目的 为揭示高速列车制动盘用Cr-Ni-Mo合金钢在不同温度与转速条件下的摩擦磨损规律及磨损机制演变特征。方法 在干摩擦条件下,于25、300、500 ℃及400、800 r/min转速下进行试验。通过摩擦系数、比磨损率及系统表征分析其摩擦学行为。核心方法创新在于：为克服传统表面能谱分析因粗糙度导致的元素信号模糊问题,本研究采用基于机械抛光的摩擦断面能谱分析技术;通过高纯试剂与对比验证以控制制样污染,并对EDS数据中的固有背景信号（如环氧树脂中的C）进行识别与扣除,从而实现了对摩擦层内O、Cr、Fe等关键元素梯度与分布的高精度表征。进一步结合断面形貌与能谱分析,实现了对脱落物来源及其分布特征的精准判别。结果 摩擦系数与比磨损率随温升呈先降后升趋势,在300 ℃、800 r/min时达到最低值,而在500 ℃、400 r/min下波动最为剧烈。磨损机制由磨粒磨损为主,转变为氧化磨损为主,高温下因氧化膜失稳进而引发疲劳磨损共同作用。结论 本研究通过方法创新,明确了氧化膜稳定性是调控摩擦性能的关键,揭示了摩擦层结构演变与磨损机制间的内在联系,为高速列车制动盘材料的耐磨设计与性能优化提供了更精准的实验依据与理论支持。
Abstract
The work aims to systematically investigate the friction and wear behaviors of Cr-Ni-Mo alloy steel, a candidate material for high-speed train brake discs, under varying thermal and mechanical conditions. A series of dry sliding tests were conducted with an HT-1000 high-temperature friction and wear tester. The tests were performed at three temperatures of 25 ℃, 300 ℃, and 500 ℃ and two rotational speeds of 400 r/min and 800 r/min under a constant load of 15 N. The friction coefficients were continuously recorded throughout the tests, and wear rates were calculated based on the Archard model. To gain comprehensive insights into the wear mechanisms, the worn surfaces and cross-sections were systematically characterized through field-emission scanning electron microscopy (SEM) combined with energy-dispersive X-ray spectroscopy (EDS). This multi-scale approach enabled a detailed correlation between surface morphology, subsurface microstructure, and elemental distribution.
Two key methodological improvements were introduced to enhance the accuracy of the analysis. Firstly, to overcome the limitations of conventional surface EDS analysis where rough topography and chemical depth gradients led to ambiguous elemental signals, the cross-sectional EDS combined with mechanical polishing was employed. By using high-purity reagents and performing comparative blank tests, potential contamination during sample preparation was controlled. Moreover, inherent background signals in the EDS data (such as carbon from the epoxy resin) were identified and subtracted, thereby achieving high-fidelity quantification of the gradients and distributions of key elements (O, Cr, Fe, etc.) within the friction layer. Secondly, by integrating cross-sectional morphology with EDS mapping, the origin and spatial distribution of detached particles were accurately identified within the friction layer, elucidating the physical pathways of material removal during the wear process.
The results revealed that both the friction coefficient and wear rate followed a non-monotonic trend with the increasing temperature and speed, initially decreasing and then rising. The most favorable tribological performance was observed at 300 ℃ and 800 r/min, where the friction coefficient reached a minimum value of 0.46 and the wear rate was also the lowest, indicating a highly stable friction state. In contrast, at 500 ℃ and 400 r/min, the friction coefficient exhibited severe fluctuations, reflecting unstable surface conditions. Morphological analysis further illustrated the evolution of wear mechanisms across temperature regimes. At low temperatures (25 ℃), abrasive wear dominated, as evidenced by regular ploughing grooves and abundant wear debris. At intermediate temperatures (300 ℃), a thin and continuous oxide film formed on the surface, serving as a solid lubricant that significantly reduced both friction and wear. At high temperatures (500 ℃), the oxide film thickened but became discontinuous, with visible cracks and delamination zones in both surface and cross-sectional images. EDS analysis confirmed oxygen enrichment in these regions, supporting the hypothesis of cyclic oxide formation and spallation. Under combined high-temperature and high-speed conditions, thermal fatigue and mechanical stress synergistically promoted the initiation and propagation of microcracks, leading to a complex wear regime involving oxidative, abrasive, and fatigue mechanisms.
The integration of cross-sectional SEM-EDS analysis provided direct evidence of the layered structure of the tribological surface, which included an oxide film, a deformation zone, and the unaffected matrix. This layered characterization offered valuable insights into the gradient evolution of friction-induced microstructures. By clarifying the transition in wear mechanisms with the increasing temperature from abrasive wear to a mixed oxidative-fatigue regime and quantitatively linking oxide film stability to tribological performance, this work unequivocally establishes that the stability of the oxide film is the key factor regulating frictional performance, revealing the intrinsic connection between the structural evolution of the friction layer and the transition of wear mechanisms. The methodological advances employed here provide more precise experimental evidence and theoretical support for the wear-resistant design and performance optimization of Cr-Ni-Mo alloy steel brake discs in high-speed railway applications.
关键词
Cr-Ni-Mo合金钢 /
摩擦磨损 /
亚表层微观结构 /
氧化膜 /
磨损机制 /
微观形貌
Key words
Cr-Ni-Mo alloy steel /
friction and wear /
subsurface microstructure /
oxide film /
wear mechanism /
microstructure morphology
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基金
2025年甘肃省科技计划项目科技专员专项（25CXGA039）
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