S.R. Lewis

Tribology of the wheel rail contact : aspects of wear, particle emission and adhesion

The wheel–rail contact is a safety critical interface. Wear, particle emission and adhesion are all wheel–rail contact phenomena and are discussed here. All three phenomena are material and system parameters and are linked together. Different countermeasures to one phenomenon such as adhesion enhancement with a friction modifier can increase the wear in the contacting bodies. The wear of railway wheels and rail is linked to the number of airborne particles generated, but the exact number and size distribution of the aerosols is unknown. The main objective of this study is to review the recent work in this field and to discuss future trends.

The modification of a slip resistance meter for measurement of railhead adhesion

The aim of this work was to find a quick, flexible and localised method for determining railhead adhesion. The proposed method is a pendulum rig, which has a rubber pad at the base of a swinging arm. The arm is released and as the rubber pad slides across the contact surface, energy is lost. This loss can be translated into a friction coefficient. Tests have been performed under dry and contaminated conditions, including water, oil and leaf layers both in the laboratory on extracted rail and in the field on live rail. Friction modifiers were also tested. The results of these tests are compared with data obtained using a hand-pushed tribometer. The performed study shows that the pendulum is a viable way to test adhesion levels in the field.

Effect of humidity, temperature and railhead contamination on the performance of friction modifiers: Pin-on-disk study

Commercially available friction modifiers are used in many different countries that have widely different atmospheric conditions. These variations in atmospheric conditions lead to varying levels of railhead oxidation and debris build-up. Friction modifiers can be applied to the rail without any prior cleaning of the rail and this can lead to varying friction modifier/iron oxide ratios potentially affecting the performance of the friction modifier. This paper reports the results of an investigation that was performed to determine the effects of varying atmospheric and oxide conditions on the performance of friction modifiers. A pin-on-disk test rig with an attached environmental chamber was used for the study. Results show that relative humidity has a pronounced effect on the way in which the friction modifier affects friction levels, and also the amount of time it remains on the disk. This also depends on the concentration of oxide in the friction modifier. Glow discharge optical emission spectroscopy analysis was also carried out to assess the effect of the friction modifier and atmospheric conditions on the chemical composition of the surface of the disk. Results show that the depth of surface modification is vastly different depending on the conditions and level of railhead debris.

Effect of Gear Surface and Lubricant Interaction on Mild Wear

In this study, a twin-disc test machine was used to simulate a rolling/sliding gear contact for three surface finishes, each run with two types of lubricants, thus seeking to develop insight into the tooth flank/lubricant tribological system. The test disc surfaces were case-carburised before the surfaces were produced by: transverse grinding followed by a mechanical abrasive polishing process; transverse grinding only; and transverse grinding followed by preheating as a final finishing step (intended to enhance the build-up of an easily sheared surface boundary layer using a sulphur additive). The twin-disc contact was lubricated with an ester-based environmentally adapted lubricant or a polyalphaolefin-based commercial heavy truck gearbox lubricant. To obtain information about the composition of chemically reacted surface layers, the specimens used were analysed using glow discharge-optical emission spectroscopy. The results indicate that the interactions between different surface finishes and lubricants have different impacts on friction behaviour, wear and the reacted surface boundary layer formed by the lubricant. Running a smooth (polished) surface with the appropriate lubricant drastically reduces the friction. Surface analysis of the ground surfaces gives clear differences in lubricant characteristics. The commercial lubricant does not seem to react chemically with the surface to the same extent as the EAL does. Micropitting was found on all ground discs with both lubricants, though at different rates. The highest amount of wear but less surface damage (i.e. micropits) was found on the preheated surface run with the commercial lubricant.

The effect of friction modifiers on wheel/rail isolation at low axle loads

Signalling block occupancy is triggered by the wheelset of a rail vehicle ‘shunting’ the track circuit. The main cause of loss of shunting is the many materials that can be present on the rail head. These include iron oxides, leaves, ballast dust, oil, as well as products deliberately applied to the rail/wheel such as grease, friction modifiers, lubricants and sand. These may lead to an indication that a signal block is unoccupied when a train is actually present. Friction modifiers (FMs) are being increasingly used for reduction of noise, lateral forces, wear, rolling contact fatigue, etc. The Kelsan® high positive friction (HPF) solid stick FM is applied directly to the wheel tread creating a thin film. Although no effects have been observed during field operation, the intention in this work was to build on previous studies and evaluate conductance across a wider range of contact conditions as studies have shown that loss of shunt is more common with light axle loads where films could have a greater effect. The testing was performed at a contact pressure of 470 MPa (equating to a 4.9 tonne axle load). An HPF stick was spring loaded against the rotating wheel disc to generate a FM film at the contact. Tests were run to measure the impedance across the discs using a modified TI21 track circuit. Static testing was also performed using discs with a pre-generated HPF film. Analysis of the results showed that the application of HPF friction modifier had no significant effect on the measured level of impedance. The highest impedance levels were recorded under pure rolling (0% slip) where FMs were not being applied. In cases where the application of FM increased impedance, the recorded impedance values were still lower than the highest values measured in the absence of a FM. This is of key relevance as several light rail operators coast their trains.

Chemistry of black leaf films synthesised using rail steels and their influence on the low friction mechanism

Fallen leaves are the main issues for train operations in the autumn season due to their low friction coefficient (COF), leading to signals being passed dangerously and amended timetables. The main aim of this study was to elucidate the mechanism of low friction due to black leaf films, which are often seen on leaf-contaminated rails. A black material was successfully synthesised in the laboratory with water extracts from sycamore leaves and a plate of R260 rail steel. The black powder made from the extracts of brown leaves (BBP) was identified as the key material of low friction by the pin-on-flat tribological test, giving a COF between 0.08 and 0.14, which was lower than the COF of commercial engine oil (approximately 0.14). X-Ray fluorescence showed that the black material was a mixture of iron and leaf-organics. Laser Raman spectroscopy revealed that graphite-like carbon was likely to be formed on iron oxides. Fourier transform infrared spectroscopy showed that the formation of iron carboxylate was likely in bulk, which possibly transformed into iron oxides on the surface. Moreover, X-ray photoelectron spectroscopy detected a relatively high concentration of phosphates only in BBP. Hence, the low friction is presumably due to graphitic carbon, iron oxides and phosphate compounds in the black leaf films, as well as mechanical separation effects of bulk leaves. This black material could be a product of the Maillard reaction or reaction between iron and organic acids, such as tannic acids.

Optimisation of a railway sanding system for optimal grain entrainment into the wheel–rail contact

To combat adhesion loss, sand is fired into the wheel–rail contact via a hose using compressed air typically from a storage hopper mounted to the under frame of the train. Many passenger trains in the UK are fitted with stepped braking controllers which range from 1 to 3 with a fourth step being ‘emergency braking’.1 Sand is fired automatically if wheel slip is detected from brake step level 2 upwards.2 Sand is automatically fired when the emergency brakes are applied irrespective of whether low adhesion/wheel slip has been detected.2 For adhesion loss in traction, sand can be applied at the driver’s discretion. Current railway standards2 govern the maximum permissible sand flow rate to protect against wheel/rail isolation of track circuits, but do not address the hose position. This results in a range of hose set-ups across different train types, some of which may not be effective at delivering sand. The work here was carried out using a full-scale laboratory rail–wheel test machine to find the position for the hose and sand flow rates that give optimum sand entrainment to the contact. It was found that ideally the hose should be aimed at the rail or nip and be as close to that contact as safely possible. The use of a 20 mm bore nozzle on the end of a 25 mm bore hose increased sand passing through the contact by up to 70% relative to widely used 25 mm bore hoses without a nozzle. Reduction in sand flow rate below the 2 kg/min threshold significantly reduced the amount of sand entering the contact. It was also shown that relatively small movements in the hose/nozzle from its ideal position and cross winds significantly reduced sand entrainment.

Towards a standard approach for the wear testing of wheel and rail materials

An examination of the literature for the wear testing methodologies for wheel and rail materials reveals that while only a few different techniques have been used, there is a wide variety in exactly how the tests have been conducted and the resulting data reported. This makes comparison of the data very difficult. This work, carried out as part of the International Collaborative Research Initiative which is aiming to bring together the wheel–rail interface researchers from across the world to collate data and knowledge to try to solve some of the common problems that are faced, has examined the different approaches used and has attempted to pull together all the good practice used into a test specification for future twin-disc testing for wheel and rail materials. The adoption of the method will allow data to be compared reliably and eventually enable data to be compiled into wear maps to use as input, for example, to multi-body dynamics simulation wear prediction tools.