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Project 75 Project Leader Prof Tara Chandra tests alternative
materials for novel insulated joints at UoW.
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Insulated rail joint assemblies are a critical component of rail
infrastructure. They provide electrical isolation between two
sections of rail for signalling purposes. Any malfunction of
electrical insulation is a significant risk to safety and
operational efficiency within the rail system. The glued insulated
joint (GIJ) assembly is continually subjected to dynamic and
variable loads imposed by the rollingstock, stresses generated by
thermal expansion, environmental extremes and electrical potential.
There is also progressive deterioration in the structural integrity
of the joint due to mechanical fatigue failure and/or metal flow
across the insulating gap. The cost to Australian industry for the
maintenance and replacement of failed or worn joints has been
conservatively estimated to be in the order of $5.4 million in
direct costs and $1.1 million in indirect costs. Further to these
calculated costs are the risks to health, safety and system
reliability posed by a signal malfunction.
This project aims to:
- Develop a finite element computer model that describes the current
behaviour of current GIJ designs under dynamic variable amplitude
loading, and to optimise design.
- Investigate the applicability of advanced materials joining methods
to the development of a novel insulated joint system with higher
rigidity and continuity of material properties across the joint.
The research was independently assessed by STEM Partnerships in
2006, with the review outlining some concerns in relation to the
increased cost of manufacturing a new novel insulated joint system,
compared to current products. The report encouraged ongoing
industry support and involvement in the project to conduct field
trials to evaluate the potential of the technology, prior to
involving joint manufacturers.
Progress to date:
- Development of finite element model of current GIJ design for
static loading completed.
- Extension of finite element model to account for variable amplitude
dynamic loading completed.
- Series 1, 2 and 3 brazing/sintering trials completed.
Future Outcomes:
- Develop improved and optimum designs for GIJ.
- Laboratory and industry testing of proposed novel insulated joints.
- If successful, new materials for an integrated insulating joint in
a steel rail, which is expected to lead to world-class advances in
the fields of materials design and novel joining methods for
dissimilar materials.
Project Leader: Professor Tara Chandra (University of Wollongong)
Project Manager: Mr Ian Marks (Queensland Rail)
