Rolling contact fatigue and wear of two different rail steels under rolling–sliding contact

• Wear and rolling contact fatigue characteristics of two different rail steel were investigated by using twin disc test.
• The wear map of the KS 60 rail is proposed.
• Relationship between wear and RCF according to slip ratio was verified.
• High strength and hardness decrease wear rate, however, high ductility and fracture toughness increase contact fatigue life.

Rolling contact fatigue and wear of rails are well-known problems. However, progress is not easy to predict because these problems interact with each other. Therefore, to reduce damage, the interactions between these two mechanisms must be clarified. In this study, the contact fatigue and wear of UIC 60 and KS 60 rail materials were investigated by twin-disc testing with various parameters. We found that ductility and fracture toughness are important factors on wear and contact fatigue. UIC 60 rail steel with higher ductility and fracture toughness than KS 60 rail steel has a higher resistance to contact fatigue but a lower resistance to wear.