This research sourced a wide variety of different as-manufactured rail steels which were best thought to represent those most commonly used on track. Characterisation of the various steel’s mechanical, compositional and metallurgical properties was undertaken using standardised techniques for comparison to the two major damage mechanisms observed on track, RCF and wear. Twin disc testing of the rail samples was conducted on a third scale twin disc rig under both wear and RCF conditions on the samples. T-Gamma was selected as the scaling method for this research as it was believed to be the most representative of full-scale conditions. The Whole Life Model, which also uses T-Gamma, which in literature has been validated for R260 steel and was believed to be the best representation of full-scale loading conditions experienced. A developed twin disc methodology was used to assess each steel, with a second methodology being developed to replicate real world environmental conditions on the rig, however this was ultimately not used in this research. The methodologies used in this research can be seen in CHAPTER 3.0: RESEARCH METHODOLOGIES. The collation of the various properties and twin disc test results allowed the creation of a matrix of data for each steel grade. Trending and correlation of this data helped to confirm existing relationships, validate the data gathered, and to identify new relationships. The main novelty of this research, however, was finding relationships from directly comparing each steel property to damage mechanism data, as seen in CHAPTER 4.0: RESULTS ANALYSIS. The trends and correlations identified during the research were used to create design principles, seen in CHAPTER 6.0: DESIGN PRINCIPLES FOR DAMAGE MECHANISM RESISTANCE, which indicate which steel properties are attributed to the resistance of the key damage mechanisms. Also included in the thesis is a summary of the properties which contribute to making naturally cooled as-manufactured steels, such as HP335, as effective at resisting certain damage mechanisms as heat treated steels. The possible reasons for each of the correlations and design principles can be found in CHAPTER 5.0: DISCUSSION.
| Date of Award | 22 Apr 2025 |
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| Original language | English |
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| Sponsors | Engineering and Physical Sciences Research Council |
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| Supervisor | Adam Bevan (Main Supervisor) & Phil Shackleton (Co-Supervisor) |
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