Dr. abdelrhani lamik voestalpine

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voestalpine Schienen GmbHvoestalpine Schienen GmbHwww.voestalpine.com

HSH® حراريا المعالجة القضبانالعالية الحمولة ذات الخطوط في للستعمال

The heat treated rails HSH® for heavy loaded tracks

Riyadh, هـ 12/05/14 ;12/05/14

Dr. Abdelrhani Lamik, لكمك عبد الغني

Technical Customer Service

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voestalpine Schienen GmbH

Challenges: Wear & Rolling Contact Fatigue (RCF)

Cracks in the running surface

Squats

Wear

Corrugation

Head Checks at gage corner

Wheel

12/05/145th Annual Middle East Rail Opportunities

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Solution?


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rails with fine pearlitic microstructure

HSH® (Head Special Hardened)

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microstructure of pearlitic rail steel

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microstructure of pearlitic rail steels

Pearlite = Ferrite (α-Iron) + Cementite (Fe3C)


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fine pearlitic microstructure

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Perlit = Ferrit (α-Eisen) + Fe3C (Zementit)

Die Lamellenform entsteht durch gekoppeltes Wachstum.

The lamellar spacing determines the hardness

the smaller the lamellar spacing, the harder the steel

HSH® - Head Special Hardened rails

360 HBW

290 HBW

BOTH SAMPLES ARE MADE FROM THE SAME RAILS AND HAVE AN IDENTICAL CHEMICAL COMPOSITION


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5th Annual Middle East Rail Opportunities

HSH® - Head Special Hardened rails

In-line process

environmentally friendlyaccelerated cooling of the rail head

fine-pearlitic structure

highest quality, highest productivity

all rail profiles (vignole rails, grooved

rails, tongue rails)

12/05/148

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field performance:

R260 vs. R350HT


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resistance against wear, R= 1.400 m

0,48

0,92

0,08

0,18

0,13

0,030,0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

1,0

0 10 20 30 40 50 60 70 80 90 100 110 120 130

Accumulated load [MGT]

Ga

ug

e c

orn

er

we

ar

[mm

]

R260

R350HT

Improvement factor 5 !

HSH in comparison with R260

after 125 Mio to


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resistance against rolling contact fatigueR =1.500 m, 100 MGT

R260

R350HT


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rail grade

crac

k d

epth

[mm

]

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resistance against corrugation (1/2)

3x less corrugation

R260

R350HT


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resistance against corrugation (2/2)

R350HT

R260source: ÖBB


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interim conclusion

The steel grade R350HT shows higher performance

than R260

but higher performance still required


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400 UHC® (acc. to EN 13674 : R400HT)

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microstructure:400 UHC® vs. R350HT


15R350HT:Hardness up to 390 BHN

400 UHC®: Hardness up to 440 BHN

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field performance:

R350HT vs. 400 UHC®


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Resistance against RCF, 1.500 m, 100 MGT

rail grade

crac

k d

epth

[mm

]

400 UHC®

R350HT

R260


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R260 R350HT R400HT

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Resistance against wear ,185 m, 100 MGT

rail grade


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we

ar

W3

[mm

]

R260 R350HT R400HT

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Resistance against corrugation,185 m, 100 MGT


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corr

uga

tion

dep

th [

mm

]

R260 R350HT R400HT

rail grade

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Resistance against corrugation,185 m, 100 MGT

R350HT

400 UHC®


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Performance of HSH® rails in switches:

Wing Rails

12/05/14 5th Annual Middle East Rail Opportunities

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400 UHC® vs. R350HT

Wing rails

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400 UHC® vs. R350HT, after 100 MGT

Type of rails and frog Railway station Average wearing of wing rails [mm]

Benefit [%]

R65 VARIO 1800 R350HT Lentvaris 1,1522 R65 VARIO 1800 400 UHC® Lentvaris 0,90

R65 VARIO 1800 R350HT Paneriai 0,9521R65 VARIO 1800 400 UHC® Paneriai 0,75

R65 VARIO 1800 R350HT Dotnuva 1,0524R65 VARIO 1800 400 UHC® Dotnuva 0,80

R65 VARIO 1800 R350HT Žasliai 1,1517R65 VARIO 1800 400 UHC® Žasliai 0,95

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WR: R260W1 = 6 mm

WR: HSH®W1 = 0,8 mm

crossing

Switch endBegin of switch

MP1, MP2, MP5, MP6…wing railMP3, MP4 …intermediate rail

MP5

MP6

MP2

MP1

MP3

MP4

WR: R260W1 = 5,5 mmWR: HSH®

W1 = 0,2 mm

MP5MP6

HSH® vs. standard carbon grade, after 120 MGT

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Performance of HSH® rails in switches:

Tongue Blades


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HSH® (R350HT) vs. standard carbon steel (R260)

R350HT

R260source: ÖBB


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Tongue blades

65% increase of the service life using the steel grade 370LHT instead of R350HT


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Rail grade strategy:EU-Project INNOTRACK 2006 – 2009

Common goals:

Innovation of infrastructure assets

Reduction of maintenance

Reduction of life cycle costs

www.innotrack.eu

11 railways 11 industries 3 construction 8 universities


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summary of the INNOTRACK projectrail grade recommendationoptimized rail grade strategy


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against wear and

corrugationagainst RCF

(Head Checks)

400 UHC®

Tonn

age

per

tra

ck a

nd y

ear

[MT

]

Radius [m]

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Résumé: the key for success


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اهتمامكم على جزيل !شكرا

Thank you very much for your attention!

[email protected]


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HSH® - Head Special Hardened rails:Microstructure of a HSH®-Rail

Head: fine-pearlitic

high wear and RCF resistance

transition zone

Web & foot: pearlitic with high ductility

high endurance limit


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The material influence (ke):Interaction of rail and wheel wear (dry)

0 20000 40000 60000 80000 1000000

5

10

15

20

25

30

35

40

R260 - railR350HT - railR400HT - railR7 wheel(R260 rail)R7 wheel(R350HT rail)R7 wheel(R400HT rail)

Wheel passes

Are

a lo

ss

[m

m²]

Decreasing rail wear with increasing rail hardness Wheel wear stays on same level with increasing rail hardness Wear determined by contact size – contact size depends on the softer partner


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Wear: wheel contra rail

From: Steele, R.; Reiff, R.P.: „Rail – It‘s behaviour and relationship to total system wear“. Proceedings of the 2nd Heavy Haul Conference, 1982, S115-164


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Steel GradesChemical Composition [% by mass] Mechanical Properties

C Si Mn CrRm

[MPa]A5 [%]

Hardness [HBW]

Standard Rail

Grades

R200 0,40 - 0,60 0,15 - 0,58 0,70 - 1,20 ≤ 0,15 ≥ 680 ≥ 14 200 - 240R220 0,50 - 0,60 0,20 - 0,60 1,00 - 1,25 ≤ 0,15 ≥ 770 ≥ 12 220 - 260R260 0,62 - 0,80 0,15 - 0,58 0,70 - 1,20 ≤ 0,15 ≥ 880 ≥ 10 260 - 300

R260Mn 0,55 - 0,75 0,15 - 0,60 1,30 - 1,70 ≤ 0,15 ≥ 880 ≥ 10 260 - 300R320Cr 0,60 - 0,80 0,50 - 1,10 0,80 - 1,20 0,80 - 1,20 ≥ 1.080 ≥ 9 320 - 360

Heat Treated

Rail Grades

R350HT(350HT HSH®)

0,72 - 0,80 0,15 - 0,58 0,70 - 1,20 ≤ 0,15 ≥ 1.175 ≥ 9 350 - 390

R350LHT

(350LHT HSH®)

0,72 - 0,80 0,15 - 0,58 0,70 - 1,20 ≤ 0,30 ≥ 1.175 ≥ 9 350 - 390

R370CrHT

(370LHT HSH®)

0,70 - 0,82 0,40 - 1,00 0,70 - 1,10 0,40 - 0,60 ≥ 1.280 ≥ 9 370 - 410

R400HT(400 UHC®)

0,90 - 1,05 0,20 - 0,60 1,00 - 1,30 ≤ 0,30 ≥ 1.280 ≥ 9 400 - 440

Rail Steel Grades EN 13674-1:2011Vignol Rails


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Purchase price Installation costs

Inspection Maintenance Delays repair work Replacement Operating costs Availability Safety

“ What you see is not always what you get ”

Performance evaluationLife Cycle Cost (LCC)


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Business

Dr. abdelrhani lamik voestalpine