轴重对轮轨材料滚动磨损与损伤行为影响

利用WR-1轮轨滚动磨损实验机研究不同轴重下轮轨材料滚动磨损与损伤性能。结果表明:轮轨试样磨损率均随轴重增加呈现线性增加趋势,且钢轨试样磨损率大于车轮试样磨损率。轮轨试样硬化率均随时间呈现先增加后趋于稳定的变化趋势,轮轨试样塑变层厚度和硬化率均随轴重增加而增大,且车轮试样硬化率大于钢轨。车轮试样和钢轨试样表面损伤形貌不同,车轮试样表面表现为垂直于滚动方向的疲劳裂纹,钢轨试样表面表现为裂纹和块状剥落,轮轨试样表面损伤均随轴重增加而更加严重;车轮试样表面裂纹疲劳断裂和钢轨试样表面块状剥落形成磨屑,成分主要为Fe2O3和马氏体,随轴重增加,磨屑尺寸呈现增大趋势,但成分与含量无明显变化。     

重载工况下车轮熔覆对轮轨磨损与损伤性能影响

利用CO2多模激光器在车轮试样表面获得Co基合金熔覆层,通过MMS-2A微机控制摩擦磨损试验机对比研究了不同轴重下轮轨试样的磨损性能与损伤机理。结果表明,车轮试样激光熔覆处理后熔覆层组织明显细化,表面硬度明显提高,约为基体的1.5倍。轮轨试样摩擦系数与磨损率随轴重增加而增大,车轮磨损率仅为钢轨的1/5~1/8;随时间增加,轮轨试样磨损量呈线性增长趋势;随轴重增加,轮轨试样表面损伤越严重,相同条件下,车轮试样损伤比钢轨轻微,轴重较小时,车轮熔覆层磨损主要为粘着磨损和氧化磨损,钢轨主要为疲劳磨损与氧化磨损。随轴重增加,轮轨试样主要为严重疲劳损伤,氧化磨损较为轻微。     

等温淬火球墨铸铁滚动磨损与损伤性能

利用不同热处理方式和球化工艺,获得两种显微组织和不同硬度的等温淬火球墨铸铁(Austempered Ductile Iron,ADI)材料,利用MMS-2A微机控制摩擦磨损试验机对比研究了两种等温淬火球墨铸铁材料、车轮材料与U71Mn钢轨匹配时的滚动磨损与损伤性能。结果表明:ADI材料与U71Mn钢轨匹配时的摩擦因数明显小于车轮材料;由于ADI材料具有自润滑效果导致其磨损率明显小于车轮材料,ADI材料的自润滑性能也降低了对摩副U71Mn钢轨的磨损率,其中含有较大球状石墨和较少残余奥氏体的ADI2材料和对摩副U71Mn钢轨的磨损率最小;ADI材料的磨损机制主要表现为轻微疲劳磨损,对摩副U71Mn钢轨的磨损机制主要表现为黏着和轻微疲劳磨损,而轮轨材料匹配时的塑性流动层显著,损伤以表面疲劳裂纹和剥层损伤为主。     

轮轨试样Co基合金激光熔覆层组织及磨损性能

为提高轮轨材料的耐磨性降低轮轨磨损,利用CO2多模激光器在轮轨试样表面获得Co基合金熔覆层,测试分析了其组织结构性能和显微硬度,利用MMS-2A微机控制摩擦磨损试验机对比研究了激光熔覆处理与未处理轮轨试样的抗磨损性能.结果表明:激光熔覆处理后在轮轨试样表面获得与基体良好结合厚度约1 mm的熔覆层;熔覆层主要由枝晶(γ-Co)和共晶组织(Cr23C6+γ-Co)构成,初生相为γ-Co过饱和固溶体,富含Cr元素,共晶组织中富含Co元素;结合区为粗大柱状晶,从中部到表层出现胞状晶、树枝晶等多种形态.离界面越远组织越细密,组织生长方向紊乱;结合区存在元素扩散,尤其是Fe、Cr和Co含量变化显著;激光熔覆Co基合金后轮轨试样硬度分别提高约52.98%和43.44%,能有效降低对摩副磨损,轮轨抗磨损能力提高约为原来的5倍.     

激光表面强化对40CrNiMo钢组织及性能的影响

为了提高常见汽车传动轴的耐磨性及力学性能,分别采用激光淬火及激光熔覆技术对40CrNiMo钢表面进行了激光强化处理.利用金相显微镜、扫描电子显微镜(SEM)观察了试样的微观形貌;利用显微硬度计测试了淬火试样的硬度;利用高低温摩擦磨损试验机测试了淬火试样的摩擦磨损性能;利用万能力学试验机对熔覆层的力学性能进行了评估.结果 表明:40CrNiMo钢经激光淬火后,表面出现一层相变硬化区,深度约为300 μm,硬度值最高可达815.6 HV2N,约为基体的3.2倍;平均摩擦系数0.391,与传统淬火工艺相比下降了42.8％,磨损量1.4 mg,降低了56.3％;主要磨损机制由疲劳磨损和黏着磨损转变为磨粒磨损,耐磨性得到较大改善.40CrNiMoA钢经激光熔覆后,表面光滑平整,合金熔覆层与基体能够形成冶金结合,其抗拉强度、屈服强度、延伸率分别为981 MPa、716 MPa、19.1％,断裂机制以韧性断裂为主,材料的强度和塑性均得到改善.     

激光淬火功率对45~#钢抗植物磨料磨损性能的影响

本文以苜蓿草粉为典型植物磨料,系统研究了激光淬火功率对45~#钢抗植物磨料磨损性能的影响。试验结果表明:在实验条件下,材料表面硬度最大值可达679HV,材料硬度最大值在距表面0.2~0.4mm之间;激光淬火后的45~#钢抗植物磨料磨损性能远高于未经激光处理的试件。激光功率对材料硬度和耐磨性的影响趋势并不完全一致,耐磨性最好的试件硬度并非最高;植物磨料对激光淬火后的45~#钢的磨损机理主要为显微切削,与未经激光淬火的试件相比,激光淬火后的45~#钢表面犁削深度明显浅而窄,但当激光功率降至1750W时,塑变疲劳和碳化物剥落明显增加。研究结论可为农业机械金属材料的耐磨性设计提供依据。     

高速车轮钢表面激光熔覆铁基合金涂层的摩擦磨损性能

为了探究激光熔覆对高速车轮钢合金涂层摩擦与磨损性能的影响,利用LDM2500-60型半导体全固态激光器在高速车轮钢表面激光熔覆制备Fe基合金涂层。分别采用金相显微镜、能量色散X射线光谱仪、X射线衍射仪(XRD)分析了熔覆涂层的组织结构、元素分布以及物相,利用MM-2000高速摩擦试验机研究了高速车轮材料激光熔覆处理前后轮轨材料的摩擦磨损性能。结果表明:激光熔覆处理能有效改善车轮材料的抗磨损性能,熔覆涂层主要由γ-Fe、Cr7C3碳化物以及含铁固溶体等物相组成,涂层组织主要以树枝晶和共晶为主;车轮合金涂层的磨损速率相比基体材料降低了51%左右,车轮熔覆铁基合金后的轮轨磨损机制主要表现为轻微的磨粒磨损和氧化磨损。     

不同介质下的轮轨摩擦噪声和磨损特性试验研究

基于MMS-2A型轮轨滚动摩擦磨损试验机的双轮对滚试验,研究轮轨摩擦磨损过程中滚动噪声、摩擦系数和磨损量与介质的关系。结果表明:轮轨间添加不同介质时,轮轨噪声发展趋势基本一致,总体来看,都是先增大,到达首个峰值后开始降低,随着循环次数的增加,噪声声压值会趋于平稳,但在声压级上却存在明显差异。相较于常规干态情况,水介质会使轮轨材料摩擦时的噪声声压级降低1.5 dB,轮轨间摩擦系数则显著下降49.4%,车轮和钢轨试样的磨损量分别降低52.4%和44.4%;而撒砂则会使轮轨材料摩擦时的噪声声压级增加2.5 dB,轮轨间摩擦系数上升12.7%,车轮和钢轨试样的磨损量则显著增加,分别增加了105%和289%。以上研究可为轨道交通减振降噪措施提供依据,并指导线路的运营维护保养。     

不同滑滚比下轮轨材料损伤行为

在MMS-2A滚滑试验机上采用法向载荷120N(模拟轴重16t),转速500r/min,研究京沪高速铁路用钢轨U71MnK和车轮ER8配副在不同滑滚比下的材料损伤行为。利用SEM,EDX对不同滑滚比下的磨痕及剖面形貌和磨损表面元素进行分析。结果表明:不同滑滚比下摩擦因数变化趋势反映材料损伤的过程;轮轨材料的硬化程度随滑滚比增加而增加;不同滑滚比条件下的损伤机制不同:在近似滚动条件下,轮轨材料损伤较轻,主要为氧化磨损和局部剥落。随着滑滚比增加,轮轨材料损伤逐渐发展为疲劳磨损为主,并伴随氧化磨损和磨粒磨损,且磨粒磨损程度随滑滚比的增加而增加。     

高速轮轨钢超声振动辅助激光熔覆涂层的滚动摩擦磨损性能

目前有关高速轮轨钢超声振动辅助下的激光熔覆研究鲜有报道。在高速轮轨钢表面施加超声振动辅助激光熔覆制备了铁钴基复合涂层来改善其耐磨性能,借助扫描电镜(SEM)、X射线衍射仪(XRD)、能量色散谱仪(EDS)等手段分析熔覆层的微观结构、物相成分和元素分布,采用GPM-30轮轨滚动接触疲劳试验机对比研究轮轨钢超声振动辅助作用下激光熔覆前后涂层的滚动摩擦磨损性能。结果表明:熔覆层主要由Fe-Cr的马氏体组织、Co-Cr的γ相固溶体、Fe-Ni固溶体以及弥散析出的含MxCy(M=Cr、W)的碳化物、硼化物、硅化物等硬质相组成;超声激光熔覆强化处理后,轮轨表面的平均显微硬度分别为539 HV3 N和582 HV3 N,磨损速率分别降低59.1%,37.3%,轮轨试环熔覆层的抗磨损性能大幅提高,磨损机制由剥落磨损和严重的疲劳磨损转变为轻微的磨粒磨损和疲劳磨损。     

Investigation on the damage mechanism and prevention of heavy-haul railway rail

The objective of this paper was to investigate wear and damage behavior of heavy-haul railway rail. Furthermore, the mechanism and preventive measures of heavy-haul rail damage were explored in detail. The results show that the rail side wear and surface spalling are dominating damage mechanism for Datong-Qinhuangdao heavy-haul railway. With the annual transport volume increasing, average wear volume and maximal wear volume of rail side each month reach 1.98 mm and 4.16 mm, respectively. Rail side wear has become the decisive factor of replacing of heavy-haul curved rail. The hardness of damage rail is higher than that of new rail due to severe work hardening and plastic streamline deformation. Fatigue cracks initiate from wear surface of damage rail and there are different propagation path on the crack growing process. The intergranular and transgranular growth are dominating propagation modes for the heavy-haul rail cracks. Furthermore, there is a competitive and restrictive coupling relationship between fatigue crack damage and rail wear. Large axle load and unreasonable matching of wheel/rail profiles would cause serious wear and spalling damage of heavy-haul wheel/rail. New wheel profile with good matching ability for CHN75 rail should be designed and optimized. The laser quenching can increase surface hardness and improve wear-resistance of wheel/rail materials. The surface damage of wheel/rail specimens with laser quenching is relatively slight. In a word, laser quenching can be used to treat rail side and wheel flange for prolonging wear life of heavy-haul wheel/rail in the field.     

轮缘固体润滑剂对轮轨减摩及损伤性能影响

用MMS-2A滚动摩擦磨损试验机完成试验工作,对比干态和3种不同固体润滑剂作用工况,分析干态和3种不同固体润滑剂作用后的轮轨摩擦性能和固体润滑剂的有效作用时间,探究固体润滑剂对轮轨摩擦性能的影响;分析不同工况下轮轨表面磨损量和表面裂纹,同时对裂纹的长度、角度、深度进行统计,分析固体润滑剂作用对轮轨损伤性能影响。结果表明:固体润滑剂具备减摩润滑作用,其中1号效果最佳,将干态下的摩擦系数0.5降低到0.2左右;固体润滑剂通过降低接触界面的摩擦系数减小轮轨界面的切向摩擦力,降低轮轨表面的磨损量,其中固体润滑剂1降低车轮和钢轨的磨损量最大,分别降低95.3%和97.1%;固体润滑剂主要通过抑制疲劳裂纹的长度来抑制轮轨疲劳裂纹的生长和扩展,通过正应力挤压作用使轮轨表面疲劳裂纹开口紧闭,缓解裂纹根部分支现象,有效抑制轮轨疲劳裂纹生长与扩展行为.     

重载机车车轮擦伤下的轮轨动态响应

车轮踏面擦伤会造成剧烈的轮轨冲击作用,加剧车辆和轨道结构部件的疲劳破坏。为揭示实际车轮擦伤状态下的重载机车-轨道耦合振动响应特征,基于车轮擦伤的现场实测数据,拟合出了车轮擦伤模型。采用重载机车-轨道耦合动力学模型,详细考虑了钢轨垫层与扣件弹条相互作用,分别从时域和频域角度仿真计算了机车车轮擦伤引起的轮轨动态响应。研究结果表明:实际车轮擦伤呈不对称的几何形状;车轮擦伤激起的冲击力对轨道部件影响较大;车轮擦伤可能引发钢轨与扣件系统的短暂分离。研究结果可为踏面损伤识别、轨道部件检修提供理论参考。     

The effect of laser surface nitriding with a spinning laser beam on the wear resistance of commercial purity titanium

Laser nitriding of commercial purity titanium using various concentrations of helium and nitrogen has been carried out. The surface appearance and microstructure of a treated layer were found to be dependent on the beam power density, interaction time, velocity and concentration of nitrogen. X-ray diffraction analyses have led to the conclusion that the dendrite layer in the resolidified zone of the nitrided specimens consisted mainly of TiN. The surface roughness of specimens after various laser treatments was investigated by SEM and a surface profilemeter. Using optical microscopy, the dendrite TiN and needle-like structure in the melt zone, and the large grain structure in the heat affected zone, were investigated. The surface wear resistance of nitriding CPTi was significantly improved compared to the untreated or laser glazed material, and the wear data were found to correlate with scanning electron microscopy observations. Two layers, having different microstructures, thickness and abrasive wear resistance were identified. Further, 100% overlapping considerably improved the wear resistance of the nitrided specimens.     

Effect of microstructure on the spalling damage in a 20Mn2SiCrMo bainitic rail

The effect of microstructure on the spalling damage in a heavy-haul 20Mn2SiCrMo bainitic wing rail was investigated. The results show that spalling damage is strongly correlated to the detailed microstructure factors which contribute to the crack propagation resistance at different levels. It is demonstrated that comparing with blocky martensite/austenite (M/A) constituents, film-like M/A constituents have better performance to retard crack propagation. Moreover, the type and proportion of M/A constituents are affected by the isothermal holding temperature during heat treatment, where typical blocky M/A constituents are found in the temperature range from 360 °C to 400 °C.     

Laser surface coating of Mo–WC metal matrix composite on Ti6Al4V alloy

Laser surface alloying of Mo, WC and Mo–WC powders on the surface of Ti6Al4V alloys using a 2 kW Nd-YAG laser was performed. The dilution effect upon the microstructure, microhardness and wear resistance of the surface metal matrix composite (MMC) coating was investigated. With a constant thickness of pre-placed powder, the dilution levels of the alloyed layers were found to increase with the incident laser power. The fabricated surface MMC layer was metallurgically bonded to the Ti6Al4V substrate. The microhardness of the fabricated surface layer was found to be inversely proportional to the dilution level. The EDAX and XRD spectra results show that new intermetallic compounds and alloy phases were formed in the MMC layer. With the existence of Mo content in the pre-placed powder, the β-phase of Ti in the MMC coating can be retained at the quenching process. With increasing weight percentage content of WC particles in the Mo–WC pre-pasted powder, the microhardness and sliding wear resistance of the laser surface coating were increased by 87% and 150 times, respectively, as compared with the Ti6Al4V alloy. The surface friction of the laser-fabricated MMC coatings was also decreased as compared with the worn Ti6Al4V substrate.