Improving railway infrastructure productivity by sustainable two material rail development

Two major problems in railway infrastructure are Rolling Contact Fatique (RCF) and high noise emission levels (up to 110 dB) through Stick Slip. For both problems, the INFRA-STAR project focuses on improve the durability and lifetime of the rail, especially on narrow radius curves with high traffic volumes and high axle loads, by applying an additional surface layer material at the top of the railhead. Major project objective is the development of this tow-material rail through RCF modelling, dynamic train/track interaction modelling, metallographic research (a.e. durability test), material application development (by laser cladding an rollung processes), and field testing.A.o railway operators, rail suppliers and maintenance workshops will gain economic benefits through an increase in reliability and durability of their railway infrastructure. The project will solve their problems with respect to crack formation (curved rail lifetime increases with 50%), noise emission (reduction with 15-20 dB), railway productivity and maintenance costs. Furthermore considerable amounts of rail materials and energy will be preserved.