Online Course - Principles of Rail Steel Production and Preventing Quality Issues

This course describes the principal elements of the steelmaking and casting process which are fundamental for the manufacturing of a high-quality rail steel.

It discusses in detail how critical defects can be reduced in the as cast semi and rail to meet ever demanding customer specifications which are increasingly essential for a high integrity rail product.

The learning aims are,

  1. Understanding the key parameters in those parts of the steelmaking and casting process which have the biggest impact on the integrity of the as cast semi and rolled rail product. ​That is cleanness, internal and surface quality and hydrogen
  2. Understanding the main factors affecting these parameters and how they can be monitored and minimised throughout the process
  3. How rail hydrogen cracking can be avoided in the rail

On demand and instant access to the full course consisting of three modules.

To maximise learning it is recommended that each module is completed in sequence.

Full Course

(save $40)

Module 1

Steelmaking and Casting of High-Quality Rail Steels

Module 2

Origin and Reduction of Surface and Internal Quality Defects in Rail Steel Manufacture

Module 3

Reducing Hydrogen Levels in Rail Steel Production and Preventing Hydrogen Cracking

  • $40.00 discount available when you purchase the three modules together.
  • Certificate on completion.

Course Modules

The course consists of three modules which should be taken in sequence in order to complete the full course.

Module 1 – Steelmaking and Casting of High-Quality Rail Steels

Content Includes:

  • Identifying and reviewing the key parameters for high quality rail steel production through BOS steelmaking, secondary steelmaking and continuous casting routes
  • Discusses the parameters in each area which can:
    • Improve cleanness
    • Minimise hydrogen levels
    • Reduce surface and internal quality issues
  • Discusses the slow cooling treatment options available to reduce hydrogen in the bloom to acceptable levels.

Module 2 – Origin and Reduction of Surface and Internal Quality Defects in Rail Steel Manufacture

Content includes:

  • Origins of both internal and surface quality defects in the bloom and their effect on the rail product and how these can be reduced during the manufacturing process
  • Detailed description of the levels at which these defects become acceptable or not acceptable for certain customer specifications
  • Discusses the role of cleanness levels within in the steel, the origins of non-metallic inclusions and how these can be minimised

Module 3 – Reducing Hydrogen Levels in Rail Steel Production and Preventing Hydrogen Cracking

Content includes:

  • Mechanisms and factors for hydrogen cracking to occur in rail steels
  • Sources of hydrogen throughout the steelmaking process and how these can be minimised by different treatments
  • Methods of hydrogen removal in the liquid and solid state
  • How hydrogen is measured throughout the process and the importance of taking accurate measurements

What the course covers

The course covers how we can adopt a clean steel practice throughout the process. It discusses how both good surface and internal quality and low hydrogen levels are all important demands to meet particularly stringent customer specifications and how these can be achieved. It covers in detail how the risk of hydrogen cracking - one of the major problems in rail steels - can be minimised and avoided.

Learning Outcomes

  • Understanding how to achieve a clean steel through the steelmaking process
  • Identifying and minimising the causes of internal and surface quality problems in the bloom and rail
  • Understanding how to achieve low hydrogen levels through the steelmaking process to achieve reduced risks of rail hydrogen cracking

Who should access the course?

Practitioners in the steel industry, such as scientists, researchers, technologists, technology managers and operations and Operational oanagement. Those who are, or who aspire to be senior leaders within the steel industry or academia.

Course Duration

3 x 40 minute modules

Course Presenter

David Bruce BSc. (Hons)
Steel Consultant

Dave’s role as a steel consultant is to offer advice in a range of steelmaking areas with his vast experience and to solve problems at all steel plants. Additionally, to support European research projects where appropriate.

Dave’s career has spanned 50 years in the steel industry. Some of this time was in research & development in the steelmaking and casting areas but the majority of the time was at the continuous casting plant at Teesside Works. Here he took up various roles from Bloom and Slab Technical Manager to Development Manager. He was responsible over many years for the technical and quality problems encountered in the production of rail quality blooms and worked closely with customers at 2 rolling mills to achieve a top quality product. He has given several papers on quality issues experienced at international conferences worldwide.

Enrolment options for this course

Enrol for the full course, or go through the modules separately (to maximise learning it is recommended that each module is completed in sequence).

Full Course

(save $40)

Module 1

Steelmaking and Casting of High-Quality Rail Steels

Module 2

Origin and Reduction of Surface and Internal Quality Defects in Rail Steel Manufacture

Module 3

Reducing Hydrogen Levels in Rail Steel Production and Preventing Hydrogen Cracking

  • $40.00 discount available when you purchase the three modules together.