Fracture in Switch Rail: Investigating R260 Steel

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Discussion Overview

The discussion revolves around the investigation of a fracture in a switch rail made of R260 steel. Participants are exploring potential causes of the crack and its subsequent growth, considering factors such as environmental conditions and material properties.

Discussion Character

  • Exploratory
  • Technical explanation
  • Debate/contested

Main Points Raised

  • One participant suggests that the fracture appears to be due to stress corrosion cracking rather than fatigue cracking, noting the rust patterns on the cracked surface.
  • Another participant points out that the rail has been outdoors for about a month, which may have contributed to the rust and the crack formation.
  • A hypothesis is proposed that the original material may have been nonhomogeneous, potentially leading to the crack's development.
  • Concerns are raised about the internal stresses in the rail, with one participant suggesting that the rail may be unsuitable for use and should be scrapped to avoid safety risks.
  • It is noted that while the rail was in use, compressive stresses may have prevented stress corrosion cracking, but the removal of ties may have created conditions conducive to accelerated cracking.
  • Another participant emphasizes that the type of crack requires both a corrosive environment and tensile stress, suggesting that the fasteners previously counteracted tensile stress, which may have changed after their removal.
  • Environmental conditions, such as humidity, are mentioned as factors that may have influenced the fracture, particularly since the fracture occurred on a slide chair.

Areas of Agreement / Disagreement

Participants express multiple competing views regarding the causes of the crack and its growth, with no consensus reached on a singular explanation.

Contextual Notes

Participants note the importance of considering the material's homogeneity and the environmental conditions, but the discussion remains open-ended regarding the specific mechanisms leading to the fracture.

sadegh2020
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TL;DR
Fracture in a switch rail
Hello everybody
We saw a fracture in a switch rail, now we're trying to find the reason, may be you can help us.
This rail is made of R260 steel.
Let me know if any other information is needed.
I have attached pictures of this rail.
Thanks in advance
 

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From the cracked surface, it looks like stress corrosion cracking, not a fatigue cracking. Nearly whole cross-section is rusted, and rust forms an irregular stripes, while for fatigue cracking you do expect at least 1/3 of cross section to be fresh, and fresh area to be continuous.
 
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Thanks for your answer.
Yesterday I captured some clear photos of cracks.
Actually it is obvious that there was a crack at the location of the fracture.
I have to add that the rail is at the outdoor environment for about a month and the rust can be from this.
Now, we should discuss 1-What caused the crack?
2- What caused the crack to grow and finally the fracture?
 

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sadegh2020 said:
Now, we should discuss 1-What caused the crack?
2- What caused the crack to grow and finally the fracture?
I hazard a guess that the original material was nonhomogeneous (either alloy-wise or crystallographic-wise) before it was even formed into a rail.
 
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This is a switch point rail and was used for about ten years without any problem. Now it is transferred to our company for repairment but after a month being at the outdoor, before repairing the fracture occurred.
 
sadegh2020 said:
but after a month being at the outdoor, before repairing the fracture occurred.
Ahh! Very high internal stresses. Sounds like its proper place is the scrap heap... cheaper than a derailment. :eek:
 
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Tom.G said:
Ahh! Very high internal stresses. Sounds like its proper place is the scrap heap... cheaper than a derailment. :eek:
Seems the stress at defective section was compressive while rail was used, therefore stress corrosion cracking did not develop. After the ties were removed, the conditions became favorable for accelerated cracking.
 
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trurle said:
Seems the stress at defective section was compressive while rail was used, therefore stress corrosion cracking did not develop. After the ties were removed, the conditions became favorable for accelerated cracking.

May you explain more :wink:
 
Tom.G said:
Ahh! Very high internal stresses. Sounds like its proper place is the scrap heap... cheaper than a derailment. :eek:
Okay what do you guess about the reason of cracking?
 
  • #10
sadegh2020 said:
May you explain more :wink:
This type of crack require both corrosive environment and tensile stress. While tied down on switch, tensile stress caused by metalurgical inclusion was likely counteracted by fasteners connecting rail to ties. After fasteners were removed, the cracking have accelerated.
 
Last edited:
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  • #11
What He Said.png
 
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  • #12
trurle said:
This type of crack require both corrosive environment and tensile stress. While tied down on switch, tensile stress caused by metalurgical inclusion was likely counteracted by fasteners connecting rail to ties. After fasteners were removed, the cracking have accelerated.
Our environment is somehow humid and the part that fracture occurred there was on a slide chair
 

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