Wheel material wear mechanisms and transitions

In order to develop more durable wheel materials to cope with the new specifications being imposed on wheel wear, a greater understanding is needed of the wear mechanisms and transitions occurring in wheel steels, particularly at higher load and slip conditions. In this work wear assessment of wheel materials is discussed as well as wear rates, regimes and transitions. Twin disc wear testing, used extensively for studying wear of wheel and rail materials, has indicated that three wear regimes exist for wheel materials; mild, severe and catastrophic. These have been classified in terms of wear rate and features. Wear rates are seen to increase steadily initially, then level off, before increasingly rapidly as the severity of the contact conditions is increased. Analysis of the contact conditions in terms of friction and slip has indicated that the levelling off of the wear rate observed at the first wear transition is caused by the change from partial slip to full slip conditions at the disc interface. Temperature calculations for the contact showed that the large increase in wear rates seen at the second wear transition may result from a thermally induced reduction in yield strength and other material properties. Wear maps have been produced using the test results to study how individual contact parameters such as load and sliding speed influence wear rates and transitions. The maps are also correlated to expected wheel/rail contact conditions. This improved understanding of wheel wear mechanisms and transitions and will help in the aim of eventually attaining a wear modelling methodology reliant on material properties rather than wear constants derived from testing.