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Developing a reliable signal wire attachment method for rail.

File Language:
English


Filetype [PDF - 13.68 MB]

Details

  • Creators:
    Workman, Dave ; Stuart, Cameron
  • Corporate Creators:
    EWI
  • Subject/TRT Terms:
  • Publication/ Report Number:
    DOT/FRA/ORD-14/33 ; EWI Project No. 53167GTH
  • Resource Type:
    Tech Report
  • Geographical Coverage:
    United States
  • Corporate Publisher:
    United States. Federal Railroad Administration. Office of Research and Development
  • Abstract:
    The goal of this project was to develop a better attachment method for rail signal wires to improve the reliability of signaling ; systems. EWI conducted basic research into the failure mode of current attachment methods and developed and tested a new ; process that provides improved performance over current techniques. EWI studied currently available stud alloys and developed a ; solid state inertia friction welding (IFW) process to better control the joining process and reduce the likelihood of forming ; martensite in the rail head. C464 Naval Brass exhibited high strength without the formation of martensite under manageable ; process parameters. ; EWI developed the new welding process and conducted a series of tests to address any barriers to implementation. The testing ; included comparative tests between current exothermic welding techniques and the new IFW process. These tests included tensile ; testing, fatigue testing of welded joints, impact testing of weld joints, shear testing, microstructural analysis, and hardness testing ; in the rail steel immediately adjacent to the joint. In these tests, no martensite was found in the rail using the newly developed ; IFW process conditions. The mechanical tests showed a joint strength comparable to exothermic processes and fatigue ; performance that was as good, or better than, existing methods. This suggests the IFW approach should allow placement of the ; weld on the rail head with low risk of rail steel damage. A conceptual design for a portable IFW machine was completed.
  • Format:
    PDF
  • Funding:
    DTFR53-12-C-00002
  • Download URL:
    https://rosap.ntl.bts.gov/view/dot/28251/dot_28251_DS1.pdf
  • File Type:
    Filetype[PDF - 13.68 MB]
  • Collection(s):
    US Transportation Collection
  • Main Document Checksum:
    urn:sha256:e0b613515a50a45c2860b8718fd084e5fe9fa5f3fc1820a46a6c3415d5101cbc
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