Development of Temperature-Controlled Shear Tests to Reproduce White-Etching-Layer Formation in Pearlitic Rail Steel

The formation of a white etching layer (WEL), a very hard and brittle phase on the rail surface, is associated with a progressive transformation of the pearlitic grain to very fragmented grains due to the cumulative passage of trains. Its formation is associated with a complex thermomechanical coupling. To predict the exact conditions of WEL formation, a thermomechanical model previously proposed by the authors needs to be validated. In this study, monotonic and cyclic shear tests using hat-shaped specimens were conducted in the temperature range of 20 C to 400 C to reproduce the WEL formation. The tests showed a strong sensitivity of the material to temperature, which does not necessarily favor WEL formation. For the monotonic tests, no WELs were produced; however, a localization of the plastic deformation was observed for tests performed at 200 C and 300 C. In this temperature range, the material was less ductile than at room temperature, leading to failure before WEL formation. At 400 C, the material exhibited a much more ductile behavior, and nanograins close to WEL stages were visible. For the cyclic tests, a WEL zone was successfully reproduced at room temperature only and confirmed the effect of shear in WEL formation. The same cyclic tests conducted at 200 C and 300 C yielded results consistent with those of the monotonic tests; the deformation was much more localized and did not lead to WEL formation.This work is part of the multi-disciplinary project MOPHAB, which aims to improve our knowledge and understanding of the mechanisms leading to the formation of the white etching layer in the materials used to construct railways and to develop corresponding numerical models. This project was supported by IRT Railenium and other industrial partners (RATP: Régie Autonome des Transports Parisiens, France, SNCF: Société Nationale des Chemins de Fer Francais, France, SAARSTAHL rail)