From weld to settlement: A comprehensive approach to evaluate the influence of dipped welds on track performance

This study investigates the influence of dipped welds on dynamic loading and railway track deterioration, with particular focus on settlement-related effects. Conducted within the Research Cluster Railway Systems (RCRS) collaboration project, it includes a statistical evaluation of over 2000 welds in Austria, identifying critical welds linked to track settlements. Three critical geometries with a depth of 0.3 mm, 0.6 mm and 0.9 mm were artificially created and analysed. Measurements and simulations compared rail and sleeper displacements, demonstrating accurate predictions of rail irregularities. The Railway Analysis Tool for Track Simulation proved accurate and efficient, guiding future dynamic ballast and rail weld fatigue tests. This tool will support the enhancement of track systems by defining maintenance limits and optimizing welding processes, ultimately improving track performance, reliability, and service life.