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TABLE OF CONTENTS Summary ......................................................................................................................................... 1 Chapter 1: Introduction .................................................................................................................. 4 Chapter 2: Analysis of Rail Corrosion........................................................................................... 5 2.1 Definition .......................................................................................................... 5 2.2 Corrosion Principles.......................................................................................... 6 Chapter 3: Microstructural Analysis.............................................................................................. 9 3.1 Rail Used in Transit Service ............................................................................. 9 3.2 Description of Test Samples ............................................................................. 9 3.3 Nondestructive Evaluation.............................................................................. 12 3.4 Metallurgical Analysis of Rails ...................................................................... 14 3.4.1 100- and 115-lb Rail ........................................................................... 14 3.4.2 136-lb Rail .......................................................................................... 15 Chapter 4: Numerical Simulations............................................................................................... 17 4.1 Finite Element Analysis Simulations.............................................................. 17 4.1.1 Two Approaches for Dimensions and Size Determination................. 19 4.1.2 Finite Element Analysis 115-lb Rail................................................... 21 4.1.3 Finite Element Analysis 136-lb Rail................................................... 22 4.1.4 Conclusions of the Finite Element Analysis....................................... 23 4.2 High Cycle Fatigue Analysis .......................................................................... 24 4.2.1 Load/Stress Environment.................................................................... 24 4.2.2 Rail Material Properties ...................................................................... 25 4.2.3 Fatigue Analysis Parameters............................................................... 25 4.2.4 Results of the High Cycle Fatigue Analysis ....................................... 25 Chapter 5: Corrosion Prevention Methods .................................................................................. 27 5.1 Presence of Salts on the Tracks ...................................................................... 27 5.2 Analysis of Ballast .......................................................................................... 29 5.3 Rail Steels ....................................................................................................... 30 5.4 Cathodic Protection......................................................................................... 31 5.5 Sacrifice Anodes............................................................................................. 31 5.6 Recommendations for Rail Corrosion Protection ........................................... 32
Chapter 6: Potential for Rail Base Flaw Detection...................................................................... 34 6.1 Available Technologies for Rail Base Flaw Detection................................... 34 6.2 Current Technologies and Examples of Nondestructive Techniques with Potential for Implementation .......................................................................... 35 6.2.1 Visual Inspection ................................................................................ 35 6.2.2 Ultrasonic Inspection .......................................................................... 36 6.2.3 Radiographic Inspection ..................................................................... 36 6.2.4 Eddy Current Inspection ..................................................................... 37 6.2.5 Electromagnetic Acoustic Transducer ................................................ 37 6.2.6 Thermographic Inspection .................................................................. 37 6.2.7 Ground Penetrating Radar................................................................... 37 Chapter 7: Draft Guidelines for Controlling and Detecting Rail Base Corrosion ....................... 38 7.1 Corrosion Prevention ...................................................................................... 38 7.1.1 Effect of Direct Current on Corrosion ................................................ 40 7.1.2 Effect of Improper Drainage on Corrosion......................................... 40 7.2 Corrosion Detection ........................................................................................ 41 Chapter 8: Future Research..........................................................................................................43 References............................................................................................ ........................................ 46 Appendix A................................................................................................................................. A-1 Appendix B ................................................................................................................................. B-1 Appendix C ................................................................................................................................. C-1 Appendix D................................................................................................................................. D-1 Appendix E ..................................................................................................................................E-1 Appendix F...................................................................................................................................F-1