Additive manufacture for railway track component life extension with premium laser-clad coatings

This is an exciting PhD research opportunity combining research at University of Sheffield with experience at Network Rail. It focuses on the mechanics and materials of the rail-wheel contact, at which high train loads routinely take rail materials to extreme stress levels. The research will develop understanding of how a large-scale additive manufacturing method using laser-clad coatings on basic steel track components can extend their life. Success in this area will mean fewer line closures for maintenance and reduced cost, thereby having a big impact on how the rail network runs.

Project detail

Additive approaches to creating graduated change in materials and mechanical properties through a component are novel in rail track manufacture (rail, insulated block joints, switches & crossings). Research challenges include understanding tolerable material imperfections through contact stress and fracture mechanics assessment, and ensuring wear, friction and plasticity of the developed surfaces meet the demands placed on them. Research will focus particularly on modelling (e.g. finite or boundary element techniques), combining this with experimental work at small and full-scale.

The research lies in the areas of contact mechanics, fracture mechanics and tribology. Alongside this the PhD includes the opportunity to spend periods with Network Rail getting a real understanding of the opportunities for improvement to the rail-wheel system, and to see how your research can be applied