Repair or Replace? Troubleshooting Common Issues with Railway Parts
When railway parts break or fail, it can be costly. Some part failures can be attributed to manufacturing defects, but many are due to excessive wear and tear over time.
No matter the case, identifying common issues with railway parts is essential to ensuring safe, smooth rail operations. After identifying the problem, you can determine the severity to decide if it can be fixed or if a complete part replacement is necessary.
To help you identify them, here are several common railway part issues, their causes, and general recommendations for repairing versus replacing.
Fractures or breaks
A common issue in railway parts is complete fractures or breaks. These usually result from manufacturing defects or the rails being used for a purpose over their max rating. In manufacturing defects, the defect itself may appear small, but the part fails when used or with excessive loads.
To avoid this, ensure that you check the use ratings for your rail components and that you buy from a manufacturer with a reputation for quality and reliability.
Corrugation
Corrugation adds what looks like waves or corrugated cardboard engraved into the top of the railheads. The lengths of these corrugations are usually two to three inches long but can be as much as 10-12 inches in heavy freight lines.
This rail issue is caused by uneven rail wear. While not always considered a serious defect, it should be replaced to ensure smoother, more efficient train operations and to minimize the chances of making the corrugation worse.
Crushed Head
You may notice that the railhead is flattened and drooped over several inches. This defect is called a crushed head. The metal of the rail is crushed but usually doesn’t show signs of cracking under the head. You may also notice:
- Flattening and widening of the rail head over several inches (and sagging)
- Small cracks in the nearby running surface
- It may appear wrinkled or show a bleeding crack at the fillet under the head.
Crushed head rail flaws occur where the metal is softer and are often caused by the repetition of heavy loads, higher speeds, and above-and-beyond use than the rail is rated for. It is not a serious rail defect but can cause rough riding of rolling stock and should be replaced as soon as possible to avoid further crushing or complete part failure.
Burned Rail (or Engine burn)
The friction of a slipping locomotive wheel can cause what looks like burning in the rail. Burned rail can eventually chip and roughen under the surface. Its presence may indicate irregularity on the running surface, which created the impact stress over the burned area.
Minor burns can be fixed by grinding the metal flat again, but a longer-term fix is to replace the part and look for any nearby track irregularities that may be causing the track stress.
Flaking
Flaking is when you see small chips, flakes, or cavities on the running surface of the rail head, most commonly around the high side of curves and switches. It happens gradually, and if it gets worse and deeper, it’s known as shelling.
It is not a serious defect, but flaking should be addressed before it becomes shelling and increases the risk of damage or part failure.
Head Check
Look in the gauge corner of a railhead. You have a head check defect if you notice shallow surface or hairline cracks. They can appear at any angle of the rail width but often at a 45-degree angle to the rail axis on high curves.
Early-stage head checks can be ground down, but more advanced cracks should have the part replaced.
Flowed Rails
With flowed rails look like the tread metal has been rolled beyond the corner, but there are no visible signs of breaking on the underside. This distortion occurs gradually upon repeated heavy loads and curved tracks but does not change the metallic structure of the metal.
Flowed rails are not a serious defect, but left unfixed, the rolling can continue, leading to blade-like or jagged edges that eventually separate from the railhead.
Mill Defects
You may see deformations or cavities inside the head, web, or base of a rail. These are mill defects that occur when the ingot is poured to create the part. It may introduce foreign material into the component as well.
Modern rail production techniques and detailed quality assurance procedures minimize the changes of mill defects. Small defects may not be an immediate concern, but deeper ones can cause the defect to increase, causing part failure.
Shelling
If you notice shell-like flakes coming off the steel, it’s known as shelling (or spalls when shallow). They are visible on any level of the gauge side, longitudinally, usually in the upper corner. It occurs where excessive pressure is put on the railhead.
When shelling occurs in curved lines, it can cause transverse separation and be potentially dangerous. Shelling should always be examined, and affected components should be replaced if significant.
Where to get quality rail parts
At NARP, we sell rail material from the point of order to timely delivery. Whether you need new, relayed, or reconditioned parts, every part goes through our rigorous quality assurance and inspection process to minimize chances of part failure under expected conditions. We’ve got everything from the ballast up.
Our team also provides comprehensive and cost-effective rail services to help you maintain your rail systems so you increase safety and stay on budget.
Browse our rail parts and components inventory and order your parts from NARP today.