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Optimization of stress-relief heat treatment for overlay weld repair of severely used rail tracks: effects on residual stress, microstructure and wear resistance

  • Kumpanat Sirivedin

    Asst. Prof. Dr.-Ing Kumpanat Sirivedin, born in 1973, is an assistant professor in the Department of Materials and Production Engineering, The Sirindhorn International Thai-German Graduate School of Engineering, King Mongkut’s University of Technology North Bangkok, Bangkok, Thailand. He received his Doctor of Philosophy in Engineering (Dr.-Ing.) at the Institute of Forming and Cutting Manufacturing Technology, Technische Universität Dresden, Saxony, Germany. His expertise is in sheet metal forming and tools and dies design.

         , Man Tuiprae

    Asst. Prof. Man Tuiprae, born in 1971, is an assistant professor in the Department of Industrial Engineering, The School of Engineering, Rajamangala University of Technology Lanna, Ching Mai, Thailand. He received his Doctor of Philosophy (PhD) at the Department of Physics and Materials Science, Chiang Mai University, Thailand. His expertise is in surface, coating, characterization, and testing materials.

         , Narin Intawong

    Mr. Narin Intawong, born in 1978, is a company owner named Thung Thong Kwao Engineering Co., Ltd. He received his master’s degree in welding engineering of Production Engineering, from King Mongkut’s University of Technology Thonburi, Thailand. His expertise is in welding engineering for rail welding, thermite, flash butt weld joint, and rail welding maintenance.

         , Charadpong Paiyarad

    Mr. Charadpong Paiyarad, born in 1973, is a supervising Engineer, Heavy Maintenance Mechanical Division, Civil Engineering Department, State Railway of Thailand. He received his bachelor’s degree in Civil Engineering from Sripatum University, Thailand. His expertise is in rail infrastructure and railway maintenance.

         and Tanaporn Rojhirunsakool

    Asst. Prof. Dr. Tanaporn Rojhirunsakool, born in 1986, is an assistant professor in the Department of Materials and Production Technology Engineering, Faculty of Engineering, King Mongkut’s University of Technology North Bangkok, Bangkok, Thailand. She received her PhD in Materials Science at the University of North Texas, Denton, United States of America. Her expertise is in high-temperature materials and materials characterization.

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Published/Copyright: February 24, 2025
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Materials Testing
From the journal Materials Testing Volume 67 Issue 3

Abstract

This study investigates the optimization of stress-relief heat treatment for overlay weld repair of severely used rail tracks. The research focuses on 900A rail steel samples that have been in service for over 20 years, exhibiting significant wear and plastic deformation. Pre-welding heat treatments at 300 °C, 400 °C, and 500 °C were applied to reduce service-induced residual stresses before flux core arc welding (FCAW) repair using high-Mn filler material. The effects of these treatments on residual stress distribution, microstructure, hardness, and wear resistance were systematically analyzed. Scanning electron microscopy (SEM), X-ray residual stress analysis, microhardness testing, and pin-on-disc wear tests were employed to characterize the samples. Results indicate that stress relief at 300 °C and 400 °C effectively reduces residual stress while maintaining or enhancing hardness and wear resistance. However, treatment at 500 °C led to over-tempering, resulting in decreased hardness and increased wear rates. The 400 °C treatment emerged as the optimal temperature, providing a balanced combination of reduced residual stress, favorable microstructure, and improved mechanical properties across all welded zones.

Keywords: overlay welding; rail track repair; residual stress; stress relief heat treatment; wear resistance
Corresponding author: Tanaporn Rojhirunsakool, High Temperature Corrosion Research Centre, Department of Materials and Production Technology Engineering, Faculty of Engineering, King Mongkut’s University of Technology North Bangkok, Bangkok, Thailand, E-mail:

Funding source: Thailand Science Research and Innovation Fund and King Mongkut’s University of Technology North Bangkok

Award Identifier / Grant number: KMUTNB-MHESI-64-16.4.

About the authors

Kumpanat Sirivedin

Asst. Prof. Dr.-Ing Kumpanat Sirivedin, born in 1973, is an assistant professor in the Department of Materials and Production Engineering, The Sirindhorn International Thai-German Graduate School of Engineering, King Mongkut’s University of Technology North Bangkok, Bangkok, Thailand. He received his Doctor of Philosophy in Engineering (Dr.-Ing.) at the Institute of Forming and Cutting Manufacturing Technology, Technische Universität Dresden, Saxony, Germany. His expertise is in sheet metal forming and tools and dies design.

Man Tuiprae

Asst. Prof. Man Tuiprae, born in 1971, is an assistant professor in the Department of Industrial Engineering, The School of Engineering, Rajamangala University of Technology Lanna, Ching Mai, Thailand. He received his Doctor of Philosophy (PhD) at the Department of Physics and Materials Science, Chiang Mai University, Thailand. His expertise is in surface, coating, characterization, and testing materials.

Narin Intawong

Mr. Narin Intawong, born in 1978, is a company owner named Thung Thong Kwao Engineering Co., Ltd. He received his master’s degree in welding engineering of Production Engineering, from King Mongkut’s University of Technology Thonburi, Thailand. His expertise is in welding engineering for rail welding, thermite, flash butt weld joint, and rail welding maintenance.

Charadpong Paiyarad

Mr. Charadpong Paiyarad, born in 1973, is a supervising Engineer, Heavy Maintenance Mechanical Division, Civil Engineering Department, State Railway of Thailand. He received his bachelor’s degree in Civil Engineering from Sripatum University, Thailand. His expertise is in rail infrastructure and railway maintenance.

Tanaporn Rojhirunsakool

Asst. Prof. Dr. Tanaporn Rojhirunsakool, born in 1986, is an assistant professor in the Department of Materials and Production Technology Engineering, Faculty of Engineering, King Mongkut’s University of Technology North Bangkok, Bangkok, Thailand. She received her PhD in Materials Science at the University of North Texas, Denton, United States of America. Her expertise is in high-temperature materials and materials characterization.

  1. Research ethics: Not applicable.

  2. Informed consent: Informed consent was obtained from all individuals included in this study, or their legal guardians or wards.

  3. Author contributions: The authors have accepted responsibility for the entire content of this manuscript and approved its submission. Kumpanat Sirivedin: conceived of the presented idea, designed the study, carried out the experiments. Man Tuiprae: conceived of the presented idea, designed the study, carried out the experiments. Narin Intawong: designed the study, carried out the experiments. Charadpong Paiyarad: supervised the findings of this work. Tanaporn Rojhirunsakool: conceived of the presented idea, designed the study, carried out the experiments, wrote the manuscript with input from all authors.

  4. Use of Large Language Models, AI and Machine Learning Tools: Use of ChatGPT and Claude to improve language, grammar, and style of writing.

  5. Conflict of interest: The authors state no conflict of interest.

  6. Research funding: This research was funded by Thailand Science Research and Innovation Fund, and King Mongkut’s University of Technology North Bangkok with Contract no. KMUTNB-MHESI-64-16.4.

  7. Data availability: Not applicable.

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Published Online: 2025-02-24
Published in Print: 2025-03-26

© 2025 Walter de Gruyter GmbH, Berlin/Boston

Articles in the same Issue

  1. Frontmatter
  2. Influence of heat input and heat exchange coefficient on temperature and stress field of a X80 steel pipeline repair-weld root pass of a type-B sleeve
  3. Optimization of stress-relief heat treatment for overlay weld repair of severely used rail tracks: effects on residual stress, microstructure and wear resistance
  4. Investigation on the axial distribution of micron inclusions and their influence on mechanical properties in a wind power spindle
  5. Influence of aerogel powder on the mechanical and stability properties of photocurable resin composites produced by stereolithography (SLA)
  6. Effect of sandblasting and aging on structural and mechanical properties of Inconel 625 coated steels for marine applications
  7. Mechanical characterization of sandwich composite structures with Alumix231 foam core between Al2024/B4C composite plates
  8. Optimization of alkali modified breadfruit peel flour-LDPE composite for car mirror casings
  9. Influence of seawater condition on shear strength of CFRP single lap bonded joints with various fiber orientation
  10. Comparative analysis of cutting methods and their impact on fatigue properties of armor steel
  11. Effect of pore structure, mechanical performance, and operational temperature on damping behavior of thermal expandible rubber-based adhesives
  12. Structural and electrical properties of CuO-doped NaNbO3 ceramics
  13. Friction and wear behavior of alkali-treated corn husk fiber reinforced polyester composites
  14. Performance of high strength natural fiber reinforced hybrid composites for structural engineering applications
  15. Fabrication and wear performance of M7C3 carbide reinforced epoxy composites
  16. Mosaic ceramic surface defect detection enhancement algorithm based on guided filter and multi-scale fusion
https://doi.org/10.1515/mt-2024-0384
Keywords for this article
overlay welding; rail track repair; residual stress; stress relief heat treatment; wear resistance

Articles in the same Issue

  1. Frontmatter
  2. Influence of heat input and heat exchange coefficient on temperature and stress field of a X80 steel pipeline repair-weld root pass of a type-B sleeve
  3. Optimization of stress-relief heat treatment for overlay weld repair of severely used rail tracks: effects on residual stress, microstructure and wear resistance
  4. Investigation on the axial distribution of micron inclusions and their influence on mechanical properties in a wind power spindle
  5. Influence of aerogel powder on the mechanical and stability properties of photocurable resin composites produced by stereolithography (SLA)
  6. Effect of sandblasting and aging on structural and mechanical properties of Inconel 625 coated steels for marine applications
  7. Mechanical characterization of sandwich composite structures with Alumix231 foam core between Al2024/B4C composite plates
  8. Optimization of alkali modified breadfruit peel flour-LDPE composite for car mirror casings
  9. Influence of seawater condition on shear strength of CFRP single lap bonded joints with various fiber orientation
  10. Comparative analysis of cutting methods and their impact on fatigue properties of armor steel
  11. Effect of pore structure, mechanical performance, and operational temperature on damping behavior of thermal expandible rubber-based adhesives
  12. Structural and electrical properties of CuO-doped NaNbO3 ceramics
  13. Friction and wear behavior of alkali-treated corn husk fiber reinforced polyester composites
  14. Performance of high strength natural fiber reinforced hybrid composites for structural engineering applications
  15. Fabrication and wear performance of M7C3 carbide reinforced epoxy composites
  16. Mosaic ceramic surface defect detection enhancement algorithm based on guided filter and multi-scale fusion
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