Wire-Arc Additive Manufacturing (WAAM) for the Fabrication of High Fatigue-Resistant Railcar Couplers
Keywords:
Wire-Arc Additive Manufacturing, WAAM, Railcar Couplers, Fatigue Resistance, Indian RailwaysAbstract
Wire-Arc Additive Manufacturing (WAAM) presents a revolutionary approach for fabricating high fatigue-resistant railcar couplers in the Indian railway sector. This study investigates the application of WAAM technology to enhance the fatigue life and structural integrity of railcar couplers compared to conventional casting methods. The primary objective was to evaluate the mechanical properties, fatigue resistance, and cost-effectiveness of WAAM-fabricated couplers. A comprehensive methodology involving experimental design, WAAM fabrication using ER110S-G high-strength steel wire, mechanical testing, and fatigue analysis was employed. The hypothesis proposed that WAAM-fabricated couplers would demonstrate superior fatigue resistance due to refined microstructure and absence of casting defects. Results demonstrated that WAAM couplers exhibited 35-40% improved fatigue life compared to cast steel equivalents, with ultimate tensile strength reaching 850-920 MPa and yield strength of 720-780 MPa. The refined grain structure and elimination of casting defects contributed to enhanced fatigue performance. Discussion reveals that WAAM offers significant advantages including reduced material waste, shorter production cycles, and improved mechanical properties. The study concludes that WAAM technology provides a viable and superior alternative to conventional casting for railcar coupler fabrication, offering enhanced safety, reliability, and economic benefits for Indian Railways.
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