延缓高速列车制动盘热裂纹扩展的机理和关键技术综述

李杰; 王莉; 王晓燕; 胡铮; 王欣; 高紫钰; 汪诗敏

doi:10.19818/j.cnki.1671-1637.2024.06.002

延缓高速列车制动盘热裂纹扩展的机理和关键技术综述

doi: 10.19818/j.cnki.1671-1637.2024.06.002

李杰^1,,
王莉¹,
王晓燕^2, ,,
胡铮³,
王欣⁴,
高紫钰¹,
汪诗敏¹

1.
北京建筑大学城市轨道交通车辆服役性能保障北京市重点实验室，北京 102616
2.
北京物资学院系统科学与统计学院，北京 101149
3.
中国北方车辆研究所，北京 100072
4.
中国航发北京航空材料研究院，北京 100095

基金项目:

国家自然科学基金项目 51675494

北京建筑大学金字塔人才培养工程项目 JDJQ20200308

详细信息

作者简介:
李杰(1977-)，男，山西太原人，北京建筑大学教授，工学博士，从事车辆传动系统摩擦与制动、表面强化研究

通讯作者:
王晓燕(1980-), 女，湖北黄州人，北京物资学院副教授，工学博士

中图分类号: U270.6
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- 文章访问数: 66
- HTML全文浏览量: 18
- PDF下载量: 8
- 被引次数: 0
出版历程
- 收稿日期: 2024-06-18
- 刊出日期: 2024-12-25

Review on mechanism and key technologies for delaying thermal crack propagation of high-speed train brake discs

1.
Beijing Key Laboratory of Service Performance Guarantee for Urban Rail Transit Vehicles, Beijing University of Civil Engineering and Architecture, Beijing 102616, China
2.
School of Systems Science and Statistics, Beijing Wuzi University, Beijing 101149, China
3.
China North Vehicle Research Institute, Beijing 100072, China
4.
AECC Beijing Institute of Aeronautical Materials, Beijing 100095, China

Funds:

National Natural Science Foundation of China 51675494

Pyramid Talent Training Project of Beijing University of Civil Engineering and Architecture JDJQ20200308

More Information

Author Bio:
LI Jie(1977-), male, professor, PhD, lijie1@bucea.edu.cn

Corresponding author: WANG Xiao-yan(1980-), female, associate professor, PhD, wangxy252@163.com

摘要

摘要: 以铸钢材料的列车制动盘为研究对象，阐述了制动盘疲劳热裂纹萌生和扩展机制，分析了应力比、温度及超载3个因素对制动盘裂纹扩展速率产生的影响，详细介绍了延缓裂纹扩展的3种关键技术，分别为喷丸强化技术、激光熔覆技术及冷喷涂技术，提出了延缓制动盘表面裂纹扩展研究的未来研究方向。研究结果表明：列车频繁的制动与缓解导致盘面受到交变热应力作用，易在材料晶界和缺陷部位产生龟裂纹，随之出现径向裂纹，最后产生周向裂纹；龟裂纹在局部集中的摩擦力作用下沿径向扩展，与径向主裂纹汇合，主裂纹长度随之增加，最终会导致制动盘失效；通过喷丸强化和冷喷涂处理，盘面会发生塑性变形，原有残余拉应力转化为残余压应力，延缓了疲劳裂纹的扩展；激光熔覆技术改善了制动盘基层金属的组织性能，提升了高温下的耐磨损能力；未来的研究重点是磨损对盘面裂纹扩展的影响、喷丸强化中晶粒细化与位错密度演化的机理和喷丸工艺参数(如弹丸直径、覆盖率、喷丸强度)的关系及高速激光熔覆在摩擦副快速成型中的应用效率，此外，针对冷喷涂技术，需研究如何通过提高颗粒速度、温度来增强塑性变形驱动力，减少沉积层中的微观结构缺陷。
- 高速列车 /
- 制动盘 /
- 服役损伤 /
- 疲劳裂纹扩展 /
- 残余应力 /
- 表面强化
Abstract: The fatigue thermal crack initiation and propagation mechanisms of train brake discs made of cast steel were analyzed. The effects of stress ratio, temperature, and overloading on the crack propagation rate of brake discs were described. Three key technologies for delaying crack propagation, including shot peening, laser cladding, and cold spraying, were systematically introduced. Future research directions for mitigating surface crack propagation in brake discs were proposed. Analysis results show that frequent braking and releasing in trains subject the disc surface to alternating thermal stress so that the formation of microcracks was induced at grain boundaries and defect sites within material. These microcracks subsequently propagate into radial cracks and eventually evolve into circumferential cracks. Microcracks are found to propagate radially under localized frictional forces, merging with primary radial cracks and increasing their length. It ultimately leads to brake disc failure. Plastic deformation of the disc surface is induced by shot peening and cold spraying treatments, transforming the residual tensile stress into residual compressive stress. Therefore, the propagation of fatigue cracks is slowed down. The microstructural properties of the base metal of brake disc are improved through laser cladding, enhancing its wear resistance at elevated temperatures. In the future, in-depth research should be carried out on the influence of wear on the propagation of surface cracks in brake discs, the mechanisms of grain refinement and dislocation density evolution during shot peening, and the correlation and quantitative relationships among shot peening parameters, such as shot diameter, coverage rate, and peening intensity. The application efficiency of high-speed laser cladding in the rapid prototyping of friction pairs should be further explored. Additionally, for cold spraying technology, attention should be paid to how to enhance the driving force for plastic deformation by increasing particle velocity and temperature, thereby reducing microstructural defects in the deposition layer.
- high-speed train /
- brake disc /
- service damage /
- fatigue crack propagation /
- residual stress /
- surface strengthening

HTML全文

图 1 制动盘传热

Figure 1. Thermal transfer of brake discs

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图 2 制动盘表面的热斑

Figure 2. Hot spots on surface of brake disc

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图 3 制动盘温度分布

Figure 3. Temperature distribution of brake disc

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图 4 制动盘裂纹扩展形态

Figure 4. Crack propagation morphology of brake discs

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图 5 疲劳裂纹扩展曲线

Figure 5. Fatigue crack propagation curve

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图 6 温度对FGH4098粉末高温合金疲劳裂纹扩展行为的影响

Figure 6. Effects of temperature on fatigue crack propagation behavior of FGH4098 powder metallurgy superalloys

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图 7 一次超载对裂尖周向等效塑性应变的影响

Figure 7. Effects of a single overload on crack tip circumferential equivalent plastic strain

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图 8 喷丸加工

Figure 8. Shot-peening

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图 9 喷丸强化后不同深度的J积分沿裂纹前沿的分布

Figure 9. Distribution of J-integral along crack front at different depths after shot peening

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图 10 铜基合金熔覆件与磨损率

Figure 10. Copper-based alloy cladding parts and wear rates

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图 11 界面处的横向裂纹

Figure 11. Transverse cracks at interface

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图 12 裂纹钝化

Figure 12. Crack passivation

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图 13 冷喷涂系统原理

Figure 13. Principle of cold spray system

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