Experimental Depiction of the Hypothesis of Flake-Like Wear Debris Generation in Rolling Contact Fatigue of the Rail–Wheel Contact Interface

ABSTRACT

Flake-like particles represent a common type of wear debris generated during the rolling contact fatigue wear test using a twin-disc test rig. It is argued that these flake-like particles are generated during the delamination process due to plastic shear strain accumulation at the wearing surfaces. This hypothesis has been developed in the last decades to explain the particle generation mechanism, yet it has not been proven conclusively. This research provides strong experimental evidence of the creation processes of wear debris propagation, aggregation, transfer, and compaction, therefore confirming the existing hypothesis and enhancing the understanding of wear mechanisms in the rolling contact interface.

KEYWORDS:

• Flake-like wear particle
• FIB milling
• rolling contact fatigue
• railway
• replica

Acknowledgements

The data reported in this paper were obtained at the Central Analytical Research Facility operated by the Institute for Future Environments (QUT) and Banyo Pilot Plant Precinct. Access to CARF is supported by generous funding from the Science and Engineering Faculty (QUT).