Applicability Verification of Restoration by Welding to Extend the Lifetime of Railway Wheel

Abstract

Railway wheels, when subjected to wear beyond their designated usage standards due to the operation of railway vehicles, are traditionally managed through a turing maintenance method. This process involves turing the entire worn portion to secure the requisite cross-sectional shape. This approach often leads to disposal after just 2 to 3 turing maintenance cycles. Excessive turing, extending beyond the worn parts, can cause the wheels to fail to meet railway operating specifications. Discarded railway wheels, which contain a high carbon content essential for driving performance, are not repurposed but are instead entirely stockpiled. This research introduces a novel welding restoration technology for railway wheels, targeting the flange portion, a principal area of wear. Utilizing submerged arc welding techniques, this method enables the localized repair of worn parts, minimizing the turing thickness and thus extending the useful life fo railway wheel. To evaluate the on-site applicability and dependability of this welding restoration method, real rail vehicle driving tests were conducted using both conventionally turned and welding-restored railway wheels. Analysis of the wheel profiles substantiated that the welding restoration method delivers mechanical performance comparable to that achieved by traditional turning maintenance.