Relating contact temperature and wear transitions in a wheel–rail contact

Earlier in an ongoing research project, we identified wear transitions, mechanisms, and regimes by experimentally testing the sliding part of a wheel–rail contact. Going further, the present study investigates the effects of elevated contact temperature and severe contact conditions corresponding to those of a wheel flange–gauge corner contact.Prior studies discussed wear in terms of contact pressure, amount and type of lubricant, sliding velocity, generated airborne particles, wear depth, coefficient of friction, and topographical measurements. This study shifts the focus to contact temperature, elemental and morphological analysis of the airborne particles, and surface-layer microstructure of test specimens by using several analytical techniques (i.e., SEM, FIB, ESCA, and energy mapping).As contact severity increased, the bulk temperature of the contacting bodies increased rapidly; this can be related to elevated contact temperature by judging the size and shape of the ultrafine particles generated. After test runs, the contacting bodies were analysed, revealing microstructural surface layer changes and differences in the amount of oxide formed in the immediate surface.When the sliding part of the wheel–rail contact under severe contact conditions is experimentally simulated using pin-on-disc methodology, the discussion shifts from analyzing steady-state measurements, such as average wear rate, to more transient behaviours during running-in. Wear transitions occurring during running-in are decisive for the outcome of the rest of the test run, according to the present results.

Research highlights▶ Airborne wear particle morphology change with increasing temperature. ▶ Higher concentration of agglomerated and round wear particles with increasing sliding velocity. ▶ In field measurement of ultrafine wear particles could possibly be used as a tool to track severe wear transitions.