Page 1 of 8

ULR - TC532923000016628F
To, Date : 12-11-2023
Test Report No.
M/s. KONKAN RAILWAY CORPORATION LIMITED (Belapur) : E2308702
Sample Received Date : 23-08-2023
Test Completion Date
Belapur Bhavan, Sector-11, C.B.D. Belapur, Navi Mumbai: 400614 : 11-11-2023

Ref. No. Challan no.: KR/W/1/33/ Vol-VI Date: 23-08-2023

Description Steel test piece sample.
Material IRS T-12:2009 Grade 880
Lab No. E23081261
Subject Metallurgical analysis for ascertaining cause of Rail Fracture
reported at km 12/4-5in KOL-MNI section
Date of fracture Km Section Location
02-08-2023 266/900-267/700 VID-RAJP yard ---
FAILURE ANALYSIS REPORT
DESCRIPTION OF THE SAMPLE :

Sample of rail fracture detected at Km 266/900-267/700 in between VID-RAJP yard which was in the service *E220
was received for failure analysis. It was in service for twenty-six years & was removed after detection on
02/08/2023. The fracture location was mid rail. USFD detected piping defect in the head.
TESTS CONDUCTED:
1. Visual
2. Macro
3. Chemical
4. Tensile
5. Hardness
6. Impact
7. Microstructure
8. Inclusion
1-8*
 Page 2 of 8
ULR - TC532923000016628F
To, Date : 12-11-2023
Test Report No.
M/s. KONKAN RAILWAY CORPORATION LIMITED (Belapur) : E2308702
Sample Received Date : 23-08-2023
Test Completion Date
Belapur Bhavan, Sector-11, C.B.D. Belapur, Navi Mumbai: 400614 : 11-11-2023

Ref. No. Challan no.: KR/W/1/33/ Vol-VI Date: 23-08-2023

Description Steel test piece sample.
Material IRS T-12:2009 Grade 880
Lab No. E23081261
Subject Metallurgical analysis for ascertaining cause of Rail Fracture
reported at km 12/4-5in KOL-MNI section
Date of fracture Km Section Location
02-08-2023 266/900-267/700 VID-RAJP yard ---
VISUAL INSPECTION:
Horizontal crack of approximately 1250 mm length observed at head-web joint. Widening of the head observed
for the length of the split. Width of head on cracked portion of rail found to be 70-71mm against specified
67mm. Total height of flat bottom rail found to be 150mm against 156mm specified.
*E220
Photographs:

As Received Condition

MACRO Test Method: IS 11371:1985(RA 2012)

The samples cut from cracked area & plain surface were etched with hydrochloric acid and water (1:1) at 60-70
degree centigrade.
Cracked surface: It revealed 4.0 wide vertical split crack 6mm below the top surface of head which is
extending up to head-web joint on the gauge side. Widening of the head observed for the length of the split.
Plain surface: No cracks, blow holes, or any other harmful defects observed.
2-8*

Photographs:

FRACTURED SIDE PLAIN SIDE

 Page 3 of 8
ULR - TC532923000016628F
To, Date : 12-11-2023
Test Report No.
M/s. KONKAN RAILWAY CORPORATION LIMITED (Belapur) : E2308702
Sample Received Date : 23-08-2023
Test Completion Date
Belapur Bhavan, Sector-11, C.B.D. Belapur, Navi Mumbai: 400614 : 11-11-2023

Ref. No. Challan no.: KR/W/1/33/ Vol-VI Date: 23-08-2023

Description Steel test piece sample.
Material IRS T-12:2009 Grade 880
Lab No. E23081261
Subject Metallurgical analysis for ascertaining cause of Rail Fracture
reported at km 12/4-5in KOL-MNI section
Date of fracture Km Section Location
02-08-2023 266/900-267/700 VID-RAJP yard ---
CHEMICAL ANALYSIS Test Method: ASTM E415:21; IS 8811:1998; EMS/QS/01:2018

A small piece of the rail was analyzed with optical emission spectrometer.
The Chemical composition complies with the specification IRST-12:2009 Grade 880.
*E220
Element C Si Mn P S Al Ni Cr Mo Cu Fe

3-8*

Result 0.78 0.27 1.15 0.028 0.028 0.001 0.007 0.005 0.001 0.006

97.69
 Page 4 of 8
ULR - TC532923000016628F
To, Date : 12-11-2023
Test Report No.
M/s. KONKAN RAILWAY CORPORATION LIMITED (Belapur) : E2308702
Sample Received Date : 23-08-2023
Test Completion Date
Belapur Bhavan, Sector-11, C.B.D. Belapur, Navi Mumbai: 400614 : 11-11-2023

Ref. No. Challan no.: KR/W/1/33/ Vol-VI Date: 23-08-2023

Description Steel test piece sample.
Material IRS T-12:2009 Grade 880
Lab No. E23081261
Subject Metallurgical analysis for ascertaining cause of Rail Fracture
reported at km 12/4-5in KOL-MNI section
Date of fracture Km Section Location
02-08-2023 266/900-267/700 VID-RAJP yard ---
0.60- 0.10- 0.80- 0.035 0.035 0.015
Specified NA NA NA NA NA
0.80 0.50 1.30 Max Max Max
Element Ti B Sn W Co Nb V Pb N Ca C.E.
Result <0.001 0.0004 0.002 <0.001 0.004 0.003 0.001 0.001 0.005 0.0005 *E220
Specified NA NA NA NA NA NA NA NA NA NA NA

TENSILE TEST

It was conducted as per IS1608:2018 & it conforms to IRST-12:2009 Grade 880.

4-8*

IRS T12 Grade 880 Y.S. UTS % Elongation Fracture

Result 555.19 990.6 10.68 WGL
Specified 460 Min. 880 Min. 10 Min.

HARDNESS TEST
It was conducted as per IS 1500 (part 1):2013 & it conforms to the specification IRST-12:2009 Grade 880
Scale Hardness (Top) Hardness (Core)
Result 298,298,298 272,278,278
HBW (2.5mm/187.5kg) Specified 260 Min. 260 Min.
 Page 5 of 8
ULR - TC532923000016628F
To, Date : 12-11-2023
Test Report No.
M/s. KONKAN RAILWAY CORPORATION LIMITED (Belapur) : E2308702
Sample Received Date : 23-08-2023
Test Completion Date
Belapur Bhavan, Sector-11, C.B.D. Belapur, Navi Mumbai: 400614 : 11-11-2023

Ref. No. Challan no.: KR/W/1/33/ Vol-VI Date: 23-08-2023

Description Steel test piece sample.
Material IRS T-12:2009 Grade 880
Lab No. E23081261
Subject Metallurgical analysis for ascertaining cause of Rail Fracture
reported at km 12/4-5in KOL-MNI section
Date of fracture Km Section Location
02-08-2023 266/900-267/700 VID-RAJP yard ---
IMPACT TEST
It was conducted as per IS 1757(PART-1): 2020
Size of Test Energy Absorbed (Joules) Average Observation
Specimen (mm) Temperature 1 2 3 (Joules)
*E220
10 X 10 X 55 Room Temp. 10.0 6.0 8.0 8.0 Specimen Fully
broken
Note: It indicates low toughness & it may be due to long sulfide inclusions

5-8*
 Page 6 of 8
ULR - TC532923000016628F
To, Date : 12-11-2023
Test Report No.
M/s. KONKAN RAILWAY CORPORATION LIMITED (Belapur) : E2308702
Sample Received Date : 23-08-2023
Test Completion Date
Belapur Bhavan, Sector-11, C.B.D. Belapur, Navi Mumbai: 400614 : 11-11-2023

Ref. No. Challan no.: KR/W/1/33/ Vol-VI Date: 23-08-2023

Description Steel test piece sample.
Material IRS T-12:2009 Grade 880
Lab No. E23081261
Subject Metallurgical analysis for ascertaining cause of Rail Fracture
reported at km 12/4-5in KOL-MNI section
Date of fracture Km Section Location
02-08-2023 266/900-267/700 VID-RAJP yard ---
MICROSTRUCTURE EXAMINATION Test Method: ASM VOLUME 9:2004
The sample cut near the fracture end, polished & etched with 2%Nital. It was examined under optical
microscope at 100-1000X. It revealed Pearlitic microstructure.
Vertical split crack (4.0 mm width) with branches & entrapment observed on the cracked area.
Photographs: *E220
Near Fracture-Mag.: 400X

Away from Fracture-Mag.: 400X

6-8*
 Page 7 of 8
ULR - TC532923000016628F
To, Date : 12-11-2023
Test Report No.
M/s. KONKAN RAILWAY CORPORATION LIMITED (Belapur) : E2308702
Sample Received Date : 23-08-2023
Test Completion Date
Belapur Bhavan, Sector-11, C.B.D. Belapur, Navi Mumbai: 400614 : 11-11-2023

Ref. No. Challan no.: KR/W/1/33/ Vol-VI Date: 23-08-2023

Description Steel test piece sample.
Material IRS T-12:2009 Grade 880
Lab No. E23081261
Subject Metallurgical analysis for ascertaining cause of Rail Fracture
reported at km 12/4-5in KOL-MNI section
Date of fracture Km Section Location
02-08-2023 266/900-267/700 VID-RAJP yard ---
INCLUSION TEST
The non-metallic inclusions severity level was checked as per IS 4163:2004 (RA 2010) method A & it
does not comply with the acceptance criteria of the specification IRST-12:2009 Grade 880 w.r.t.
sulfide inclusions.
*E220
Magnification 100X
Location Longitudinal
D
A (Sulfide) B (Alumina) C (Silicate)
(Globular Oxides)
Observatio
Thin Heavy Thin Heavy Thin Heavy Thin Heavy
n
Result 3.0 2.5 -- -- -- 1.5 1.0 --
Specified 2.5 2.0 2.5 2.0 2.5 2.0 2.5 2.0
Note: Slag entrapment observed
PHOGRAPHS 7-8*
Slag Entrapment - 100X Sulphide inclusions-100X
 Page 8 of 8
ULR - TC532923000016628F
To, Date : 12-11-2023
Test Report No.
M/s. KONKAN RAILWAY CORPORATION LIMITED (Belapur) : E2308702
Sample Received Date : 23-08-2023
Test Completion Date
Belapur Bhavan, Sector-11, C.B.D. Belapur, Navi Mumbai: 400614 : 11-11-2023

Ref. No. Challan no.: KR/W/1/33/ Vol-VI Date: 23-08-2023

Description Steel test piece sample.
Material IRS T-12:2009 Grade 880
Lab No. E23081261
Subject Metallurgical analysis for ascertaining cause of Rail Fracture
reported at km 12/4-5in KOL-MNI section
Date of fracture Km Section Location
02-08-2023 266/900-267/700 VID-RAJP yard ---
CONCLUSION:

 No crack was detected by USFD in June.2023 but horizontal crack of approximately 1250 mm length
observed at the head & web joint of rail on 02/08/2023. This was due to vertical split crack in the *E220
head of the rail. Vertical split head defects are common fatigue defects & are considered dangerous
given that they can develop rapidly & their presence is difficult to detect, even with ultrasonic testing.
Vertical split head is a critical rail defect affecting safety of train operation. It is a longitudinal defect.
The origin is an internal longitudinal seam, segregation or inclusion from the manufacturing process.
The separation progresses longitudinally & horizontally, parallel to the side of head, then gradually
turns to gauge or field side of the head. Growth is usually rapid after the seam or separation opens
up. It continues to grow rapidly until the split turns outward. It is usually not visible on the surface
until it has grown up to a length of several feet
 Long sulfide inclusions observed & this may be the cause of vertical split head.

Recommendation: Looking at the entrapment at the crack area & long sulfide inclusions, it is advisable to
use rail made from relatively clean steel. Improved rail steel having enhanced fracture toughness and
8-8*
ductility should be used.

For Earth Metallurgical Services Pvt. Ltd. (Authorized Signatory)

S.N Parikh
(Metallurgist)
--------------End of Report------------------