With the rapid development of railways towards high speed and larger carrying capacity, the problem of wear and fatigue damage between wheel/rail is gradually becoming serious. However, traditional pearlite wheel/rail has reached the limit, which leads to more attention to developing a novel wheel/rail material. This study aims to report a novel carbide-free bainite wheel steel. The wear-resistance of novel steel was tested by a rolling-sliding wear experiment under heavy-haul condition and investigated the impacts of the running speeds on the damage mechanism of wear and fatigue. The results show that the yield strength of the bainite wheel was as high as 950 MPa and the hardness was 415 HV, which was superior to most of the reported typical wheel steel. During the process of wear, the surface damage of the wheel was mainly adhesive wear and fatigue damage, and the gradient strain layer (GS layer) was formed on the wheel surface. As the running speed increased, fatigue damage gradually became more serious than adhesive wear, and the shear stress and strain of the GS layer were enhanced. The higher thickness and hardening were produced on the GS layer, which is the main reason for the higher wear-resistance of the bainitic wheel under higher running speeds. In addition, the wear-resistance of the novel wheel steel was better than that of the reported wheel steel. This novel bainitic wheel is a promising wheel for heavy-haul condition applications, which could provide a guide in choosing bainitic wheel steel for the railway.

The Cu-rich phase is a high-efficiency and ultra-stable precipitation-strengthening phase and has been widely used in many steels and alloys, especially in heat-resistant steels and alloys. Creep damage is accompanied with the coarsening of the second phase. In the present work, the calculation of phase diagrams (CALPHAD) method and elastic–plastic mechanics are coupled with the phase field (PF) approach to investigate the growth behavior and the accompanying stress/strain field evolution of nano-sized Cu-rich precipitates in an Fe-Cr-Ni-Cu medium-entropy alloy. The results show that creep strain is intensified with the coarsening of Cu-rich particles. The simulated size of Cu-rich particles is in good agreement previous experimental reports. The plastic strain tends to shear the Cu-rich phase when they are relatively fine (~11 nm) are bypassed by the plastic strain due to the enhancing stress concentration around the interface, and the creep strain is rapidly aggravated with the growth of Cu-rich particles. The coarsening of Cu-rich particles will be retarded by the adjacent particles due to the overlapping of the diffusion zone, and hence the creep strain was reduced when crept for the same time. The retard effect will vanish when their distance is sufficiently long (~>60 nm). When the size of the Cu-rich particles is identical, the creep strain will be mitigated with elongation of the distance between two Cu-rich particles.

Wear resistance of brake discs has a significant effect on the safety of high-speed trains. In this work, the rolling–sliding wear resistance of a low-carbon martensitic brake disc steel was investigated. The microstructure evolution and mechanical properties from the worn surface to the matrix were analyzed to promote parameters for the application of this steel. The results indicated that a ratcheting strain zone was formed at the surface of the brake disc steel under asymmetric cycling load and presented the morphology of the plastic flow line. An equation between the shear strain and the depth from the surface was established, which reflected the gradient distribution of the shear strain. The martensite lath refined into the nano/sub-micron grain and strip on the topmost surface. The micron scratch test results exhibited that the hardening rate and fracture toughness of the ratcheting strain zone varied continually along with depth, and the highest hardening rate occurred on the worn surface due to the increase of dislocation density and grain refinement. Additionally, the brake disc steel obtained better wear resistance than that of other wear-resistant materials used for railways due to steel having the highest hardening rate in the ratcheting strain zone.