Flanged steel wheels are critical components in industrial applications, particularly in environments that require heavy-duty performance and durability like rail systems and heavy machinery. While these steel wheels are sturdy and robust, they can experience wear and tear over time due to their constant exposure and use in harsh conditions.
Rockett, Inc. manufactures single-flanged, double-flanged, and flat-faced rail wheels, with the most common design being the single-flanged wheels. We use high-quality 1045-grade forged steel for increased durability and a longer lifespan. While our wheels are built to endure heavy use, nothing lasts forever. Therefore, a common question we’re asked is whether flanged steel wheels are able to be repaired.
Let’s explore the repairability of flanged rail wheels, the types of damage that are most likely to occur, and when replacement is often the better option.
Common Types of Flanged Steel Wheel Damage
Flanged steel wheels are made to withstand significant stress, but they’re not immune to damage. Some of the most common issues that can happen with these wheels are:
- Wear and tear. Over time, the tread on the wheel can become worn down, especially if the wheels are used to carry large loads. This wear can lead to a loss of traction and compromised performance.
- Deformation. Flanged wheels can also become deformed due to excessive weight, impact, or improper use. Continuing to use deformed wheels is not a good idea, as it can affect the wheel’s alignment, leading to uneven wear and poor fit.
- Cracking. In some cases, cracks can develop in the steel due to stress, fatigue, or material defects. Cracks are particularly concerning as they can compromise the structural integrity of the wheel.
- Flange damage. The flange is a crucial feature that is responsible for keeping the wheel on the track. If this part suffers damage, the wheel can derail or fail in guiding the equipment.
Repairing Flanged Wheels: What’s Possible?
Whether or not a flanged rail wheel can be repaired depends on several factors, including the type and extent of the damage. Repairs are possible, but they must be prepared by experienced professionals who have specialized equipment and expertise.
Re-machining and resurfacing can address tread and flange wear. If the tread is worn but the wheel is in otherwise good condition, these repair methods can restore the wheel’s surface. The process involves removing a thin layer of material from the wheel to create a smooth, even surface, restoring the wheel’s original profile. Like tread wear, flange wear can often be addressed by reshaping the flange to its initial specifications.
In cases of deformation, heat treatment can be used to restore the wheel. The process carefully heats the steel to a specific temperature and then cools it under controlled conditions. This process relieves stress and realigns the wheel. Lastly, small cracks can sometimes be repaired through welding. In this case, the damaged area is cleaned, and a welding filler material is applied to fill the crack. Re-machining may occur after to ensure a smooth surface.
When Replacement Is the Better Option
While it may be possible to repair flanged steel wheels, it’s not necessarily the better choice. In many situations, a replacement is the safer and more cost-effective option. Here are the situations where we strongly suggest replacing the steel wheel:
- Extensive damage. If the wheel has multiple issues or extensive problems, such as severe wear combined with deformation and cracks, repairs are likely not practical or reliable. Only a replacement wheel ensures that the equipment operates safely and efficiently.
- Compromised structural integrity. Any time the structural integrity of a steel wheel is compromised with large cracks or deep gouges, repair attempts may not return the wheel to a safe condition. Only small cracks can be repaired, and even this is not always guaranteed.
- Cost considerations. While some people prefer repairs because they think it costs less, this isn’t always the case. A new wheel can be cheaper, and you don’t have to worry about downtime or not being able to restore the wheel to a safe condition.
Preventative Measures to Extend Wheel Life
To minimize the need for repairs or replacements of flanged rail wheels, regular maintenance and inspections are crucial. Addressing issues early on can prevent further deterioration. Also, make sure that you’re using the equipment according to the manufacturer’s specifications. This includes not overloading the wheels or handling them improperly. Lubrication can also reduce friction and wear, especially if the wheels are exposed to heavy loads or harsh conditions.
Flanged Steel Wheels by Rockett Inc.
Rockett, Inc. makes single-flanged, double-flanged, and flat-flanged wheels using 1045-grade forged steel. Our rail wheels are made to handle heavy-duty loads and conditions, and we can even create custom wheels according to your exact specifications. If you need new or replacement wheels, contact us today for a free quote.
