Evaluation of Quality Weld Deposit on Different Types of Rails

Welding of high-carbon rail steels is widely applied in railway maintenance to restore worn rail surfaces and extend service life. However, the weldability of these steels is limited by their high carbon content and susceptibility to brittle microstructures in the heat-affected zone. This paper evaluates the quality of weld deposits applied to different grades of railway rails (UIC 1100, UIC 900A, and UIC HSH) using submerged arc welding (SAW) and flux-cored arc welding (FCAW) technologies with various filler materials. Weld quality was assessed through macrostructural examination, HV30 hardness measurements, and microstructural analysis. The results show that inappropriate combinations of filler materials and welding parameters lead to excessive hardness and martensitic structures, which are undesirable for in-service performance. In contrast, selected multi-layer welding procedures produced bainitic or tempered microstructures with favourable hardness distributions. Based on the experimental results, optimal welding procedures and filler material combinations for rail renovation are proposed.