Patent Publication Number: US-11655514-B2

Title: Deeply-hardened-surface turnout rail with high degree of undercooling and the preparation method thereof

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority from CN 202011164327.4, filed Oct. 27, 2020, the contents of which are incorporated herein by reference in their entireties. 
     FIELD OF INVENTION 
     The invention relates to a turnout rail production technology, in particular to a deeply-hardened-surface turnout rail with high degree of undercooling and the preparation method thereof. 
     BACKGROUND OF THE INVENTION 
     Turnouts are the key components and core hubs for railway track connection and train guiding, which must be comprehensively updated and upgraded in a new railway operation environment characterized by high speed and heavy load. One of the prime tasks is to develop the rails, the key base material, for manufacturing turnouts. 
     The quality of turnouts of high-speed railways is essential to train operation speed and safety. For the moment, prominent problems exist in turnout production: insufficient transition between switch rails and nose rails, excessive displacement and high transition resistance. Great efforts must be put into the research and development of turnout rails to meet the urgent demand for high-speed turnout rails as a result of the development of high-speed railways in China. 
     Due to the extremely unfavorable operational conditions for turnouts as a result of heavy axle loads, high traffic density and heavy traffic flows of heavy-loaded railways, the turnouts of heavy-loaded railways are worn and damaged much faster and more severe than those of the same type used for ordinary railways, which must be replaced frequently. The frequent replacement of turnouts not only increase the maintenance workload and cost of railway administrations, but also create potential risks for operation safety. In addition to manufacturing processes, the operation performance of turnouts mainly depends on the performance of turnout rails. Currently, either at home or abroad, the turnouts of heavy-loaded railways are mostly hot-rolled supplied in an air-cooled state, which are cut, milled and heat-treated at turnout factories. 
     With the adoption of the secondary-heating off-line heat treatment process, the rail head surface layer is hardened rather shallow, and, with the increment in depth, the hardness is reduced faster. In operation, pre-mature wearing and defects due to contact fatigue can occur easily; meanwhile, bending is a common phenomenon during the heat treatment on turnout rails, leading to less guaranteed straightness along the full length of rail; moreover, this process also significantly increases energy consumption, reduces the efficiency in turnout production and produces environmental pollution. As a result, it has become an urgent demand to research and develop a high-performance turnout rail which is featured in higher ductility, longer service life, environmental protection and energy conservation. 
     Turnout rails, especially switch rails, are often machined into extremely thin points at the end of a transfer track. To guarantee safety and durability of turnout rails, the surface layer is usually hardened to a required depth and gradient. Therefore, the ordinary carbon steel turnout rails produced by adopting the existing process can hardly meet the demand for developing heavy-loaded railways at home and abroad, and a deeply-hardened-surface turnout rail with high degree of undercooling and a preparation method are urgently needed. 
     BRIEF SUMMARY OF THE INVENTION 
     The invention aims to solve the technical problem by providing a deeply-hardened-surface turnout rail with high degree of undercooling featured in even hardness distribution and a deeply hardened surface layer and the preparation method thereof. 
     The invention provides a method for preparing a deeply-hardened-surface turnout rail with high degree of undercooling in the technical solution formulated to solve the above problems. The method comprises the following steps: 
     Feeding molten iron for converter smelting→furnace rear argon blowing station→LF (Ladle Furnace) refining→RH (Ruhrstahl-Heraeus) vacuumization→casting steel blanks→slow cooling in the slow cooling pit→austenitic homogenization→rail rolling→heat treatment; in the converter smelting process, adding 0.2-0.3% Cr, 0.04-0.06 V and 0.75-0.80% C; the heat treatment process is divided into two cooling stages. 
     Wherein, according to the method for preparing a deeply-hardened-surface turnout rail with high degree of undercooling, the temperature for austenitic homogenization is 1,000° C.-1,300° C. and the duration is 200-500 minutes. 
     Further, the total deformation during rolling is 85-95%. 
     Further, the heat treatment process includes the step of treating the rolled rail in the heat treatment unit with the residual heat; the temperature when feeding into the heat treatment unit is 800-850° C. 
     Further, the heat treatment process lasts for 110 seconds; for the first 80 seconds after the rolled rail is fed into the heat treatment unit, the rolled rail is cooled at a speed of 3-5° C./s; for the last 30 seconds, the rolled rail is cooled at a speed of 0.5-2° C./s. 
     Further, the medium used for cooling in the heat treatment process is compressed air or a mixture of water and air; if the cooling medium is a mixture of air and water, the air-to-water compression ratio is ≤1:3. 
     Further, after heat treatment, the rail is naturally cooled down to a temperature below 100° C. and then straightened by vertical and horizontal straightening machines. 
     The invention also provides a deeply-hardened-surface turnout rail with high degree of undercooling prepared with said method. 
     Further, the chemical components (by weight percentage) of the deeply-hardened-surface turnout rail with high degree of undercooling are as follows: C0.75-0.80%, Si0.1-0.6%, Mn0.6-1.3%, P≤0.020%, S≤0.020%, Cr0.2-0.3%, V0.04-0.06%; the rest include Fe and unavoidable impurities. 
     The beneficial effects of the invention are: 
     In the invention, 0.2-0.3% Cr and 0.75-0.80% C are added into the smelting process to improve rail hardenability; 0.04-0.06% V is added into the process to evenly distribute rail hardness, resulting in higher anti-contact fatigue performance and better wearing performance. In addition, two-stage cooling is adopted in the invention to not only increase the degree of under cooling of turnout rails, but also significantly improve the deeply hardened surface layer. The turnout rail prepared with the method described in the invention meets HBW2-0.6*HBW3-0.4*HBW1&gt;0, at the same time, the hardness difference between any two points at the three positions—HBW1, HBW2 and HBW3 is not more than 30 HBW, and the difference between surface hardness and the hardness measured at 30 mm below the surface layer ≤5HRC; compared with the ordinary rolled carbon steel heat-treated turnout rails, it has a deeper deeply-hardened surface layer; the hardness is distributed more evenly, the anti-contact fatigue performance is higher and the resistance to wearing is ideal. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will be described in conjunction with the following drawings, wherein: 
         FIG.  1    shows the locations for hardness inspection of turnout rail section in embodiments and the comparative examples. 
         FIG.  2    shows the marks for the locations for hardness inspection of turnout rail section in embodiments and comparative examples. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     In details, the invention provides a method for preparing a deeply-hardened-surface turnout rail with high degree of undercooling. The method comprises the following steps: 
     Feeding molten iron for converter smelting→furnace rear argon blowing station→LF refining→RH vacuumization→casting steel blanks→slow cooling in the slow cooling pit→austenitic homogenization→rail rolling→heat treatment; in the converter smelting process, adding 0.2-0.3% Cr, 0.04-0.06 V and 0.75-0.80% C; the heat treatment process is divided into two cooling stages. 
     In the present invention, 0.75-0.80% C, 0.2-0.3% Cr and 0.04-0.06% V are added in the smelting process. Wherein, C and Cr are added to move the C curve rightwards and thus improve hardenability of the turnout rail. V is mainly for precipitation hardening so that the hardness is distributed more evenly at the rail head, the anti-contact fatigue performance is better and the resistance to wearing is ideal. 
     In the invention, the temperature for austenitic homogenization is 1,000° C.-1,300° C. and the duration is 200-500 minutes. The purpose is to allow large and uniform original austenitic grain size, promote homogenization of components and guarantee evenness and controllability of the pearlite structure after rail rolling and heat treatment. 
     In the invention, the heat treatment process includes two-stage cooling: the entire heat treatment process takes 110 seconds. 
     Stage 1 (pre-phase change): due to a unit weight greater than 60 kg/m, the rail web of a turnout rail is about twice that of an ordinary symmetric rail. As a result, the rolled turnout rail has a high heat capacity, with the rail surface temperature as high as 900-1,000° C. High finishing rolling temperature results in that the degree of undercooling cannot be further increased and the heat at the center of rail head cannot be dissipated in the follow-up heat treatment process. 
     Therefore, in stage 1, forced cooling is conducted on the rolled turnout rail. That is, for the first 80 seconds after the rolled rail is fed into the heat treatment unit, cooling is performed at a speed of 3-5° C./s, with the purpose of increase the degree of undercooling, reduce heat capacity at the center of the rail, increase the phase change drive force at the center and improve center hardness. When cooling in stage 1 is too slow, the ideal cooling effect cannot be achieved; when cooling is too fast, the rail surface is cooled too fast while the center cannot be cooled fast enough due to the high heat capacity, there will be significant transition in hardness gradient of the rail, and the expected even transition of hardness gradient cannot be achieved. 
     In stage 2, i.e. the last 30 seconds, cooling is performed at a speed of 0.5-2° C./s, both the surface and the center of the turnout rail are beyond the phase change point, in which case the cooling speed can be reduced accordingly for further dissipation of heat at the center. 
     The invention not only increases the degree of under cooling of turnout rails, but also significantly improves the deeply hardened surface layer. The prepared turnout rail shows significant improvement in wearing performance and anti-contact fatigue performance. 
     The following embodiments are provided to further illustrate the invention. 
     
       
         
           
               
             
               
                 TABLE 1 
               
             
            
               
                   
               
               
                 Chemical components (%) of the turnout rails in embodiments and 
               
               
                 comparative examples 
               
            
           
           
               
               
            
               
                   
                 Chemical elements (%) 
               
            
           
           
               
               
               
               
               
               
               
               
            
               
                 Item 
                 C 
                 Si 
                 Mn 
                 P 
                 S 
                 Cr 
                 V 
               
               
                   
               
               
                 Embodiment 1 
                 0.75 
                 0.10 
                 0.62 
                 0.010 
                 0.010 
                 0.21 
                 0.04 
               
               
                 Embodiment 2 
                 0.76 
                 0.15 
                 0.68 
                 0.011 
                 0.006 
                 0.22 
                 0.04 
               
               
                 Embodiment 3 
                 0.76 
                 0.20 
                 0.76 
                 0.013 
                 0.005 
                 0.22 
                 0.04 
               
               
                 Embodiment 4 
                 0.77 
                 0.27 
                 0.84 
                 0.014 
                 0.007 
                 0.23 
                 0.04 
               
               
                 Embodiment 5 
                 0.79 
                 0.32 
                 0.92 
                 0.015 
                 0.008 
                 0.23 
                 0.05 
               
               
                 Embodiment 6 
                 0.78 
                 0.37 
                 1.01 
                 0.015 
                 0.011 
                 0.23 
                 0.05 
               
               
                 Embodiment 7 
                 0.79 
                 0.42 
                 1.10 
                 0.013 
                 0.013 
                 0.24 
                 0.06 
               
               
                 Embodiment 8 
                 0.80 
                 0.53 
                 1.20 
                 0.012 
                 0.015 
                 0.24 
                 0.06 
               
               
                 Embodiment 9 
                 0.80 
                 0.59 
                 1.29 
                 0.011 
                 0.011 
                 0.25 
                 0.06 
               
               
                 Comparative 
                 0.70 
                 0.65 
                 0.55 
                 0.010 
                 0.010 
                 0.05 
                 0.03 
               
               
                 example 1 
                   
                   
                   
                   
                   
                   
                   
               
               
                 Comparative 
                 0.77 
                 0.34 
                 1.01 
                 0.015 
                 0.009 
                 0.23 
                 0.03 
               
               
                 example 2 
                   
                   
                   
                   
                   
                   
                   
               
               
                 Comparative 
                 0.78 
                 0.33 
                 1.02 
                 0.016 
                 0.008 
                 0.24 
                 0.07 
               
               
                 example 3 
                   
                   
                   
                   
                   
                   
                   
               
               
                 Comparative 
                 0.79 
                 0.35 
                 1.03 
                 0.014 
                 0.007 
                 0.25 
                 0.07 
               
               
                 example 4 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 2 
               
             
            
               
                   
               
               
                 Treatment processes and structures in  
               
               
                 embodiments and comparative examples 
               
            
           
           
               
               
               
               
            
               
                   
                 Cooling speed  
                 Cooling speed 
                   
               
               
                   
                 in stage 1 
                 in stage 2 
                   
               
               
                 Item 
                 (° C./s) 
                 (° C./s) 
                 Structure 
               
               
                   
               
            
           
           
               
               
               
               
            
               
                 Embodiment 1 
                 3 
                 0.5 
                 P 
               
               
                 Embodiment 2 
                 3 
                 0.5 
                 P 
               
               
                 Embodiment 3 
                 3 
                 0.5 
                 P 
               
               
                 Embodiment 4 
                 4 
                 1 
                 P 
               
               
                 Embodiment 5 
                 4 
                 1 
                 P 
               
               
                 Embodiment 6 
                 4 
                 1 
                 P 
               
               
                 Embodiment 7 
                 5 
                 2 
                 P 
               
               
                 Embodiment 8 
                 5 
                 2 
                 P 
               
               
                 Embodiment 9 
                 5 
                 2 
                 P 
               
               
                 Comparative 
                 0 
                 0 
                 P 
               
               
                 example 1 
                   
                   
                   
               
               
                 Comparative 
                 2 
                 0.3 
                 P 
               
               
                 example 2 
                   
                   
                   
               
               
                 Comparative 
                 2.5 
                 0.3 
                 P 
               
               
                 example 3 
                   
                   
                   
               
               
                 Comparative 
                 6 
                 3 
                 M 
               
               
                 example 4 
               
               
                   
               
            
           
         
       
     
     The rest process parameters are the same for embodiments and comparative examples. 
     Samples are taken from rail sections for hardness testing as shown in the drawings. See table 3 for details. 
     
       
         
           
               
             
               
                 TABLE 3 
               
             
            
               
                   
               
               
                 Hardness inspection in embodiments and comparative examples 
               
            
           
           
               
               
            
               
                   
                 Section hardness (HBW 2.5/187.5) 
               
            
           
           
               
               
               
               
               
               
               
               
               
               
               
               
               
               
            
               
                   
                   
                   
                   
                   
                   
                   
                   
                   
                 HBW 
                 HBW 
                 HBW 
                   
                 Formula 
               
               
                 Item 
                 A1 
                 A3 
                 B1 
                 B2 
                 C1 
                 C2 
                 D1 
                 E1 
                 1 
                 2 
                 3 
                 Range 
                 Result 
               
               
                   
               
            
           
           
               
               
               
               
               
               
               
               
               
               
               
               
               
               
            
               
                 Embodiment 
                 321 
                 316 
                 318 
                 315 
                 319 
                 320 
                 319 
                 319 
                 319.3 
                 317.5 
                 316.0 
                 6 
                 0.17 
               
               
                 1 
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 Embodiment 
                 322 
                 317 
                 319 
                 319 
                 319 
                 320 
                 320 
                 320 
                 320.0 
                 319.5 
                 317.0 
                 5 
                 1.30 
               
               
                 2 
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 Embodiment 
                 325 
                 320 
                 322 
                 321 
                 322 
                 322 
                 323 
                 323 
                 323.0 
                 321.5 
                 320.0 
                 5 
                 0.30 
               
               
                 3 
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 Embodiment 
                 351 
                 353 
                 351 
                 354 
                 350 
                 353 
                 348 
                 350 
                 350.7 
                 353.5 
                 353.0 
                 4 
                 1.43 
               
               
                 4 
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 Embodiment 
                 353 
                 355 
                 355 
                 356 
                 352 
                 355 
                 351 
                 353 
                 353.3 
                 355.5 
                 355.0 
                 4 
                 1.17 
               
               
                 5 
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 Embodiment 
                 355 
                 356 
                 356 
                 356 
                 353 
                 356 
                 352 
                 355 
                 354.7 
                 356.0 
                 356.0 
                 3 
                 0.53 
               
               
                 6 
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 Embodiment 
                 362 
                 363 
                 363 
                 364 
                 363 
                 363 
                 360 
                 368 
                 362.7 
                 363.5 
                 363.0 
                 2 
                 0.63 
               
               
                 7 
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 Embodiment 
                 365 
                 365 
                 365 
                 364 
                 365 
                 367 
                 362 
                 360 
                 365.0 
                 365.5 
                 365.0 
                 3 
                 0.50 
               
               
                 8 
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 Embodiment 
                 367 
                 368 
                 364 
                 366 
                 364 
                 368 
                 364 
                 363 
                 365.0 
                 367.0 
                 368.0 
                 4 
                 0.20 
               
               
                 9 
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 Comparative 
                 315 
                 316 
                 314 
                 313 
                 312 
                 313 
                 310 
                 310 
                 313.7 
                 313.0 
                 316.0 
                 6 
                 −2.07 
               
               
                 example 1 
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 Comparative 
                 325 
                 314 
                 322 
                 314 
                 326 
                 303 
                 322 
                 323 
                 324.3 
                 308.5 
                 314.0 
                 23 
                 −9.63 
               
               
                 example 2 
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 Comparative 
                 336 
                 326 
                 333 
                 315 
                 334 
                 334 
                 333 
                 334 
                 334.3 
                 324.5 
                 326.0 
                 21 
                 −4.83 
               
               
                 example 3 
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 Comparative 
                 374 
                 357 
                 374 
                 343 
                 375 
                 375 
                 374 
                 374 
                 374.3 
                 359.0 
                 357.0 
                 32 
                 −4.93 
               
               
                 example 4 
               
               
                   
               
            
           
         
       
     
     Table 3 shows that all embodiments meet HBW2-0.6*HBW3-0.4*HBW1&gt;0, indicating that the hardness of the rail prepared with the method in the invention decreases uniformly from the surface to the center, and the hardness is greater at the depth. 
     Samples are respectively taken from the rail heads for wearing testing in embodiments and comparative examples. The results are given in table 4. 
     
       
         
           
               
             
               
                 TABLE 4 
               
             
            
               
                   
               
               
                 Rail head wearing in embodiments and comparative  
               
               
                 examples in the invention 
               
            
           
           
               
               
               
            
               
                   
                 Test parameters 
                   
               
            
           
           
               
               
               
               
            
               
                   
                   
                 Number of rotation 
                 Wearing  
               
               
                 Item 
                 Load (N) 
                 (ten-thousand times) 
                 loss (g) 
               
               
                   
               
            
           
           
               
               
               
               
            
               
                 Embodiment 1 
                 980 
                 10 
                 0.27 
               
               
                 Embodiment 2 
                 980 
                 10 
                 0.29 
               
               
                 Embodiment 3 
                 980 
                 10 
                 0.28 
               
               
                 Embodiment 4 
                 980 
                 10 
                 0.25 
               
               
                 Embodiment 5 
                 980 
                 10 
                 0.23 
               
               
                 Embodiment 6 
                 980 
                 10 
                 0.22 
               
               
                 Embodiment 7 
                 980 
                 10 
                 0.21 
               
               
                 Embodiment 8 
                 980 
                 10 
                 0.20 
               
               
                 Embodiment 9 
                 980 
                 10 
                 0.19 
               
               
                 Comparative 
                 980 
                 10 
                 0.42 
               
               
                 example 1 
                   
                   
                   
               
               
                 Comparative 
                 980 
                 10 
                 0.38 
               
               
                 example 2 
                   
                   
                   
               
               
                 Comparative 
                 980 
                 10 
                 0.32 
               
               
                 example 3 
                   
                   
                   
               
               
                 Comparative 
                 980 
                 10 
                 0.22 
               
               
                 example 4 
               
               
                   
               
            
           
         
       
     
     Samples are respectively taken from the rail heads for contact fatigue testing in embodiments and comparative examples. The results are given in table 5. 
     
       
         
           
               
             
               
                 TABLE 5 
               
             
            
               
                   
               
               
                 Contact fatigue of the rails in embodiments and  
               
               
                 comparative examples in the invention 
               
            
           
           
               
               
               
               
               
            
               
                   
                   
                   
                 Rotation 
                 Contact fatigue/ 
               
               
                   
                 Contact  
                 Slip 
                 speed 
                 ten-thousand 
               
               
                 Item 
                 stress/MPa 
                 frequency/% 
                 rpm 
                 times 
               
               
                   
               
            
           
           
               
               
               
               
               
            
               
                 Embodiment 1 
                 1,350 
                 5 
                 1,000 
                 25 
               
               
                 Embodiment 2 
                 1,350 
                 5 
                 1,000 
                 26 
               
               
                 Embodiment 3 
                 1,350 
                 5 
                 1,000 
                 27 
               
               
                 Embodiment 4 
                 1,350 
                 5 
                 1,000 
                 42 
               
               
                 Embodiment 5 
                 1,350 
                 5 
                 1,000 
                 43 
               
               
                 Embodiment 6 
                 1,350 
                 5 
                 1,000 
                 44 
               
               
                 Embodiment 7 
                 1,350 
                 5 
                 1,000 
                 45 
               
               
                 Embodiment 8 
                 1,350 
                 5 
                 1,000 
                 46 
               
               
                 Embodiment 9 
                 1,350 
                 5 
                 1,000 
                 47 
               
               
                 Comparative  
                 1,350 
                 5 
                 1,000 
                 20 
               
               
                 example 1 
                   
                   
                   
                   
               
               
                 Comparative 
                 1,350 
                 5 
                 1,000 
                 21 
               
               
                 example 2 
                   
                   
                   
                   
               
               
                 Comparative 
                 1,350 
                 5 
                 1,000 
                 22 
               
               
                 example 3 
                   
                   
                   
                   
               
               
                 Comparative 
                 1,350 
                 5 
                 1,000 
                 23 
               
               
                 example 4 
               
               
                   
               
            
           
         
       
     
     According to above results, the method described in the invention can effectively increase the hardness of the deeply hardened surface layer and significantly improve the wearing performance and anti-contact fatigue performance of the rail. The turnout rail prepared with the method in the invention applies to heavy-loaded railways and high-speed railways with heavy axle loads and high density.