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Weld Repair of Manganese Frogs for Enhanced Performance

Document Series
Technical Reports
Federal Railroad Administration
Report Number
Subject Best Practices, Rail and Infrastructure Integrity, Track
Reciprocating wire feed, constant voltage, Flux-Cored Arc Welding, heat-affected zone, radiographic testing, Shielded Metal Arc Welding, ultimate tensile strength, yield strength.

When special trackwork contact surfaces (such as manganese-steel turnout frogs) become worn and damaged, they can be repaired to extend their lifetime, but current repair methods typically cannot return these surfaces to their original durability. Since worn or damaged frogs in freight and shared corridors have a detrimental effect on ride quality and increase life cycle costs, improved repair processes can extend the service life of frogs and improve the safety and efficiency of rail operations. In this project, EWI developed a new flux-cored arc welding (FCAW) procedure to repair manganese frogs. When EWI tested a repaired frog in simulated revenue service conditions at the Transportation Technology Center, the test results show a significant improvement in the durability of the repair as compared to traditional repair methods. Future work plans include revenue service trials, as well as refinements to weld procedures and materials.

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Last updated: Friday, January 13, 2017