Rolling contact fatigue (RCF) is currently one of the principal limitations of railway infrastructure productivity. Head checks in particular are prevalent in curves and switches where flange contact at the gauge corner results in increased slip and decreased wheel-rail contact area. These surface-initiated cracks can lead to complete failure of the rail and potentially a derailment. The focus of the EU 5th Framework project InfraStar is on improving the durability and lifetime of the rail along stretches af track with narrow and moderate radius curve, high traffic volumes and high axle loads by applying a surface coating to the railhead. The main goal of the project is to develop a railhead with an additianal surface layer (the InfraStar two-material rail) which prevents RCF and reduces noise emissions in narrow-radius curved rail. Results are presented here from twin-disc laboratory testing and metallurgical analysis of specimens with the two selected new surface layer materials. The effects of lubrication, applied load and coating thickness were studied. An eddy current probe was used for crack detection. Both materials survived 200,000 cycles of water-lubricated twin-disc testing without crack formation, in contrast to UIC (260 grade) 900A base material which showed severe cracking after only 4000 cycles. Metallurgical investigations show excellent RCF resistance and bonding of the tested coatings.
Rolling contact fatigue and wear behaviour of the infrastar two-material rail
2003
7 Seiten, 10 Bilder, 5 Tabellen, 9 Quellen
Aufsatz (Konferenz)
Englisch
Rolling contact fatigue and wear behaviour of the InfraStar two-material rail
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