Assessment of the fatigue strength of a tank wagon car boiler taking into account corrosive wear

Purpose. The goal of the article is to present the results of research on determining the stress-strain state of a tank car boiler’s shell and assessing its fatigue strength using computer modeling. This was done while accounting for various levels of corrosion wear. Methodology. A specific methodology based on general calculation principles for railway vehicle components was used to assess the tank car boiler’s resistance to failure from repeated loads. Various scenarios simulating metal corrosion damage were examined: complete absence of corrosion; corrosion with a depth of up to one millimeter; corrosion with a depth of up to two millimeters; corrosion damage with a depth of up to three millimeters. Findings. Based on the analysis, the depth and location of corrosion significantly impact the strength of a tank car boiler. These factors are critical when evaluating the reliability of the structural elements. Therefore, the degree and location of metal corrosion wear must be taken into account when determining the strength of the boiler. Originality. The research revealed a direct relationship between changes in fatigue safety factors in the most stressed areas of a tank car boiler and the appearance and development of corrosion defects. The findings demonstrate the critical importance of the metal shell’s thickness for ensuring the structural reliability of the tank, particularly for wagons nearing the end of their service life. The proposed methodology allows for the evaluation of extending the service life of such tank cars by taking into account the level of corrosion damage. Practical value. The study found that areas around the bottoms and manholes of the tank car boiler are critical zones for corrosion damage with a depth of three millimeters or more. This level of damage makes further operation of the boiler impossible. However, if corrosion is less deep (up to two millimeters), the boiler’s service life can be extended to thirty years. If there are no signs of corrosion, the service life can be extended by twelve years beyond the standard term, for a total possible service life of thirty-six years. Implementing these results will allow for more informed decisions regarding the extension of tank car service life and help prevent accidents related to worn-out rolling stock.