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• The contact load between the roller and the raceway in the bearing is measured. • Proposing a life prediction method for the bearing under variable load conditions. • Bearings at different locations of one wheelset show different fatigue lives. In this paper, a life prediction method for axle box bearing rolling contact fatigue under wheel-rail excitation conditions is present. The dynamic contact load between the rollers and the outer raceway was considered the critical mechanical parameter for rolling contact fatigue of the bearing and measured based on strain detection of the bearing outer ring. In the bench test, the different excitation frequencies were simulated by a polygonal roller with varying rotation speeds. Then, the load spectrums of the measured loads were compiled and used as the input data for the life prediction model of rolling contact fatigue. Since the subsurface material element of the raceway is subject to the complex multiaxial stress state during service, the fatigue life was estimated based on the improved moment of the load path model. Besides, the linear damage accumulation rule was applied to evaluate the fatigue life of the bearings, considering the varying contact load that the outer raceway was subject to. Finally, the predicted fatigue lives of two double-row tapered roller bearings under different excitation conditions were present based on the proposed method. [ABSTRACT FROM AUTHOR]

This study explores the comparative fatigue performance of decarburized surfaces in railway components, emphasizing rolling contact fatigue, crack propagation, and acoustic emission. The investigation entails the examination of two grades of railway steels, namely R260 and U71Mn, to analyze crack and surface characteristics subsequent to fatigue testing employing a Twin Roller Machine. The purpose is to discern the impact of decarburization on the fatigue life of these materials. The results reveal distinct patterns in crack propagation and acoustic emission between decarburized and non-decarburized surfaces, providing valuable insights into the fatigue behavior of railway components. This comparative analysis contributes to a nuanced understanding of the material's response to cyclic loading. [ABSTRACT FROM AUTHOR]

Railway wheels are usually attached to axles by press-fitting; therefore, the mechanical processes taking place during operation can result in failure, with fatal consequences for the axle seats. This manuscript describes the effect of laser hardening on the residual stress state, microstructural parameters (lattice defects—dislocations, crystallites, microstrains, etc.), and mechanical properties of laser-hardened EA1N steel railway axles under fatigue life conditions. Differences were found between ground, single-track, and multi-track hardened surfaces. Tensile residual stresses, low dislocation densities and hardnesses, and different microstructures (tempered cubic martensite) were found at the overlapped tracks and at the boundary of the heat-affected zone and bulk surface compared with the hardened zone. As a result, the surface treatment of axle seats by laser hardening improved the fatigue failure resistance compared with untreated seats. Optimal properties of the integrity of the axle seat surface were achieved, including fatigue resistance, which seems to be positively influenced mainly by sufficient hardness and the appropriate microstructure. The influence of the other investigated parameters was not evident, and was reduced by the presence of fretting corrosion and press-fitting. [ABSTRACT FROM AUTHOR]

Cavity defects can aggravate the rail crack initiation. To study their effect on rail fatigue crack initiation behaviour, a peridynamic model of rail crack initiation considering the characteristics of the cavity defect was proposed. First, based on the low-cycle fatigue test data, the bond failure criterion of the rail material was derived and verified to characterize the fatigue damage performance. Then, mathematical expressions for circular, triangular and rectangular defect characteristics were proposed, establishing a prefabricated method for rail cavity defects. Based on the ordinary state-based peridynamic fatigue theory, a rail crack initiation model with the cavity defect was constructed. Finally, the behaviour of rail crack initiation with the cavity defect was analysed. [ABSTRACT FROM AUTHOR]

Fatigue refers to the progressive and localized structural damage that occurs when a material is subjected to repeated loading and unloading, typically at levels below its ultimate strength. Several failure mechanisms have been observed in practical scenarios, encompassing high-cycle, low-cycle, thermal, surface, corrosion, and fretting fatigue. Fatigue, connected to the failure of numerous engineered products, stands out as a prevalent cause of structural failure in service. Conducting research on the advancement and application of fatigue analysis technologies is crucial because fatigue analysis plays a critical role in determining the service life of components and mitigating the risk of failure. This study compiles data from a wide range of sources and offers a thorough summary of the state of fatigue analysis. It focuses on the effects of different parameters, including hardness, temperature, residual stresses, and hardfacing, on the fatigue life of different materials and their alloys. The fatigue life of alloys is typically high at low temperatures, but it is significantly reduced at high temperatures or under high-stress conditions. One of the main causes of lower fatigue life is residual stress. High-temperature conditions and hardfacing processes cause the development of tensile residual stresses, which in turn decreases fatigue life. But, if the hardness of the material significantly increases due to hardfacing, then the fatigue life also increases. This manuscript focuses on reviewing the research on fatigue-life prediction methods, shortcomings, and recommendations. [ABSTRACT FROM AUTHOR]

Rail welded joints are a critical component of seamless railway tracks, and they are essential for maintaining the continuity and smoothness of the tracks. However, they also represent weak points in the entire track, which makes these areas susceptible to frequent damage and rail breaks. This study employs an impact wear testing platform with controlled energy to compare and analyse the impact wear characteristics of three different locations (i.e. , weld zone, heat-affected zone and base material) on the U75VG flash-butt welding joint. Results indicate significant differences in material properties, such as hardness and microstructure, within different zones of the flash welded rail joints, which leads to varying impact damage behaviours. The heat-affected zones, which are located on both sides of the weld zone, exhibit the weakest ability to resist impact deformation. Thus, these areas are the most vulnerable in the entire welded rail joint and are prone to damages, such as squat. In general, damage in different zones of the welded joint gradually evolves from plastic deformation and local pitting into fatigue wear with delamination as the main failure mechanism, while the surface of the heat-affected zone tends to develop an oxide debris layer. The distinct damages observed in different zones of the welded joint pose challenges to the problem of track irregularities. This study offers a theoretical framework for predicting the evolution of damage in welded joints. • The impact wear behaviour of flash-welded joints was analysed using the method of controlled dynamic energy. • Three distinct zones of the welded joint were identified, and the respective mechanisms of damage accumulation were revealed. • Identifying the differentiation of damage accumulation in welded joints may lead to squat formation, which may potentially reduce the service life of the track. [ABSTRACT FROM AUTHOR]