Performance Enhancement of Railway Track Welding Electrodes via Natural Fiber-Based Composite Coatings
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Abstract
The performance of shielded metal arc welding electrodes plays a critical role in ensuring the reliability and durability of railway track maintenance under electrically driven manufacturing conditions. To improve welding efficiency while promoting sustainable material utilization, this study investigates the incorporation of natural lignocellulosic fibers into low-hydrogen electrode coatings for railway welding applications. Jute, flax, and bamboo fibers were introduced into E7018-type composite coatings and systematically evaluated in terms of arc stability, spatter generation, slag detachability, weld mechanical properties, and microstructural evolution. The results demonstrate that the bamboo fiber electrode exhibits the most stable welding arc, achieving a 45% reduction in spatter loss and a 12% increase in impact toughness at 0◦C compared with the conventional coating. The enhanced performance is associated with refined weld microstructures containing a higher proportion of acicular ferrite, while all fiber-modified electrodes show improved slag removal characteristics. The proposed natural fiber-based composite coating provides an environmentally friendly and high-performance alternative for railway welding consumables without compromising mechanical strength. Furthermore, the findings offer useful insights into material optimization for electromagnetic-assisted welding systems and electrically driven manufacturing processes, supporting the development of sustainable engineering solutions for advanced industrial applications.
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