列车车轮踏面局部损伤激光熔覆修复涂层性能分析
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华东交通大学 机电与车辆工程学院

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江西省自然科学基金(项目编号:20232BAB204003)与江西省青年科学基金(项目编号:20242BAB20205)与江西省自然科学基金优青项目(20252BAC210001),


Study on the Performance of Local Laser Additive Repair Coatings on Train Wheel Treads
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    摘要:

    目的 探究车轮局部修复激光熔覆涂层磨损性能。方法 本研究选用铁基、钴基及316L不锈钢三种合金粉末作为修复材料,采用激光熔覆技术对列车轮缘局部损伤进行经济高效的修复。在车轮踏面开展局部修复,并利用LGPS-30C轮轨接触模拟试验台进行滚动-滑动摩擦试验,系统分析了三种涂层的耐磨性能及抗滚动接触疲劳性能。并通过扫描电子显微镜和光学显微镜对涂层磨损形貌进行分析。 结果 激光熔覆形成的涂层主要由树枝状晶体与共晶组织组成,涂层硬度相较于基材轮对显著提升。磨损形貌的宏观与微观分析揭示了三种涂层性能的差异:其中钴基合金涂层的磨损表面较为光滑,未见裂纹萌生,表现出最佳的耐磨性能;相比之下,316L不锈钢合金涂层出现明显剥落,磨损较为严重;而铁基合金涂层虽磨损表面较为平整,但在涂层与基材界面处存在较深裂纹及裂纹扩展现象,存在涂层断裂与脱落的潜在风险。结论 使用车轮试样进行局部激光熔覆修复并经过滚动-滑动摩擦试验后,三种合金涂层相比之下,钴基合金涂层表现更为优异。

    Abstract:

    Coatings prepared by laser cladding technology possess excellent properties such as wear resistance, corrosion resistance, and resistance to fatigue wear, along with the advantage of achieving metallurgical bonding between the coating and the substrate. This study aims to realize the cost-effective and efficient repair of localized railway wheel damage using laser additive technology, employing three different types of alloy powders: Fe-based, Co-based, and 316L stainless steel. Localized repairs were carried out on wheel surfaces, and the rolling contact fatigue performance of the three coatings was comparatively analyzed. ER9 wheel steel was machined into small-scale wheels with a diameter of 60 mm, and notches were introduced on the surface to simulate localized damage. Using a TF-YF6000 laser system, Fe-based, Co-based, and 316L stainless steel coatings were deposited on the substrate surface under the following parameters: laser power of 2600 W, spot diameter of 3 mm, scanning speed of 0.6 m/min, and an overlap ratio of 50%. Rolling-sliding friction tests were subsequently conducted on the LGPS-30C wheel–rail contact simulation test bench. The microstructural morphology, phase composition, and nanohardness of the coatings were analyzed using a scanning electron microscope (SEM), X-ray diffractometer (XRD), optical microscope (OM), and nanoindenter, respectively. The results indicated that the coating surfaces were dense and exhibited good metallurgical bonding. The Fe-based, Co-based, and 316L stainless steel coatings primarily consisted of dendritic and eutectic microstructures, and their hardness was significantly enhanced compared to the base wheel material. Macro- and microscopic analysis of the wear morphology revealed critical differences in performance among the three coatings: the Co-based alloy coating exhibited a notably smooth and flat wear surface without any signs of crack initiation, demonstrating the best wear resistance; in contrast, the 316L stainless steel alloy coating showed significant flaking and more severe wear; while the Fe-based alloy coating displayed a relatively flat surface, it developed deeper cracks and extensive crack propagation at the substrate–coating interface, indicating a potential risk of coating fracture and detachment. The surface of the Fe-based coating exhibited fine scratches and ploughing marks, with an abrasive wear mechanism. The Co-based coating surface showed evidence of material accumulation, indicating an adhesive wear mechanism. The 316L stainless steel surface displayed pronounced spalling, with its wear mechanism primarily characterized as fatigue wear.

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  • 收稿日期:2025-12-01
  • 最后修改日期:2026-01-10
  • 录用日期:2026-02-16
  • 在线发布日期: 2026-03-20
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