A Comprehensive Overview of Manufacturing and In-service Defects in Rails: Occurrence and Remedies

Indian Railways, the second-largest rail network in Asia and the fourth-largest in the world, has been a cornerstone of India's progress for 162 years. With over 19,000 trains serving 7,112 stations, this national institution is vital to the country’s economic and social development. It strengthens regional connectivity, enhances citizen mobility, and fuels commercial growth, all while providing top-tier logistics and transportation infrastructure. In 2021, Indian Railways freight revenues were $16 billion. Furthermore, the auto sector favours Indian Railways as its primary transporter. Although using trains for transportation has many benefits and is safe, the frequency of train accidents is continually rising. Indian Railways reported 373 train derailments between 2009 and 2015. More than 60% rail accidents are due to defects in the rail tracks. Derailment has been responsible for more than 50% of railway accidents in the past three years. Defective track, mostly rail, has been the cause of 29% of these occurrences. In the past three years, derailment-related accidents have increased by 67%. This paper discusses the different types of in-service defects in rail steels, which are the causes of accidents in India. The study also intends to identify ways of reducing the disastrous effects of vehicle derailments through suitable measures according to the gravity of railway accidents. The role of metallurgy in development of materials for rails is also highlighted.