United States Department of Transportation
i
Mobile 3D Printing of Rail Track Surface for Rapid Repairment
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2024-09-01
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[PDF-12.15 MB]
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Edition:Final Report
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Abstract:This study reports on mobile 3D printing of rail track surface for rapid repairment. The frequent replacement of worn rails on tracks brings an immense economic burden on the railroad industry, and also causes significant interruptions to railroad operation. Restoration of worn rails via additive manufacturing, i.e., 3D printing, can considerably reduce the associated maintenance costs. The scope of this study is to utilize metal additive manufacturing (AM) technologies to repair worn rails that are used in the U.S. railway transportation system (e.g. 75-lb/yd light transit rails, or 136-lb/yd heavy freight rails). More specifically, this study aims to understand the interactive mechanisms between the deposited materials and the high-carbon rail steel to identify and alleviate the effect of the associated drawbacks, i.e., residual thermal stresses, micro pores, micro cracks, and martensite nucleation, on the resulting mechanical and metallurgical properties of the repaired rail.
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