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Influence of surface topography and surface modifications on seizure initiation in lean lubricated sliding contacts
KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Machine Design (Div.).
KTH, School of Industrial Engineering and Management (ITM), Machine Design (Dept.), Machine Design (Div.).
2007 (English)In: Wear, ISSN 0043-1648, E-ISSN 1873-2577, Vol. 262, 986-995 p.Article in journal (Refereed) Published
Abstract [en]

Seizure initiation in lean-lubricated contacts was experimentally studied using a transient test method of ball-on-disc type at two different sliding velocities, 2 and 3.8 m/s. Four different nodular cast iron surfaces were tested against a bearing ball of 100Cr6 steel: a fine-milled and roller-burnished surface, a ground and lapped surface, a ground and lapped laser-melted surface, and finally a ground surface. The results show that the ground surface, even though it is smoother than the fine-milled and roller-burn i shed surface, shows indications of seizure at a lower load. No graphite nodules from the nodular cast iron were visible in the surfaces on inspection with an optical light microscope. In contrast, the ground and lapped surface suffered no initial or total seizure in these tests. In this case, many graphite nodules were visible in the surface, and these nodules became detached in the contact zone, where they probably acted as a solid lubricant. Many graphite nodules were also visible in the ground and laser-melted surface, though in this case the graphite nodules did not become detached. This surface topography initiated seizure under a low normal load, and increased sliding velocity lowered the total seizure load significantly.

Place, publisher, year, edition, pages
2007. Vol. 262, 986-995 p.
Keyword [en]
seizure, surface topography, sliding velocity, lubrication, nodular cast iron
National Category
Reliability and Maintenance
Identifiers
URN: urn:nbn:se:kth:diva-11577DOI: 10.1016/j.wear.2006.10.014ISI: 000245063500026Scopus ID: 2-s2.0-33847060484OAI: oai:DiVA.org:kth-11577DiVA: diva2:277797
Note
QC 20100721Available from: 2009-11-20 Created: 2009-11-20 Last updated: 2017-12-12Bibliographically approved
In thesis
1. On wear transitions in the wheel-rail contact
Open this publication in new window or tab >>On wear transitions in the wheel-rail contact
2009 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Wear transitions in the wheel–rail contact are of increasing interest since the general trend in railway traffic is toward increased velocities and axle loads. Curving increases the risk of flanging, causing the contact to change from an almost pure rolling wheel tread–rail head contact to more of a sliding wheel flange–rail gauge contact on the high rail in curves.

Under wheel flange–rail gauge contact conditions, wear transitions to severe or catastrophic wear will occur if the contact is improperly lubricated. Such a transition is the most undesirable transition in the wheel–rail contact, as it represents a very expensive operating condition for railway companies. The contact conditions responsible for this transition are very severe as regards sliding velocity and contact pressure, and thus place high demands on both the lubricant and the wheel and rail materials.

The focus of this thesis is on the transitions between different wear regimes in a wheel–rail contact. Wear is discussed both in traditional tribological terms and in terms of the categories used in the railway business, namely mild, severe and catastrophic wear. Most of the work was experimental and was performed at the Royal Institute of Technology (KTH), Department of Machine Design.

The effects of contact pressure, sliding velocity, and type of lubricant have been investigated, producing results that resemble those of other studies presented in the literature. The absence of research relating to the wheel flange–rail gauge contact is addressed, and it is concluded that a lubricant film must be present on rails in curves to prevent severe or catastrophic wear. The formulation of this lubricant can further increase its wear- and seizure-preventing properties. To obtain a deeper understanding of wear transitions, methods such as airborne particle measurement and electron microscopy have been used.

Paper A presents the test methodology used to detect seizure and discusses the wear-reducing influence of free carbon in highly loaded contacts.

Paper B presents the testing of seizure-initiating conditions for a range of environmentally adapted lubricants applied to wheel and rail materials; a transient pin-on-disc test methodology was used for the testing.

Paper C presents the use of pin-on-disc methodology to study the wear-reducing effects of a wide range of lubricants. The best performing lubricant was a mineral oil containing EP and AW additives.

Paper D relates wear rates and transitions to airborne particles generated by an experimentally simulated wheel–rail contact. The airborne particles generated varied in size distribution and amount with wear rate and mechanism.

Paper E relates additional analysis techniques, such as FIB sectioning, ESCA analysis, airborne particle measurements, and SEM imaging of airborne wear particles, to the contact temperature.

 

Place, publisher, year, edition, pages
Stockholm: KTH, 2009. 31 p.
Series
Trita-MMK, ISSN 1400-1179 ; 2009:23
Keyword
Wear transitions; Wheel; Rail; Wear regime; Wear mechanism
Identifiers
urn:nbn:se:kth:diva-11563 (URN)978-91-7415-511-2 (ISBN)
Public defence
2009-12-11, M3, Brinellvägen 64, KTH, Stockholm, 10:15 (Swedish)
Opponent
Supervisors
Projects
Samba 6
Note
QC 20100721Available from: 2009-11-20 Created: 2009-11-20 Last updated: 2012-01-27Bibliographically approved
2. An experimental study on wear transitons in the wheel-rail contact
Open this publication in new window or tab >>An experimental study on wear transitons in the wheel-rail contact
2007 (English)Licentiate thesis, comprehensive summary (Other scientific)
Place, publisher, year, edition, pages
Stockholm: KTH, 2007. 25 p.
Series
Trita-MMK, ISSN 1400-1179 ; 2007:02
National Category
Other Materials Engineering
Identifiers
urn:nbn:se:kth:diva-4389 (URN)
Presentation
2007-04-23, Rum M37, KTH, Brinellvägen 64, Stockholm, 13:15
Opponent
Supervisors
Note
QC 20101118Available from: 2007-05-22 Created: 2007-05-22 Last updated: 2012-01-27Bibliographically approved

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