| ZHAO Hai,XU Haifeng,ZHOU Tingwei,YUAN Hang,XU Zhenlin,HE Yizhu.Effect of Wheel-rail Hardness Matching on Wear Performance of Heavy-haul Bainitic Wheel Steel[J],54(3):118-129 |
| Effect of Wheel-rail Hardness Matching on Wear Performance of Heavy-haul Bainitic Wheel Steel |
| Received:March 02, 2024 Revised:July 09, 2024 |
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| DOI：10.16490/j.cnki.issn.1001-3660.2025.03.010 |
| KeyWord:hardness ratio bainite wheels pearlitic rail wheel-rail matching wear behavior rolling contact fatigue |
| Author | Institution |
| ZHAO Hai |
School of Materials Science and Engineering, Anhui University of Technology, Anhui Ma'anshan , China;Ma'anshan Iron & Steel Co., Ltd., Anhui Ma'anshan , China |
| XU Haifeng |
School of Materials Science and Engineering, Anhui University of Technology, Anhui Ma'anshan , China |
| ZHOU Tingwei |
School of Materials Science and Engineering, Anhui University of Technology, Anhui Ma'anshan , China |
| YUAN Hang |
School of Materials Science and Engineering, Anhui University of Technology, Anhui Ma'anshan , China |
| XU Zhenlin |
School of Materials Science and Engineering, Anhui University of Technology, Anhui Ma'anshan , China |
| HE Yizhu |
School of Materials Science and Engineering, Anhui University of Technology, Anhui Ma'anshan , China |
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| Abstract: |
| Bainitic steel is used as a new wheel-rail material to replace pearlite due to its excellent comprehensive properties, and it is gradually applied in the field of wheel-rail contact. By exploring the hardness matching behavior of bainitic wheel materials and different active rail materials, the work aims to provide a theoretical reference for the safety and reliability of bainitic wheel service. The rolling slip wear and contact fatigue tester was used to carry out matching tests on the wheel-rail materials with three wheel-rail hardness ratios (0.87, 0.96, 1.13), and the rail wheel material hardness ratio (Hr/Hw) was explored. The impact on the service performance and damage behavior of wheel-rail materials was investigated. The damage morphology and plastic deformation degree of the wheel-rail material contact surface were analyzed through metallographic microscope, scanning electron microscope and microhardness, and the FCB wheel material was compared with the traditional pearlite wheel material, and finally, the matching behavior and selection rule of bainitic wheels and pearlite tracks in service were discussed. The results showed that the wheel-rail hardness ratio significantly affected the matching material wear and damage behavior. When Hr/Hw increased from 0.87 to 1.13, the amount of wheel material wear rate increased slightly, which was 0.188 mg/m, 0.203 mg/m, and 0.217 mg/m, respectively, and the wear mechanism changed from slight fatigue wear to severe fatigue wear. The amount of rail material wear was significantly reduced, the wear amounts were 0.104 mg/m, 0.069 mg/m, and 0.042 mg/m, representing reductions of 33.7% and 59.6%, respectively, and the degree of surface fatigue wear gradually decreased. The thickness of the plastic deformation layer of the FCB wheel sample increased with the increase of Hr/Hw, and its thickness was 82 μm, 98 μm, and 110 μm respectively, while the thickness of the plastic deformation layer of the rail sample decreased, and the thickness was 183 μm, 153 μm, and 128 μm, respectively. The surface hardening rate of the wheel material was positively correlated with Hr/Hw, while the rail material was negatively correlated. The fatigue crack morphology of wheel-rail materials was related to their microstructure. The fatigue cracks in the FCB wheel samples propagated almost parallel to the surface, and with the increase of Hr/Hw, the average fatigue crack length and depth of the wheel material decreased. The average crack length was between 126.6 μm and 145.3 μm, while the average crack depth was between 12.8 μm and 6.2 μm. The average crack angle increased from 8.4°-9.7°. The fatigue cracks in the rails always propagated at a small angle along the ferrite flow lines, and the average fatigue crack length of the rail material decreased from 95.8 μm to 125.2 μm, while the average crack depth and angle increased. The average crack depth ranged from 25.5 μm to 29.4 μm, and the average crack angle was distributed between 8.8° and 15.9°. When matched with the same type of rail, bainitic wheels had better wear resistance and fatigue damage resistance than typical pearlitic wheel steel (CL65). In the case of FCB wheels, it was observed that when the contact patch energy dissipation value (Tγ/A) was below 200 N/mm2, the wear rate remained relatively stable regardless of the hardness ratio. However, when Tγ/A exceeded 200 N/mm2, an increase in the hardness ratio led to a more severe wear rate, potentially resulting in catastrophic wear (Hr/Hw>1). The wear diagram for the rail indicates that a hardness ratio (Hr/Hw) greater than 1 corresponds to minor wear on the rail, with no significant impact of Tγ/A on the wear rate of the track steel. Conversely, when the hardness ratio is less than 1, an increase in Tγ/A results in accelerated rail wear. |
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