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A numerical framework for simulation of the steady-state thermal behaviour in keyhole mode welding has been developed. It is based on the equivalent heat source concept and consists of two parts: computational thermo-fluid dynamics and heat conduction. The solution of the thermo-fluid dynamics problem by the finite element method for a bounded domain results in a weld pool interface geometry being the input data for a subsequent heat conduction problem solved for a workpiece by a proposed boundary element method. The main physical phenomena, such as keyhole shape, thermo-capillary and natural convection and temperature-dependent material properties are taken into consideration. The developed technique is applied to complete-penetration keyhole laser beam welding of a 15 mm thick low-alloyed steel plate at a welding speed of 33 mm/s and a laser power of 18 kW. The fluid flow of the molten metal has a strong influence on the weld pool geometry. The thermo-capillary convection is responsible for an increase of the weld pool size near the plate surfaces and a bulge formation near the plate middle plane. The numerical and experimental molten pools, cross-sectional weld dimensions and thermal cycles of the heat affected zone are in close agreement.
The damage detection and repair control have become important tasks for ballast and slab tracks. Measurements which compare the damaged and the repaired status of the same track section at different times, or which compare a damaged and an intact track section at the same time, have been successfully performed at some sites in Germany. The loss of contact between the sleeper and the track plate, between the track plate and the base plate, and between the base plate and the base layer have been analysed. The soil properties of each site have been measured and have been used to establish realistic track-soil models. Theoretical results of the wavenumber domain and the finite-element boundary element method have been compared with the experimental results. The observed experimental and theoretical results, changes in the time histories of displacements and velocities due to train passages and in the transfer functions (receptances) due to hammer impacts, are encouraging that these measurements can be used to detect track damage.