I share some pictures of our current challenge with Helsingør Hornbæk Gilleleje Banen number 4. The project has changed managers multiple times in fifteen years, and the national regulations have changed also in that period. We have also lost some documentation due to the death of earlier managers.

We have made the unfortunate discovery that the profile on one of the axle journals is incorrect. I say "discovery" because the origin of the work is lost to those who have passed. The wheels and axles were turned at the national railway workshops 18 years ago, when they still had a wheel lathe. The workshops and the persons involved are now gone, and unfortunately, also the documentation.

Under current standards, we are required to document the condition of the wheels and axles. We were required to lift the locomotive again and drop the wheels for inspection and measurement. Here we found that one axle was turned with a sharp corner on the journal. Why? We don't know. Supposedly all the work was done by experienced national railway staff, but that is suspect.

So, the point of posting here: any doubt that we need to replace this axle? The axle journal does not have enough material remaining to turn it down enough to return the fillet. The whole situation is extremely frustrating and expensive to correct.

It's not up to me, but every machinist knows that sharp inside corners are stress risers. You'd better figure on replacement. Sorry about that.

I've been trying to delete my post. If you look at that picture again, you might be able to use a smaller radius tool to round that out... can't really tell from here. GOOD LUCK.

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Perhaps I'm seeing an artifact in the photo, but it looks like a fairly substantial heat crack in the journal surface just below the thumb holding the square. If so, I would question the integrity of the axle anyway.

Edit: When I first looked at this photo it was on my phone. On the larger screen of my laptop the line appears to just be a light corrosion line not a crack. The only way I could see to add the necessary fillet would to be to undercut the hub face into the wheel center a bit.

Can you machine to add a radius in a slight undercut under the wheel but not cutting into the wheel?

Can you spray weld, then machine a new fillet? Like this bloke does: https://www.youtube.com/watch?v=FLYdhfgF6Pg

My interpretation of the CFR is that it does not allow welding of any kind on axles, driver tires, and wheels (not including acceptable repairs to driver centers), and any welding on those items condemns them. I imagine the same is true of European regulations.

I'm in agreement with Kelly assuming there's replaceable hub liner practice in Denmark. No means of building up to then reprofile is likely to be legal or robust.