Dr. abdelrhani lamik voestalpine

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voestalpine Schienen GmbHvoestalpine Schienen GmbH
www.voestalpine.com
HSH® ‫حراريا‬ ‫المعالجة‬ ‫القضبان‬
‫العالية‬ ‫الحمولة‬ ‫ذات‬ ‫الخطوط‬ ‫في‬ ‫للستعمال‬
The heat treated rails HSH®
for heavy loaded tracks
Riyadh,
12/05/14; 12/05/14 ‫هـ‬
Dr. Abdelrhani Lamik, ‫الغني‬ ‫عبد‬ ‫لكمك‬
Technical Customer Service

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voestalpine Schienen GmbH
Challenges: Wear & Rolling Contact Fatigue (RCF)
Cracks in the running surface
Squats
Wear
Corrugation
Head Checks at gage corner
Wheel
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Solution?
12/05/145
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rails with fine pearlitic microstructure
HSH® (Head Special Hardened)


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microstructure of pearlitic rail steel

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microstructure of pearlitic rail steels
Pearlite = Ferrite (α-Iron) + Cementite (Fe3C)
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fine pearlitic microstructure

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 Perlit = Ferrit (α-Eisen) + Fe3C (Zementit)
Die Lamellenform entsteht durch gekoppeltes Wachstum.
The lamellar spacing determines the hardness
 the smaller the lamellar spacing, the harder the steel
HSH® - Head Special Hardened rails
360 HBW290 HBW
BOTH SAMPLES ARE MADE FROM THE SAME RAILS AND HAVE AN
IDENTICAL CHEMICAL COMPOSITION
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5th Annual Middle East
HSH® - Head Special Hardened rails
 In-line process
environmentally friendly
 accelerated cooling of the rail head
 fine-pearlitic structure
 highest quality, highest productivity
 all rail profiles (vignole rails, grooved
rails, tongue rails)
12/05/148

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field performance:
R260 vs. R350HT
12/05/145
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resistance against wear, R= 1.400 m
0,48
0,92
0,08
0,18
0,13
0,03
0,0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1,0
0 10 20 30 40 50 60 70 80 90 100 110 120 130
Accumulated load [MGT]
Gaugecornerwear[mm]
R260
R350HT
Improvement factor 5 !
HSH in comparison with R260
after 125 Mio to
12/05/145
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resistance against rolling contact fatigue
R =1.500 m, 100 MGT
R260
R350HT
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rail grade
crackdepth[mm]

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resistance against corrugation (1/2)
3x less corrugation
R260
R350HT
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resistance against corrugation (2/2)
R350HT
R260
source: ÖBB
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interim conclusion
The steel grade R350HT shows higher performance
than R260
 but higher performance still required
12/05/145
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400 UHC®
(acc. to EN 13674 : R400HT)

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microstructure:
400 UHC® vs. R350HT
12/05/145
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R350HT:
Hardness up to 390 BHN
400 UHC®:
Hardness up to 440 BHN

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field performance:
R350HT vs. 400 UHC®
12/05/145
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Resistance against RCF, 1.500 m, 100 MGT
rail grade
crackdepth[mm]
400 UHC®
R350HT
R260
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R260 R350HT R400HT

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Resistance against wear ,185 m, 100 MGT
rail grade
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wearW3[mm]
R260 R350HT R400HT

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Resistance against corrugation,185 m, 100 MGT
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corrugationdepth[mm]
R260 R350HT R400HT
rail grade

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Resistance against corrugation,185 m, 100 MGT
R350H
T
400
UHC®
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Performance of HSH® rails in switches:
Wing Rails
12/05/14 5th Annual Middle East21

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22/05/14
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400 UHC® vs. R350HT
Wing rails

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32/05/14
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400 UHC® vs. R350HT, after 100 MGT
Type of rails and frog Railway station Average wearing of
wing rails [mm]
Benefit
[%]
R65 VARIO 1800 R350HT Lentvaris 1,15
22R65 VARIO 1800 400 UHC® Lentvaris 0,90
R65 VARIO 1800 R350HT Paneriai 0,95
21R65 VARIO 1800 400 UHC® Paneriai 0,75
R65 VARIO 1800 R350HT Dotnuva 1,05
24R65 VARIO 1800 400 UHC® Dotnuva 0,80
R65 VARIO 1800 R350HT Žasliai 1,15
17R65 VARIO 1800 400 UHC® Žasliai 0,95

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WR: R260
W1 = 6 mm
WR: HSH®
W1 = 0,8 mm
crossing
Switch endBegin of switch
MP1, MP2, MP5, MP6…wing rail
MP3, MP4 …intermediate rail
MP5
MP6
MP2
MP1
MP3
MP4
WR: R260
W1 = 5,5 mmWR: HSH®
W1 = 0,2 mm
MP5MP6
HSH® vs. standard carbon grade, after 120 MGT

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Performance of HSH® rails in switches:
Tongue Blades
12/05/14 5th Annual Middle East Rail
Opportunities
25

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HSH® (R350HT) vs. standard carbon steel
(R260)
R350HT
R260
source: ÖBB
Opportunities
26

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Tongue blades
 65% increase of the service life using the steel grade 370LHT
instead of R350HT
Opportunities
27

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Rail grade strategy:
EU-Project INNOTRACK 2006 – 2009
Common goals:
 Innovation of infrastructure assets
 Reduction of maintenance
 Reduction of life cycle costs
www.innotrack.eu
 11 railways
 11 industries
 3 construction
 8 universities
Opportunities
28

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summary of the INNOTRACK project
rail grade recommendation
optimized rail grade strategy
12/05/14 5th Annual Middle East29
against wear and
corrugation
against RCF
(Head Checks)
400 UHC®
Tonnagepertrackandyear[MT]
Radius [m]

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Résumé: the key for success
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‫اهتمامكم‬ ‫على‬ ‫جزيل‬ ‫!شكرا‬
Thank you very much for your attention!
abdelrhani.lamik@voestalpine.com
12/05/145
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HSH® - Head Special Hardened rails:
Microstructure of a HSH®-Rail
Head: fine-pearlitic
 high wear and RCF resistance
transition zone
Web & foot: pearlitic with high ductility
 high endurance limit
12/05/14 5th Annual Middle East
33

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The material influence (ke):
Interaction of rail and wheel wear (dry)
0 20000 40000 60000 80000 100000
0
5
10
15
20
25
30
35
40
R260 - rail
R350HT - rail
R400HT - rail
R7 wheel
(R260 rail)
R7 wheel
(R350HT rail)
R7 wheel
(R400HT rail)
Wheel passes
Arealoss[mm²]
 Decreasing rail wear with increasing rail hardness
 Wheel wear stays on same level with increasing rail hardness
 Wear determined by contact size – contact size depends on the softer partner
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Wear: wheel contra rail
From: Steele, R.; Reiff, R.P.: „Rail – It‘s behaviour and relationship to total system wear“. Proceedings of the 2nd
Heavy Haul Conference, 1982, S115-164
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Steel Grades
Chemical Composition [% by mass] Mechanical Properties
C Si Mn Cr
Rm
[MPa]
A5
[%]
Hardnes
s [HBW]
Standard
Rail
Grades
R200 0,40 - 0,60 0,15 - 0,58 0,70 - 1,20 ≤ 0,15 ≥ 680 ≥ 14 200 - 240
R220 0,50 - 0,60 0,20 - 0,60 1,00 - 1,25 ≤ 0,15 ≥ 770 ≥ 12 220 - 260
R260 0,62 - 0,80 0,15 - 0,58 0,70 - 1,20 ≤ 0,15 ≥ 880 ≥ 10 260 - 300
R260Mn 0,55 - 0,75 0,15 - 0,60 1,30 - 1,70 ≤ 0,15 ≥ 880 ≥ 10 260 - 300
R320Cr 0,60 - 0,80 0,50 - 1,10 0,80 - 1,20 0,80 - 1,20 ≥ 1.080 ≥ 9 320 - 360
Heat
Treated
Rail
Grades
R350HT
(350HT
HSH®)
0,72 - 0,80 0,15 - 0,58 0,70 - 1,20 ≤ 0,15 ≥ 1.175 ≥ 9 350 - 390
R350LH
T
(350LHT
HSH®)
0,72 - 0,80 0,15 - 0,58 0,70 - 1,20 ≤ 0,30 ≥ 1.175 ≥ 9 350 - 390
R370CrH
T
(370LHT
HSH®)
0,70 - 0,82 0,40 - 1,00 0,70 - 1,10 0,40 - 0,60 ≥ 1.280 ≥ 9 370 - 410
R400HT
(400 UHC®)
0,90 - 1,05 0,20 - 0,60 1,00 - 1,30 ≤ 0,30 ≥ 1.280 ≥ 9 400 - 440
Rail Steel Grades EN 13674-1:2011
Vignol Rails
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 Purchase price
 Installation costs
 Inspection
 Maintenance
 Delays
 repair work
 Replacement
 Operating costs
 Availability
 Safety
“ What you see is not always what you get ”
Performance evaluation
Life Cycle Cost (LCC)
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