating muffle 2 min

[1] Check List of Alumino Thermit Welding type SkV-E (V-TRW-17000-003.A), Siemens Ltd. 2014. All Rights Reserved. Only for BTS - Project internal use.
The SkV-E Welding Method :
Literature Review

[1] Technical Data The Thermit SkV-E Process : Thermit Welding (GB) Ltd.
 The SkV-E Welding Method :

[1] Technical Data The Thermit SkV-E Process : Thermit Welding (GB) Ltd.
28
30
32
 Microstructure and Mechanical Properties

Material Material
R350HT R350HT
By by
Heat Affected Zone Stress Intensity Factor ; K Imitated HAZ
•Stress Ratio •Stress Ratio
•Frequency •Frequency
•Grain size Fracture Toughness ; KIC •Grain size

•Residual Stress •Residual Stress

Life Assessment
By R-code (R6)
 Literature Review

[1] P.I. Christodoulou et al. / Theoretical and Applied Fracture Mechanics 83 (2016) 51–59.
Test specimen
 Imitated Heat Affected Zone

Temp. Schematic representation of

930 C Hold ? min
heat cycle simulation

Time (s)

55

10

5
Heat cycle affected specimen
 The effect of many factors to KIC

• Microstructure
• Temperature
• Thickness
• Crack size and location

KIc increases with decreasing strain rate and increasing temperature

[Link]

[1] Check List of Alumino Thermit Welding type SkV-E (V-TRW-17000-003.A), Siemens Ltd. 2014. All Rights Reserved. Only for BTS - Project internal use.
 Fatigue crack growth rate equation
Author Equation Regime Note
Klesnil-Lukas da
dN

 C K m  K thm  1,2

 C K 
Paris da m 2
dN
Walker da

C
K m 2 R≥0
dN 1  R m (1 )

C2 R≥0
Foreman da
 K m2 2,3
dN 1  R K c  K

38
 Characteristics of the
fatigue crack growth rate curve

region I there is a threshold

stress intensity range, ΔKth
region II the crack growth rate,
da/dN, is often some power
function of stress intensity
factor, ΔK

region III the crack growth

rate curve rises to an
asymptote where the fracture
toughness, ΔKIC
Literature Review
 Literature Review

Fracture Toughness, KIC

Can be described as fracture toughness of material
(material resistance to crack propagation)

K IC   app ac

Where
K IC is the critical stress intensity factor for plane strain condition in mode I failure.

ac is the critical crack length in an infinite plate

 app is the applied stress

 is a parameter dependent on specimen and crack geometry

42
 Literature Review
KIc Fracture Toughness

KIC, the critical stress intensity factor, fracture

toughness of material is obtained by determining
the ability of material to withstand the load in the
presence of a sharp crack before failure.
according to ASTM E 399 specifications.

43
 Results of 4PBT

• 4PBT of specimens of R350HT (HAZ)

Objective: to evaluate stress intensity

factor range, ΔK and Fracture Toughness,
ΔKIC

Concept: ΔK and ΔKIC is often used within

the damage tolerant design approach, which
define a loading criterion under which the
crack will not grow.
 Charpy-V notch test ASTM Standard E23

For a variety of steel in US unit [Rolfe-Novak] For a variety of low-alloy steel in SI unit [Iwadate et al]

   
2 2
 K IC    K IC  
   5 CVN   0.05    0.6478 CVN   0.0098
    y       y  
 y    y  

[Link] Viswanathan
45
 Crack length measurement method
Crack opening displacement measurements were performed using a COD
extensometer in accordance with ASTM standard E1820

46
 Test specimen

W+0.01W 2W+0.01W W+0.01W

ISO 12108:2002(E)
4xφ8
B=5

W=
an= 4.5 10
0.325

2W+0.01 2W+0.01 Unit: mm

W W
55

Size of test specimens of 4PBT specimen thickness 5 mm

 crack growth rate and
Stress intensity factor range for 4PBT

crack growth rate ISO 12108:2002(E)

da
crack growth rate 
dN
stress intensity factor range
P
K  101.5 g ( ) (1)
B W
 0.923  0.199 (1  sin  ) 4

g()  3(2 tan )1/ 2   (2)
 cos 
where
   / 2 and   a / W
g ( )  stressintensityfactor function
a  crack length
The relationship between K, applied stress (S) and crack size (a) is:

K  YS a
Stress Distributions
• Fourth Order Polynomial Stress Distribution
2 3 4
a a a a
Y  C1  C2    C3    C4    C5  
T  T  T  T  49
 Equipment

4PBT were performed testing

machine
 Literature Review

[1] P.I. Christodoulou et al. / Theoretical and Applied Fracture Mechanics 83 (2016) 51–59.
 Literature Review

[1] P.I. Christodoulou et al. / Theoretical and Applied Fracture Mechanics 83 (2016) 51–59.
[1] P.I. Christodoulou et al. / Theoretical and Applied Fracture Mechanics 83 (2016) 51–59.
[1] P.I. Christodoulou et al. / Theoretical and Applied Fracture Mechanics 83 (2016) 51–59.
[1] P.I. Christodoulou et al. / Theoretical and Applied Fracture Mechanics 83 (2016) 51–59.
[1] P.I. Christodoulou et al. / Theoretical and Applied Fracture Mechanics 83 (2016) 51–59.
[1] P.I. Christodoulou et al. / Theoretical and Applied Fracture Mechanics 83 (2016) 51–59.
Failure Assessment Diagram
(FAD)
R-Code V.5
• R6

59
Introduction
 Introduction

[1] [Link] ; 20160906

 Introduction

[1] [Link] ; 20160906

 Introduction

[1] [Link] ; 20160906