Experimental and Numerical Investigation of Flash-butt-welded Joints in Pearlitic-steel Rails: Fatigue and Residual Stress

This study is focused on the performance evaluation of flash-butt-welded rail joints concerning their mechanical strength and fatigue life. Residual stresses created in heat-affected zone were measured effects welding process notch sensitivity behavior weld region experimentally assessed. Aiming at clarifying physical phenomenon behind flash-butt welding, nonlinear transient thermomechanical finite-element analyses performed to reconstitute simulate subsequent formation residual stresses. A new hypothesis for explaining higher temperatures web than foot head was suggested numerically verified. Experimental results showed high highlighted microstructure variations In general, a good agreement achieved between numerical experimental measurements stresses, which essential understanding joints. relevant outcome simulation hot burrs from as prescribed heat inputs convenient part surface. strategy has shown adequate explain non-uniform temperature changes corresponding originated