Method for repairing rail wheels

A method of repairing a rail wheel having a rim including a worn body element and a worn tread and a worn flange thereon formed for engagement with a rail, the rail wheel including a boss defining an axis thereof in which an axle is receivable, and a web connecting the rim and the boss together, the method comprising:

• (a) removing a selected segment of the rim comprising the worn body element, the worn tread and the worn flange, to define a remaining segment of the rim having a remaining body element and a first engagement surface on the remaining body element, the first engagement surface being at least partially planar and positioned to define an acute angle relative to the axis, the acute angle having a vertex and defining an opening of the acute angle;
• (b) providing a replacement workpiece comprising a replacement body element having a second engagement surface thereon formed to mate with the first engagement surface, the replacement workpiece comprising a replacement tread and a replacement flange on the replacement body element positioned opposite to the second engagement surface;
• (c) positioning the replacement workpiece to locate the second engagement surface spaced apart from the first engagement surface by a predetermined distance, to define a predetermined gap between the first and second engagement surfaces;
• (d) positioning at least one heating element in the predetermined gap, to heat respective first and second heated portions of the remaining body element and the replacement body element and the first and second engagement surfaces by induction heating, the first heated portion extending a first preselected distance from the first engagement surface into the remaining body element and the second heated portion extending a second preselected distance from the second engagement surface into the replacement body element;
• (e) providing a non-oxidizing atmosphere covering the first and second engagement surfaces and the first and second heated portions;
• (f) in the non-oxidizing atmosphere, with said at least one heating element, heating the first and second heated portions and the first and second engagement surfaces to a predetermined hot working temperature, the first and second heated portions and the first and second engagement surfaces being plastically deformable while at the hot working temperature;
• (g) while the first and second heated portions are at the hot working temperature, and while at least one of the first and second engagement surfaces is moving relative to the other, engaging the first and second engagement surfaces together, and urging the replacement workpiece against the remaining segment in a direction away from the vertex and toward the opening, and against the remaining segment, to plastically deform the first and second engagement surfaces and at least parts of the first and second heated portions;
• and
• (h) allowing the first and second engagement surfaces and the first and second heated portions to cool, to bond the replacement workpiece and the remaining segment of the rim together.