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.
Key words
Cr-Ni-Mo alloy steel /
friction and wear /
subsurface microstructure /
oxide film /
wear mechanism /
microstructure morphology
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Funding
2025 Gansu Provincial Science and Technology Plan Project-Science and Technology Specialist Special Program (25CXGA039)
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