WRIST · Project

Better Rail Welding That Cuts Track Maintenance and Extends Rail Lifespan

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Every time two pieces of rail are welded together, heat weakens the metal around the joint — like how soldering a pipe makes the area nearby softer. That weak spot wears out faster and forces expensive repairs. WRIST figured out how to weld rails with much less heat damage, using two improved techniques: a better version of the chemical welding crews already use trackside, and a friction-based method that generates less damaging heat. They built working prototypes, quality-monitoring systems, and tested everything on real rail steel — including next-generation bainitic steel that's harder and lasts longer but is notoriously difficult to weld.

By the numbers

consortium partners across the project

countries represented in the consortium

67%

industry partners in the consortium

total deliverables completed

demonstrated prototype deliverables

SMEs in the consortium

industry partners in the consortium

The business problem

What needed solving

Rail welds are the weakest link in any track — the heat from welding degrades the surrounding steel, creating spots that wear out faster, crack sooner, and force expensive unplanned maintenance closures. This problem gets worse with next-generation bainitic rail steels, which are harder and longer-lasting but extremely sensitive to welding heat. Rail operators and infrastructure managers need welding methods that preserve the steel's strength at the joint.

The solution

What was built

The project built working prototypes of improved aluminothermic and orbital friction welding equipment, including a weld finishing tool, clamping mechanisms, and test rigs. They also delivered an online weld quality control system with web-based data management for real-time monitoring. All equipment was validated on both conventional and bainitic rail steels, with 30 deliverables completed in total.

Audience

Who needs this

Rail infrastructure managers (e.g., Network Rail, ProRail, Infrabel, DB Netz)Track maintenance contractors handling rail welding operationsWelding equipment manufacturers serving the railway sectorSteel producers developing bainitic and premium rail gradesRailway engineering consultancies specifying welding procedures

Business applications

Who can put this to work

Railway infrastructure maintenance

enterprise

Target: Rail infrastructure managers and track maintenance contractors

If you are a rail infrastructure operator spending heavily on weld repairs and unplanned track closures — this project developed prototype welding tools and online quality control systems that reduce the heat-affected zone in rail welds. The result is joints that last longer and need less maintenance, meaning fewer track possessions and more capacity for rail traffic. The consortium of 12 partners across 6 countries validated both aluminothermic and orbital friction welding improvements.

Welding equipment manufacturing

mid-size

Target: Manufacturers of rail welding machines and consumables

If you are a welding equipment manufacturer looking to upgrade your product line for next-generation rail steels — this project produced working prototypes including a weld finishing tool, orbital friction welding test equipment, and clamping mechanisms for intermediate welding components. These designs address the growing demand for joining bainitic rail steels that conventional equipment struggles with. With 10 demonstrated deliverables and 30 total outputs, there is a substantial technology package ready for licensing.

Rail steel production

enterprise

Target: Steel producers developing advanced bainitic rail grades

If you are a steel producer investing in bainitic rail grades but facing market resistance because existing welding methods degrade your product's advantages — this project proved that both aluminothermic and orbital friction welding can successfully join bainitic rails while preserving their superior mechanical properties. The project delivered actual joined rails of both conventional and bainitic steel, removing a key barrier to adoption of your premium product.

Frequently asked

Quick answers

What would it cost to adopt these welding improvements?

The project data does not include specific pricing or cost-per-weld figures. However, the objective states these processes target significant cost reduction in track maintenance through longer-lasting joints and less repair welding. A licensing or technology transfer discussion with the consortium would clarify equipment and implementation costs.

Can this work at industrial scale on real rail networks?

The project planned full-scale field testing in industrial or commercial test tracks, and delivered prototype equipment capable of creating orbital friction welds with a range of process parameters. The online weld quality control system with web-based data management was also delivered, which is essential for deployment across a rail network.

Who owns the IP and how can I license it?

The consortium of 12 partners across 6 countries — led by the Belgian Welding Institute — collectively developed these technologies under an EU-funded RIA project. IP ownership and licensing terms would need to be negotiated with the relevant consortium members. SciTransfer can help identify the right contact for your specific interest.

Does this work with the rail steels we already use?

Yes. The project specifically addressed both conventional rail steels and advanced bainitic rail steels. One key deliverable was the actual realisation of joined rails using one conventional and one bainitic rail steel, proving compatibility across grades.

How does the quality control system work?

The project delivered an online weld quality control and data analysis system for aluminothermic welding, plus an in-process control package linked to a web-based data management system. This means weld quality is monitored during the process itself, with data stored centrally for analysis and traceability.

Is this compliant with European rail standards?

The project was designed to meet more stringent infrastructure requirements imposed by increased speed and load on European railways. Based on available project data, full regulatory certification details are not specified, but the consortium includes 8 industry partners who operate under these standards daily.

What is the project timeline and current status?

WRIST ran from May 2015 to January 2019 and is now closed. All 30 deliverables have been completed. The technologies are at prototype stage and ready for further commercialisation discussions.

Consortium

Who built it

The WRIST consortium is exceptionally industry-heavy at 67%, with 8 out of 12 partners coming from industry and 3 being SMEs. This is a strong signal that the technology was developed with commercial deployment in mind, not just academic publication. The 6-country spread across Belgium, Germany, France, Netherlands, Sweden, and the UK covers the major European rail markets. The coordinator — the Belgian Welding Institute — is a well-established applied research organization, not a university, which typically means faster technology transfer. With 3 universities providing scientific depth and 1 dedicated research organization, the balance between practical engineering and fundamental understanding is solid.

BELGISCH INSTITUUT VOOR LASTECHNIEK VZWCoordinator · BE
PRORAIL BVparticipant · NL
PNO Innovationparticipant · FR
UNIVERSITY OF HUDDERSFIELDparticipant · UK
TECHNISCHE UNIVERSITEIT DELFTparticipant · NL
CHALMERS TEKNISKA HOGSKOLA ABparticipant · SE

How to reach the team

The coordinator is the Belgian Welding Institute (Belgisch Instituut voor Lastechniek VZW) in Belgium. SciTransfer can help you reach the right person on the project team.

Order a report on this consortium See BELGISCH INSTITUUT VOOR LASTECHNIEK VZW profile →

Next steps

Talk to the team behind this work.

Want an introduction to the WRIST team to discuss licensing their welding prototypes or quality control system? Contact SciTransfer — we connect businesses with EU research teams.

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