Microstructural defects, mechanical properties and bonding integrity of flash-butt welds in premium rail

The welding of heavy-haul train rails via the flash-butt welding process involves heating the rail ends to a suitable temperature with an electrical current, and then forging the rail ends together. The process is well established, however adequate strength can be difficult to achieve when welding newer high alloy rails. Experimental modelling of the forging process and the artificial reproduction of defects within test welds aided in developing theorems on how these defects form and welding procedure practices to avoid as a means of mitigating the presence of defects.